Low energy consumption centralized melting furnace

Abstract

This utility model discloses a low-energy centralized melting furnace, including a furnace body and a fan system. The fan system includes a melting-condition fan unit: a melting-condition fan connected to the melting burner on the furnace body via a melting-condition pipeline; and a non-melting-condition fan unit: a non-melting-condition fan connected to the insulating burner on the furnace body via a non-melting-condition pipeline; the non-melting-condition fan is also connected to the melting-condition pipeline via a non-melting-condition pipeline; the power of the melting-condition fan is greater than that of the non-melting-condition fan. This utility model adopts a newly designed fan system, splitting the original one fan system into two systems. When melting is not required, the power supply to the melting-condition fan is cut off, leaving only the non-melting-condition fan operating, thus achieving energy savings. The advantages are even more pronounced during non-melting phases of a shift, especially during weekend shift changes.

Description

Technical Field

[0001] This utility model relates to the technical field of melting furnace equipment, specifically to a low-energy centralized melting furnace. Background Technology

[0002] Centralized melting furnaces are generally divided into a metal melting section and a molten metal holding section. A blower typically provides high-pressure air for combustion, which mixes with the combustion gas in specially designed burners to radiate heat and melt the metal, while also holding the molten metal at a suitable temperature. Looking at various types of melting furnaces both domestically and internationally, a single blower typically supplies air to both the melting and holding burners, with the designed airflow generally meeting the required intake air volume for the burners' rated power. This design is standard and widely used by known domestic and international aluminum alloy melting furnace manufacturers, such as Dongda Sanjian, Zhengying Rigan, and Shijiexi.

[0003] The main source of power consumption in melting furnaces is the combustion fan. In manufacturing enterprises, order-based production is a common business strategy. Under full-load production conditions, the aforementioned continuous centralized melting furnaces can achieve maximum efficiency. However, when there are insufficient production orders, or in discontinuous melting conditions where the molten metal's insulating burners are still running, the fan only supplies power to the insulating burners, inevitably leading to energy waste and increasing the burden on the enterprise.

[0004] The problem that needs to be solved is how to save electricity consumption and reduce enterprise expenses during periods of non-full-capacity melting in centralized melting furnaces. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a low-energy centralized melting furnace and a gearbox with a low-energy centralized melting furnace, thereby solving the problem that existing centralized melting furnaces use a single set of fan supply equipment for the ignition and ventilation of the metal melting burner and the molten metal heat-insulating burner, and the fans operate continuously around the clock, resulting in high electricity costs.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a low-energy centralized melting furnace, including a centralized melting furnace body, and a fan system connected to the centralized melting furnace body, wherein the fan system includes a melting condition fan unit and a non-melting condition fan unit.

[0007] The melting condition blower unit includes a melting condition blower, which is connected to the melting burner on the centralized melting furnace body through a melting condition pipeline.

[0008] The non-melting condition blower unit includes a non-melting condition blower, which is connected to the heat-insulating burner on the centralized melting furnace body through a non-melting condition pipeline.

[0009] The non-molten chemical condition fan is also connected to the molten chemical condition pipeline through the non-molten chemical condition pipeline.

[0010] The power of the blower in the melting process is greater than that of the blower in the non-melting process.

[0011] This utility model also has the following technical features:

[0012] The melting process pipeline includes a first melting pipeline, a second melting pipeline, a third melting pipeline, and a fourth melting pipeline that are connected in series.

[0013] The melting process blower is connected to the first melting pipeline, and the fourth melting pipeline is connected to the melting burner on the main body of the centralized melting furnace.

[0014] A first valve is installed between the first melting pipeline and the second melting pipeline.

[0015] A second valve is installed between the second melting pipeline and the third melting pipeline.

[0016] The diameter of the first melting pipe is smaller than that of the second melting pipe, and the diameter of the second melting pipe is larger than that of the third melting pipe.

[0017] The non-fusible pipeline includes a first non-fusible pipeline, a second non-fusible pipeline, and a third non-fusible pipeline that are connected together.

[0018] The non-melting condition blower is connected to the first non-melting pipeline, and one end of the third non-melting pipeline is connected to the second melting pipeline, while the other end is connected to the heat-insulating burner on the main body of the centralized melting furnace.

[0019] A third valve is installed between the first non-melting pipeline and the second non-melting pipeline. A baffle is installed on the side of the third non-melting pipeline closer to the second melting pipeline, and a fourth valve is installed on the side of the third non-melting pipeline farther from the second melting pipeline.

[0020] The first, second, third, and fourth valves are all butterfly valves.

