3. High-efficiency heat recovery continuous isothermal annealing furnace
The electric furnace developed by Suzhou Industrial Park Shenglong Electric Furnace Manufacturing Co., Ltd. has two furnaces, and the two furnaces are arranged in parallel. Each furnace is arranged in a preheating section, a heating and holding section, a quick cooling section, an isothermal section and a cooling section. In the two furnaces, a heat exchange mechanism is arranged between the preheating section of one furnace and the cooling section of the other furnace, and the heat released by one furnace workpiece is fully utilized as a preheating of the other furnace, so that The furnace workpiece is heated to above 400 °C.
The furnace type energy-saving isothermal annealing furnace technology and heat recovery technology are integrated, and the workpiece preheating is developed as secondary energy, which has obvious energy saving effect. Take the 250KW SLRTd-250 annealing furnace as an example, the annual output can reach 5,400 tons, and the annual energy saving is 800,000 degrees. Compared with the ordinary energy-saving annealing furnace, the annual electricity saving cost is 55-600,000 yuan. Two years of electricity saving costs can be used to recover the entire equipment investment.
The furnace type has stable processing quality, the bearing parts have an annealing hardness of HRB89-92, the metallographic structure is 2-3 grades, and the pass rate is 100%.
4. Oil-electric, gas-electric composite heating technology
(1) Oil-electric composite heating technology
In the 1990s, the southeast coastal provinces and cities lacked electricity and less coal. Jinzhou Electric Furnace Co., Ltd. innovated and developed the roller-bottom type oil-electric composite heating isothermal spheroidizing annealing furnace, successfully integrating advanced technology and heat treatment equipment to innovate and make bearings. The spheroidizing annealing of steel is shortened to 8-9 hours, and the spheroidizing annealing microstructure achieves the ideal goal of uniform, fine, diffused and rounded distribution; advanced fuel technology makes the soot blackness series reach Ringermann level 1, fully in line with Environmental requirements.
(2) Gas-electric composite heating technology
Natural gas is a high-quality primary energy source. Jinzhou Electric Furnace Co., Ltd. combines natural gas temperature control heating and electric heating temperature control according to the conditions of users, and develops gas-electric composite heating roller bottom spheroidizing annealing furnace to realize temperature control. Electromechanical integration of electronic control and process control, the quality of annealing is leading domestically, and the energy saving level has reached a new height.
5. Bearing steel intelligent annealing control system
The School of Materials of Hebei University of Technology gives full play to the advantages of mathematics, computers, electrical appliances, materials, software and other disciplines in the development of bearing steel intelligent annealing control system. In the case of fully utilizing the original annealing furnace body of the enterprise, the system can be configured to intelligently adjust the heating temperature and cooling rate of each zone according to the parameters such as the thermal characteristics of the heating furnace, the temperature field distribution, and the amount of furnace charge obtained during the operation. The same parameters automatically control the entire process of annealing. No action factor.
The system is characterized by improved spheroidizing annealing quality, improved production efficiency, and energy saving.
(1) Excellent annealing quality: The annealing product using this technology can stably obtain 2-3 grade structure by spheroidizing quality. It can meet the European SEP1520 annealing standard implemented by SKF, FAG and other world's largest bearing companies. To lay a good foundation for improving the life and reliability of bearings.
(2) Increasing productivity: The annealing cycle can shorten the annealing cycle by 1/3-1 times in a continuous (push-type) annealing furnace; in the trolley type, through-cycle annealing furnace can be reduced from the current 36-hour cycle to less than 15 hours. .
(3) Energy saving and consumption reduction: The cost of electricity consumption is greatly reduced. The current operating furnace is reduced from the current power consumption of 280-480KWh/ton to 240KWh/ton; the cycle operating furnace is reduced from the current 400-600KWh/ton to 300 KWh/ Less than tons.
Under the premise of ensuring the annealing quality of 2-3 grades, this technology has been applied to large-scale industrial production in many enterprises, and has achieved significant benefits.
Hebei Rolling Mill Bearing Co., Ltd., with a daily output of 6 tons and a power consumption of 470KWh/ton; the daily output after the transformation is increased to 12 tons, and the power consumption will reach 235KWh/ton.
Dalian Longyan Forging Factory treats hot-rolled bearing steel balls with 540KW trolley-type furnace. The daily output is 15 tons and the power consumption is 300KWh/ton. The low-valley electricity accounts for more than 85% of the total electricity consumption, and the annealing cost is about 130 yuan/ton.
Dalian Metallurgical Bearing Co., Ltd. has rebuilt three 360KW pusher-type annealing furnaces for four consecutive years. The power consumption of the ferrule is ≤210KWh/ton, and the annual production capacity has reached 25,000 tons. Two 440KW bar annealing furnaces, daily processing Φ20- Φ130 bar material 20 tons, power consumption ≤ 270KWh / ton, of which low valley accounted for more than 90% of the total amount, annealing power consumption cost <100 yuan / ton.
Shandong Liangshan Bearing Co., Ltd. prior to the transformation, the annealing energy saving 1/3, the production efficiency increased by 1/3, not only that, due to the fine annealing structure, the quenching temperature is reduced, the holding time is shortened, quenching energy saving 8%.
Guangdong Shaoguan Southeast Bearing Co., Ltd. produces automobile hub bearings. The quality of the annealed after the transformation has reached the European SEP1520 standard implemented by FAG, and has become a FAG semi-finished product supplier. The annual quality benefit is more than 10 million yuan.
The long-term use of many companies indicates that the technology is mature and reliable.
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