02
2024
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02
Improvement of old electric furnaces, achieving good energy-saving effects
However, as a key equipment for high-temperature products, the main requirements for the use of industrial electric furnaces are as follows: 1) Temperature requirements: the ability to achieve operating temperature, temperature control accuracy, furnace temperature difference, etc. 2) Operation requirements: Easy to operate and high level of intelligence. 3) Reliability requirements: Ensure that various components of the electric furnace, such as the heating element, lining, and control system, do not frequently malfunction under normal operating conditions. 4) Energy consumption requirements: Take various measures to reduce energy consumption. Only by achieving low energy consumption of electric furnaces can the success of industrial electric furnaces replacing gas kilns be achieved.
A certain company purchased a high-temperature electric furnace with an effective volume of 4m3 for calcining aluminum oxide products, with a calcination temperature of 1650 ℃. The main problem with the electric furnace during use is: 1) The heating element is severely damaged, and almost every furnace will experience heating element fracture. 2) The energy consumption is too high, and the sintering cost is too high. 3) The furnace lining is severely damaged, and almost every furnace needs repair. 4) The large temperature difference causes significant fluctuations in the quality of the calcined products. The existence of these problems has caused this electric furnace to be almost unable to be put into normal use, and requires our company to make improvements.
Our company has conducted a detailed inspection and diagnosis of the electric furnace, and the main reason for its inability to function properly is: 1) insufficient design power, resulting in the heating element operating under overload. The consequence of overloaded operation is not only that the heating element is prone to damage, but also that due to the high surface temperature of the heating element, it is easy to cause damage to the furnace lining due to high temperature. It is also easy to cause uneven sintering degree of the products near the heating element, leading to quality fluctuations. 2) The furnace lining has excessive heat storage and poor insulation performance, resulting in significant heat loss and increased energy consumption. 3) There are problems with the circuit design of the control system, resulting in excessive non functional consumption. Excessive non functional consumption not only significantly increases power consumption, but also has a certain impact on transformers or the power grid, and is often punished by the power management department.
Based on the above diagnostic results, our company has modified the electric furnace. The measures taken are as follows: 1) The number of heating elements has been increased to increase their power usage, ensuring that the heating elements do not operate under overload. 2) Adopting the composite furnace lining structure designed and produced by our company. Not only can it reduce the heat storage capacity of the furnace lining by about 20-30%, but it can also reduce the actual operating power of the electric furnace by about 20%. 3) We have adopted an intelligent control system designed and manufactured by our company. This control system can ensure that the operating voltage of the electric furnace is always maintained at 220V or 380V, eliminating the impact of no functional consumption.
The improved electric furnace has been in use for more than half a year, and its results show that: 1) the electric furnace has strong reliability in operation, without any damage to the heating element or furnace lining, meeting the requirements for normal production. 2) The small temperature difference in the furnace results in a significant improvement in the quality of the calcined products. 3) The energy-saving effect is very obvious. Previously, the electricity consumption for calcining a furnace of products was about 5700-5800 degrees, but now the electricity consumption is usually 4500-4600 degrees, which is about 20% energy-saving. It can be seen that the improvement of the electric furnace is a very successful example.
With the increasing environmental requirements and the continuous rise in natural gas prices, the demand for large industrial electric furnaces has sharply increased. However, as a key equipment for high-temperature products, the main requirements for the use of industrial electric furnaces are as follows: 1) Temperature requirements: the ability to achieve operating temperature, temperature control accuracy, furnace temperature difference, etc. 2) Operation requirements: Easy to operate and high level of intelligence. 3) Reliability requirements: Ensure that various components of the electric furnace, such as the heating element, lining, and control system, do not frequently malfunction under normal operating conditions. 4) Energy consumption requirements: Take various measures to reduce energy consumption. Only by achieving low energy consumption of electric furnaces can the success of industrial electric furnaces replacing gas kilns be achieved.
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