[0021] Compared with the prior art, this utility model has the following technical effects:

[0022] (I) The low-energy centralized melting furnace provided by this utility model adopts a newly designed fan system, which splits the original one fan system into two systems. When melting is not required, the power supply to the fan in the melting mode is cut off, and only one fan in the non-melting mode is kept in operation, thereby saving electricity. The advantages are more obvious during the non-melting stage of the shift, especially during the weekend shift rotation.

[0023] (II) The low-energy centralized melting furnace provided by this utility model has two sets of fan units that do not interfere with each other. The original melting mode fan unit is retained. When the melting mode fan unit has a problem, the non-melting mode fan unit can be used for heat preservation operation. When the non-melting mode fan unit has a problem, the melting mode fan unit can be used to supply heat preservation burners, thus strengthening the furnace's fault resistance capability. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the low-energy centralized melting furnace of this utility model.

[0025] The meanings of the labels in the attached diagram are as follows:

[0026] 1-Melting condition blower unit, 2-Non-melting condition blower unit, 3-First melting burner, 4-Second melting burner, 5-Third melting burner, 6-Insulation burner.

[0027] 1-1-Fan for melting conditions, 1-2-Pipeline for melting conditions.

[0028] 2-1- Non-molten metal condition fan, 2-2- Non-molten metal condition pipeline.

[0029] 1-2-1-First melting pipeline, 1-2-2-Second melting pipeline, 1-2-3-Third melting pipeline, 1-2-4-Fourth melting pipeline, 1-2-5-First valve, 1-2-6-Second valve.

[0030] 2-2-1-First non-fusible pipeline, 2-2-2-Second non-fusible pipeline, 2-2-3-Third non-fusible pipeline, 2-2-4-Third valve, 2-2-5-Baffle plate, 2-2-6-Fourth valve.

[0031] The specific content of this utility model will be further explained in detail below with reference to the embodiments. Detailed Implementation

[0032] Unless otherwise specified, all components in this invention are made from components known in the prior art.

[0033] The following are specific embodiments of the present invention. It should be noted that the present invention is not limited to the following specific embodiments. All equivalent modifications made based on the technical solutions of this application fall within the protection scope of the present invention.

[0034] Example 1:

[0035] This embodiment provides a low-energy centralized melting furnace, such as... Figure 1As shown, it includes a centralized melting furnace body and a fan system connected to the centralized melting furnace body. The fan system includes a melting condition fan unit 1 and a non-melting condition fan unit 2.

[0036] The melting condition blower unit 1 includes a melting condition blower 1-1, which is connected to the melting burner on the centralized melting furnace body through a melting condition pipeline 1-2.

[0037] The non-melting condition blower unit 2 includes a non-melting condition blower 2-1, which is connected to the heat-insulating burner 6 on the centralized melting furnace body through a non-melting condition pipeline 2-2.

[0038] The non-molten condition blower 2-1 is also connected to the molten condition pipeline 1-2 via the non-molten condition pipeline 2-2.

[0039] The power of the blower 1-1 in the melting condition is greater than that of the blower 2-1 in the non-melting condition.

[0040] In this embodiment, the melting condition blower 1-1 is a 15KW centrifugal blower, and the non-melting condition blower 2-1 is a 3KW centrifugal blower.

[0041] During normal melting and production, the 15kW blowers for the three melting burners and the 3kW blower for the modified insulated burner are all running and in operation. When there is no melting or feeding during the shift, the feeding trolley hopper remains stationary. If it remains in this position for 15 minutes, the three melting burners are shut off. If no one operates the feeding trolley for another 15 minutes, the 15kW melting mode blower is powered off. At this time, only the 3kW non-melting mode blower continues to operate, supplying gas to the insulated burner for combustion, thus achieving energy savings. When combustion is needed again, the operator simply restarts the combustion blower and ignites the three melting burners, restoring production to its original state. This cycle of automatic shut-off and manual start-up provides reliable energy savings while also significantly reducing gas consumption.

[0042] Without affecting the efficiency of the melting furnace, it has achieved the goal of saving electricity consumption under non-full-capacity operating conditions. It has been used in the company's production and operation for a long time and has generated high economic benefits.

[0043] Traditional centralized melting furnaces use a single blower system to supply heat to the metal melting burners and the molten metal heat-preserving burners for ignition and ventilation. When not melting, the blowers operate continuously around the clock to maintain the temperature of the molten metal, resulting in high electricity costs.

