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1. Main Dimensions, Production Capacity, and Specific Energy Consumption of The Walking Beam Reheating Furnace
1.1 Main Dimensions of The Walking Beam Reheating Furnace
Centerline spacing of loading and unloading roller track: 7800 mm
Internal length of furnace : 8500 mm
Internal width of furnace: 14500 mm
Fixed Beam Top Elevation: +825 mm
furnace bottom area: ~113.1 m2
1.2 Production Capacity and Material layout in Walking Beam Reheating Furnace
Hourly production rate: Maximum 60 t/h, average 45 t/h
Maximum discharge frequency: 120 pieces/hour
1.3 Specific Energy Consumption
The specific energy consumption of the furnace refers to the energy consumed per unit of output. In the case of continuous production at the maximum capacity of 60 t/h, with an inlet temperature of 750°C, outlet temperature of 980°C, and a maximum air excess coefficient of α=1.1, the specific energy consumption is 1000 kJ/kg.
2. Process Performance and Structural Description of The Furnace and Its Auxiliary Equipment.
The furnace is divided longitudinally, from the loading end to the discharge end, into the furnace preheating section and the heating section/soaking section.
Improving the heating transfer efficiency and ensuring uniform heating of scrapped pipes are the prerequisites for the reasonable configuration of the furnace structure and burner selection. The design utilizes natural gas as fuel, and the heating section/soaking section of the stepping beam-type reheating furnace employs adjustable end-flame natural gas burners. The advantages of these burners are high heat transfer efficiency and uniform temperature distribution. Additionally, the heating section/soaking section is divided into three temperature control zones along the width of the furnace to ensure temperature uniformity in the length direction of the scrapped pipes.
The scrapped pipe reheating furnace is a stepping beam-type furnace supported by heat-resistant cast steel beams for supporting the steel pipes. The top surface of the movable beams and fixed beams is tooth-shaped with curvature, allowing the steel pipes to be evenly spaced within the furnace. With each stepping operation, the steel pipes rotate by an angle, ensuring more uniform heating and preventing bending or deformation of the steel pipes inside the furnace. The stepping beams are supported by support columns, raising them approximately 450mm above the furnace bottom to facilitate the proper circulation of furnace gas around the steel pipes, ensuring uniform heating.
The flue gas inside the furnace is discharged through the exhaust pipe located below the charging end of the furnace, and then collected. The collected flue gas is passed through an air preheater to recover the residual heat in the flue gas. Afterward, the flue gas is released into the atmosphere through the chimney via the flue.
The scrap pipe reheating furnace adopts side feeding and side discharging through the in-furnace cantilever roller conveyor. The in-furnace cantilever roller conveyor is driven and speed-controlled by an AC variable frequency motor, which is matched with the speed of the external roller conveyor.
Translation: The furnace bottom mechanism adopts an inclined rail double-layer frame structure. The lifting and translation movements of the stepping beam are driven by hydraulic cylinders. The holes through which the support columns of the stepping beam pass through the furnace bottom are sealed with dry "drag plates". The loading and unloading cycle is 28 seconds, which can meet an operating frequency of 120 tubes per hour.
All mechanical movements of the furnace are automatically controlled by PLC. Industrial cameras are installed at the loading and unloading ends to monitor the operation of loading and unloading steel tubes inside the furnace.
3. Reheating Furnace Technical Performance Table
| No. | Project Name | Unit | Technical Data |
| 1 | Usage of the reheating furnace | Reheating of raw pipe | |
| 2 | Heating steel grades | High-quality carbon structural steel, high-quality alloy structural steel, stainless steel | |
| 3 | Scrapped pipe specifications | mm | Length 6000~135000mm x ф178~242mm x 5~25mm |
| 4 | Production capacity of furnace | t/h | 45t/h (average), maximum 60t/h |
| 5 | Inlet temperature | ºC | 500~750 |
| 6 | Outlet temperature | ºC | 980±10 |
| 7 | Fuel type and calorific value | kJ/m3 | Natural gas, 8800x4.1868 |
| 8 | Rated fuel consumption | m3/h | 1700 |
| 9 | Rated air consumption | m3/h | 18190 |
| 10 | Rated flue gas volume | m3/h | 19720 |
| 11 | Fuel consumption per unit | kJ/kg | 1000 |
| 12 | Air preheating temperature | ºC | 400 |
| 13 | Stepping mechanism form | Inclined platform rollers | |
| 14 | Stepping beam stroke | mm | 180mm (lifting), 260mm (translating) |
| 15 | Stepping cycle | s | 25s (adjustable range 25-80s) |
| 16 | Stepping beam pitch | mm | 300 |
| 17 | Number of stepping beams | 8 | |
| 18 | Number of fixed beams | 8 | |
| 19 | Smoke exhaust mode | Natural smoke exhaust | |
| 20 | Stack | H=45m, upper diameter 1.35m |
4. Combustion System
The combustion system adopts conventional combustion method to ensure temperature uniformity along the length of the steel pipes. There are 15 adjustable natural gas high-speed burners arranged along the furnace head, and the furnace temperature is controlled in three sections along the furnace width. The flue gas at the furnace tail is discharged into the atmosphere through the flue, air heat exchanger, flue damper and a 45-meter high brick stack.
