 压铸周刊（2014年8月20日 德国维赫尔市）史杰克西集团（古默斯巴赫）的研发人员已开发出新型耐热预熔区废气挡板，能够有效缩短自由熔化过程时间、减少气体能耗、改善金属产能，更重要的是再次提高StrikoMelter熔炉的效能。 新型废气挡板能够在熔炉清洗过程中降低自由熔化的时长，每次约20分钟左右。“现在我们已经研发出能够永久承受900摄氏度左右高的废气温度的材料，”史杰克西的研发人员Rudolf Hillen解释道：“该废气挡板不仅能够在自由熔化过程中降低15%的能耗，整个系统的整体效能也提高了百分之五左右。” 日常铸造厂的操作性能不仅仅指保持较低的能耗和金属烧损。系统的可用性也起着关键作用——每一小时的停工期都意味着收入的减少。不过，为了确保系统的永久效能及高效性能，在日常熔化操作过程中对熔炉进行定期保养工作是绝对必要的。这包括熔炉的清洗，通常是每班一次。在该过程中，熔化室必须在额定电压下进行自由熔化。只有这样才能将残余的渣滓移除。 “自由熔化过程的长短对系统的产能有着直接的影响，因此需尽可能地缩短。”史杰克西的经理Rudi Riedel解释道。在这样的背景下，热能工艺技术制造商史杰克西如今已经研发出覆盖预熔区的废气挡板。该设计能够承受自由熔化过程中形成的高废气温度。 “预熔区废气挡板能够降低自由熔化过程中累积的生产停滞期，约为每班次20分钟。这样，每天就可以多出一个小时的生产时间。”Riedel解释道，“同时，自由熔化过程中的能耗约降低了15%。清洁盐的消耗也通过废气挡板得以降低。” 所有型号的StrikoMelter熔炉都配有耐火预熔区挡板，同时也可以进行改装以适应现有系统。“对于每小时两吨以上熔化率的熔炉来说，我们废气挡板的效果尤佳，”史杰克西集团的研发人员Rudolf Hillen解释道。在性能超过该数值的系统中，此类投资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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