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2024
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Comparative examples of energy consumption and calcination costs between gas kilns and high-temperature electric furnaces
Compared with gas kilns, high-temperature electric furnaces have the following advantages: 1. Simple operation and high degree of automation. 2. Large loading capacity. 3. The calcination cycle is short. 4. The calcination quality of the product is stable. 5. Save labor costs. 6. Save environmental costs.
A certain listed company uses a gas kiln to calcine steel ladle breathable brick cores. The volume of the gas kiln is 7m3, and the actual loading capacity is about 5 tons. The calcination temperature is 1580-1600 ℃, and the actual calcination time for each kiln is about 140 hours (heating+insulation). Each kiln consumes approximately 1500m3 of natural gas. The power consumption of the two fans (auxiliary exhaust fan and smoke exhaust fan) is about 3800 kWh. The actual consumption cost of calcining one furnace is approximately 1500m3 of natural gas × 3.9 yuan/m3=5850 yuan; Electricity consumption 3800 kWh × 0.9 yuan/degree=3420 yuan. The total is 9650 yuan. The sintering cost per ton of product is approximately 1930 yuan.
The company has ordered a high-temperature electric furnace produced by our company, with an effective volume of 4m3 and a calcination temperature of 1580-1600 ℃. The actual loading capacity is about 5 tons. The design power of this electric furnace is 300KW, with an average usage power of about 200KW. The calcination time of each furnace is about 40 hours, and the actual power consumption is about 200KW × 40 hours=8000 kWh, with an electricity bill of approximately 8000 kWh × 0.9 yuan/degree=7200 yuan. The actual sintering cost per ton of product is 1440 yuan.
Compared with gas kilns, high-temperature electric furnaces have the following advantages:
1. Easy to operate and highly automated. The electric furnace can automatically heat up, insulate, and cool down according to the sintering requirements of the calcined products.
2. Large loading capacity. The loading capacity of electric furnaces is usually 1.6-1.8 times that of gas kilns.
3. The calcination cycle is short. Due to the faster heating and cooling of electric furnaces compared to gas kilns, their calcination cycle can usually be shortened by half.
4. The calcination quality of the product is stable. The electric furnace can fully follow the sintering temperature curve of the product for heating, insulation, and cooling, and each furnace can achieve good sintering degree of the sintered product.
5. Save labor costs. Usually, electric furnaces only require one person on duty during operation, and the calcination cycle is short, which can significantly save labor costs.
6. Save environmental costs. The use of an electric furnace does not require a desulfurization and denitrification device, and even if corresponding treatment measures need to be taken for the harmful gases generated during the calcination process, the operating cost is much lower than that of desulfurization and denitrification.
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2022-04-08
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