5. Stepping Mechanism
The stepping mechanism consists of eight fixed beams and eight movable beams supporting steel pipes, with a beam spacing of 1700mm. The fixed beams are fixed to the furnace bottom steel structure by supports. The support columns for the movable beams pass through the furnace bottom and are fixed to the stepping frame. To ensure equal spacing of the steel pipes inside the furnace and to rotate the steel pipes at each stepping operation, the fixed beams and movable beams are tooth-shaped beams with curvature. Both the beams and columns are made of heat-resistant steel casting.
The holes in the furnace bottom through which the support columns pass are sealed with a double-layer "drag plate" seal. The lower drag plate is made of 1Cr18Ni9 steel plate lined with refractory insulation material, and the drag plate inside the furnace is made of heat-resistant cast steel. The lifting and lowering movement of the stepping beams is driven by two hydraulic cylinders, while the forward and backward movement of the stepping beams is accomplished by a single translational hydraulic cylinder. The spacing between the steel pipes inside the furnace (i.e., the pitch of the beams) is 300mm, the horizontal movement of the movable beams is 260mm, and the remaining 40mm is the distance for the steel pipes to rotate within the tooth groove. In the event of an accident, the steel pipes cannot be removed from the furnace and remain in the same position on the fixed beams for a long time. To prevent temperature unevenness, an accident cycle operation can be adopted, where the movable beams rise, retreat 40mm, and then descend, allowing the steel pipes to step in place and rotate. The cycle of movement for the movable beams is 25 seconds. To ensure the accuracy of the speed and position of the stepping beams during movement, as well as to meet the precise requirements for light handling and accurate stepping distance, the stroke of the lifting and lowering and the forward and backward movement of the stepping beams are controlled by two stroke detection devices.
Step Beam Operation Diagram:
6. In-furnace Loading and Unloading Cantilever Roller Conveyor
The in-furnace loading and unloading roller conveyor consists of a set of cantilever rollers individually driven by AC variable frequency speed-controlled motors. The rollers have an arc-shaped self-positioning surface, and the roller surface is inclined at an angle of 2.5° with respect to the feeding centerline. This arrangement allows the centerline of the feed to align as closely as possible with the centerline of the roller conveyor, facilitating the movement of the scrap pipes by the stepping beam. The roller shafts are hollow and water-cooled, utilizing a closed-loop water cooling system.
The motor is connected to the roller shaft gear through a separate coupling, and the roller shaft is connected to the wear-resistant bearings.
Insulating baffles are placed between the roller shaft and the furnace shell to reduce heat loss and prevent overheating of the bearings.
One roller conveyor can be dismantled without shutting down the furnace. In the event of a power failure, an emergency power supply is required to keep the roller conveyor running.
Performance of the Entry Cantilever Rollers
Quantity 8 pieces
Type Ring-shaft cylindrical
Cooling Shaft and rollers
Diameter 180mm
Length ~320mm
Roller Conveyor Speed 0.25-1.8m/sec
Motor Power 4.0Kw
Roller Material 3Cr24Ni7SiNRe
Performance of the Discharge Cantilever Rollers
Quantity 8 pieces
Type Ring-shaft cylindrical
Cooling Water-cooled shaft
Diameter 180mm
Length ~320mm
Motor Power 4.0Kw
Roller Material ZGCr25Ni20Si2
7. Furnace Tail Loading Buffer Plate
On the centerline of the furnace's feed roller conveyor and on the opposite side of the feed furnace door, there is a terminal water-cooled baffle. The baffle is composed of supports, water-cooled shafts, buffers and other components, and is individually fixed on the external concrete foundation of the furnace.The baffle protects the furnace wall when there is a malfunction in the feeding system, ensuring normal production. The baffle is cooled with clean circulating water.
8. Automatic Control System
An exclusively designed PLC system is employed for the electrical automation control system.
The Electrical Control System Primarily Serves the Following Functions:
--Interface with the rolling mill control system (two methods: hardwired connection and network communication)
--Control of the feeding sequence for the charging platform and furnace front
--Feed control
--Discharge Control
--Transportation of billets within the furnace
--Control of billets on the entry and exit roller conveyors
--Tracking the position of billets inside the furnace
--Control of the hydraulic supply system in the hydraulic station
--Control of fan-related functions
--Manual control
--Automatic recording of the number of scrapped pipes entering and exiting the furnace, with the ability for manual intervention.
--Furnace area control with secondary management functions (including billet tracking and scrapped pipe management).
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Company Profile
| Professional Professional technical and management team with abundant experience in the implementation of domestic and international projects; |
| Responsive Responsively and meticulously, translating your needs into complete solutions; |
| Integration Integrating various technologies and resources in China and fulfilling complementary advantages, by relying on professional teams; |
| Motivation Motivated to provide the optimal solution and quality products; |
| Exceptional Exceptional, delivery and,implementation of projects to meet, your expectations; |
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