[0044] This utility model patent introduces a new ducted fan design for a centralized melting furnace. Unlike traditional furnaces with a single fan supplying both melting and heat-preserving burners, the new fan duct system uses a partition to separate the original single fan, which only operates on the melting burners of the centralized melting furnace, while the newly added ducted fan operates exclusively on the heat-preserving burners. Through the electrical control system settings, when melting operations are not in progress, the traditional single fan is disconnected to save energy, while only the newly added ducted fan supplies the heat-preserving burners. This has already shown significant improvement during daily operations, especially during off-peak hours, shift work, or maintenance periods, where the energy-saving effect is even more pronounced.

[0045] As a preferred embodiment:

[0046] The melting process pipeline 1-2 includes a first melting pipeline 1-2-1, a second melting pipeline 1-2-2, a third melting pipeline 1-2-3, and a fourth melting pipeline 1-2-4, which are connected in series.

[0047] The melting blower 1-1 is connected to the first melting pipeline 1-2-1, and the fourth melting pipeline 1-2-4 is connected to the melting burner on the main body of the centralized melting furnace.

[0048] In this embodiment, the fourth melting pipeline 1-2-4 has a total of three paths, which are respectively connected to the third melting pipeline 1-2-3 and the first melting burner 3, the third melting pipeline 1-2-3 and the second melting burner 4, and the third melting pipeline 1-2-3 and the third melting burner 5.

[0049] As a preferred embodiment:

[0050] A first valve 1-2-5 is installed between the first melting pipeline 1-2-1 and the second melting pipeline 1-2-2.

[0051] A second valve 1-2-6 is installed between the second melting pipeline 1-2-2 and the third melting pipeline 1-2-3.

[0052] The diameter of the first melting pipe 1-2-1 is smaller than the diameter of the second melting pipe 1-2-2, and the diameter of the second melting pipe 1-2-2 is larger than the diameter of the third melting pipe 1-2-3.

[0053] As a preferred embodiment:

[0054] The non-fusible condition pipeline 2-2 includes a first non-fusible pipeline 2-2-1, a second non-fusible pipeline 2-2-2, and a third non-fusible pipeline 2-2-3, which are connected in series.

[0055] The non-melting condition blower 2-1 is connected to the first non-melting pipeline 2-2-1, and one end of the third non-melting pipeline 2-2-3 is connected to the second melting pipeline 1-2-2, and the other end is connected to the heat-insulating burner 6 on the main body of the centralized melting furnace.

[0056] As a preferred embodiment:

[0057] A third valve 2-2-4 is installed between the first non-melting pipeline 2-2-1 and the second non-melting pipeline 2-2-2. A baffle 2-2-5 is installed on the side of the third non-melting pipeline 2-2-3 closer to the second melting pipeline 1-2-2. A fourth valve 2-2-6 is installed on the side of the third non-melting pipeline 2-2-3 away from the second melting pipeline 1-2-2.

[0058] Use a DN100 baffle plate to install at the branch flange to cut off the ventilation duct from the original 15KW centrifugal fan to the DN50 insulated burner.

[0059] As a preferred embodiment:

[0060] The first valve 1-2-5, the second valve 1-2-6, the third valve 2-2-4, and the fourth valve 2-2-6 are all butterfly valves.

[0061] The first valve 1-2-5 and the second valve 1-2-6 are DN150 butterfly valves, and the third valve 2-2-4 and the fourth valve 2-2-6 are DN100 butterfly valves.

[0062] The specific working process of this utility model:

[0063] When this invention is applied to a melting furnace in a production workshop under non-full-capacity conditions, practical verification has shown that it produces the following economic benefits:

[0064] The workshop operates on both the morning and night shifts, with the melting furnace running for 16 hours a day. During the two-shift production period, the concentrated material feeding time is basically maintained at 4 hours per shift. This means that there are 16 hours of idle time for material feeding during the 24-hour production period each day.

[0065] Theoretical calculation: By consulting the relationship between fan air volume, air pressure, and fan power, the following formula can be theoretically applied to calculate the fan input power, which is equivalent to the motor output power:

[0066] P = Q * p / (3600 * n1 * n2 * 1000).

[0067] In the formula, P is the input power (kW), and Q is the air volume (m³ / s). 3 / h), p is the wind pressure (Pa), n1 is the fan efficiency, which is generally taken as 0.719 to 0.8, and n2 is the mechanical efficiency, which is generally taken as 1 for direct shaft connection.

[0068] According to theoretical calculations, during operation, the power of the melting combustion fan (melting condition fan) is calculated as P(combustion) = 2800*8300 / (3600*0.8*1000)≈8(kw); the power of the newly added holding fan (non-melting condition fan) is calculated as P(holding) = 860*5800 / (3600*0.8*1000)≈1.73(kw).

