 壓鑄周刊（2014年8月20日 德國維赫爾市）史杰克西集團（古默斯巴赫）的研發人員已開發出新型耐熱預熔區廢氣擋板，能夠有效縮短自由熔化過程時間、減少氣體能耗、改善金屬產能，更重要的是再次提高StrikoMelter熔爐的效能。 新型廢氣擋板能夠在熔爐清洗過程中降低自由熔化的時長，每次約20分鐘左右。“現在我們已經研發出能夠永久承受900攝氏度左右高的廢氣溫度的材料，”史杰克西的研發人員Rudolf Hillen解釋道：“該廢氣擋板不僅能夠在自由熔化過程中降低15%的能耗，整個系統的整體效能也提高了百分之五左右。” 日常鑄造廠的操作性能不僅僅指保持較低的能耗和金屬燒損。系統的可用性也起著關鍵作用——每一小時的停工期都意味著收入的減少。不過，為了確保系統的永久效能及高效性能，在日常熔化操作過程中對熔爐進行定期保養工作是絕對必要的。這包括熔爐的清洗，通常是每班一次。在該過程中，熔化室必須在額定電壓下進行自由熔化。只有這樣才能將殘余的渣滓移除。 “自由熔化過程的長短對系統的產能有著直接的影響，因此需盡可能地縮短。”史杰克西的經理Rudi Riedel解釋道。在這樣的背景下，熱能工藝技術制造商史杰克西如今已經研發出覆蓋預熔區的廢氣擋板。該設計能夠承受自由熔化過程中形成的高廢氣溫度。 “預熔區廢氣擋板能夠降低自由熔化過程中累積的生產停滯期，約為每班次20分鐘。這樣，每天就可以多出一個小時的生產時間。”Riedel解釋道，“同時，自由熔化過程中的能耗約降低了15%。清潔鹽的消耗也通過廢氣擋板得以降低。” 所有型號的StrikoMelter熔爐都配有耐火預熔區擋板，同時也可以進行改裝以適應現有系統。“對于每小時兩噸以上熔化率的熔爐來說，我們廢氣擋板的效果尤佳，”史杰克西集團的研發人員Rudolf Hillen解釋道。在性能超過該數值的系統中，此類投資的回收期通常不用一年。
StrikoMelter: New hot gas baffle
StrikoWestofen reduces energy consumption during melting-free process by about 15 %
A shortened melting-free process, reduced gas consumption and an improved material yield: to increase still more the efficiency of your StrikoMelter melting furnaces, the StrikoWestofen Group (Gummersbach) has now developed a heat-resistant shaft cover. This so-called “hot gas baffle” reduces the duration of the melting-free process during furnace cleaning by approx. 20 minutes each time. “We have now been able to develop a material which permanently stands up to the high exhaust gas temperatures of about 900 degrees Celsius,” developer Rudolf Hillen from StrikoWestofen explains. “The hot gas baffle not only reduces the energy consumption during the melting-free process by about 15 percent: the overall efficiency of the system also rises by about five percent.”
Efficiency in day-to-day foundry operation means more than just keeping energy consumption and metal losses low. The availability of the system also makes a substantial contribution – every hour of downtime means a loss of revenue. Nevertheless, regular maintenance cycles for the melting furnaces during day-to-day melting operation are indispensable in order to ensure the permanent efficiency and high performance of the systems. This includes furnace cleaning, which is usually carried out once per shift. During this process, the melting chamber has to be melted free at full burner power. Only then can the remaining dross be removed. “The duration of the melting-free process has an immediate effect on the productivity of the system and should therefore be as short as possible,” explains StrikoWestofen manager Rudi Riedel. Against this background, the manufacturer of thermal Process technology has now developed a hot gas baffle which covers the melting shaft. The design withstands the exhaust gas temperatures which develop during the melting-free process. “The shaft cover reduces the production downtime accumulating during the melting-free process by about 20 minutes per shift. As a result, one more hour is available for production each day,” Riedel explains. “At the same time, the energy consumption during the melting-free process is by about 15 percent. The hot gas baffle also reduces the consumption of cleaning salts.”
An investment that pays off
The fire-resistant shaft cover is available for all StrikoMelter melting furnaces and can also be retrofitted to existing systems. “Our hot gas baffle is especially efficient when used with furnace sizes displaying a melting performance of upwards of two tonnes of aluminium per hour,” explains developer Rudolf Hillen from the StrikoWestofen Group. In systems with a performance upwards of this figure, the payback period for an investment of this kind is usually less than one year in length.
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