[0069] In practice, by using a clamp meter to measure the actual input current to the motor, the combustion fan line current is maintained at approximately 14A during operation, while the fan current is maintained at approximately 3.3A. With a motor power factor of 0.85, then:

[0070] In actual work process,

[0071] P(melting)≈1.732*380*14*0.85=7.83(kw).

[0072] P(keep) ≈ 1.732 * 380 * 3.3 * 0.85 = 1.85 (kW).

[0073] That is, the actual motor power is not much different from the theoretical calculation, and the economic benefit analysis is based on the actual calculation.

[0074] Before the project was upgraded, the melting furnace consumed 7.83 * 24 = 187.92 kWh of electricity in 24 hours.

[0075] After the project was upgraded, the power consumption for 8 hours of melting operation was (7.83 + 1.85) * 8 = 77.44 kWh, and the power consumption for 16 hours of heat preservation operation was 1.85 * 16 = 29.6 kWh.

[0076] According to calculations, the daily electricity savings on weekdays are 187.92 - 77.44 - 29.6 = 80.88 kWh.

[0077] On non-working days, the workshop mainly focuses on aluminum molten metal insulation. At this time, only the non-molten metal blowers are kept running, while the molten metal blowers are shut down. The resulting economic benefits are more considerable.

[0078] The above technical solutions are only preferred embodiments of this utility model, but the protection scope of this utility model is not limited thereto. Any changes or substitutions that can be conceived by those skilled in the art without creative effort within the technical scope disclosed in this utility model are covered within the protection scope of this utility model.

Claims

1. A low-energy consumption centralized melting furnace, comprising a centralized melting furnace body, further comprising a fan system arranged in communication with the centralized melting furnace body, wherein the fan system comprises a melting condition fan unit (1); The melting condition fan unit (1) comprises a melting condition fan (1-1), and the melting condition fan (1-1) is communicated with a melting burner on a central melting furnace body through a melting condition pipeline (1-2), characterized in that, the fan system further comprises a non-melting condition fan unit (2); the non-melting condition fan unit (2) comprises a non-melting condition fan (2-1), and the non-melting condition fan (2-1) is connected to a heat preservation burner on the centralized melting furnace body through a non-melting condition pipeline (2-2); the non-melting condition fan (2-1) is further connected to a melting condition pipeline (1-2) through the non-melting condition pipeline (2-2); the power of the melting condition fan (1-1) is greater than that of the non-melting condition fan (2-1).

2. The low energy concentration melting furnace of claim 1, wherein, the melting condition pipeline (1-2) comprises a first melting pipeline (1-2-1), a second melting pipeline (1-2-2), a third melting pipeline (1-2-3) and a fourth melting pipeline (1-2-4) arranged in communication; the melting condition fan (1-1) is connected to the first melting pipeline (1-2-1), and the fourth melting pipeline (1-2-4) is connected to a melting burner on the centralized melting furnace body.

3. The low energy concentration melting furnace of claim 2, wherein, a first valve (1-2-5) is arranged between the first melting pipeline (1-2-1) and the second melting pipeline (1-2-2); a second valve (1-2-6) is arranged between the second melting pipeline (1-2-2) and the third melting pipeline (1-2-3); the pipe diameter of the first melting pipeline (1-2-1) is smaller than that of the second melting pipeline (1-2-2), and the pipe diameter of the second melting pipeline (1-2-2) is greater than that of the third melting pipeline (1-2-3).

4. The low energy concentration melting furnace of claim 3, wherein, the non-melting condition pipeline (2-2) comprises a first non-melting pipeline (2-2-1), a second non-melting pipeline (2-2-2) and a third non-melting pipeline (2-2-3) arranged in communication; the non-melting condition fan (2-1) is connected to the first non-melting pipeline (2-2-1), one end of the third non-melting pipeline (2-2-3) is connected to the second melting pipeline (1-2-2), and the other end of the third non-melting pipeline (2-2-3) is connected to the heat preservation burner on the centralized melting furnace body.

5. The low energy concentration melting furnace of claim 4, wherein, a third valve (2-2-4) is arranged between the first non-melting pipeline (2-2-1) and the second non-melting pipeline (2-2-2), a baffle (2-2-5) is arranged on the side of the third non-melting pipeline (2-2-3) close to the second melting pipeline (1-2-2), and a fourth valve (2-2-6) is arranged on the side of the third non-melting pipeline (2-2-2) away from the second melting pipeline (1-2-2).

6. The low energy concentration melting furnace of claim 5, wherein, the first valve (1-2-5), the second valve (1-2-6), the third valve (2-2-4) and the fourth valve (2-2-6) are butterfly valves.

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