- Model NO.: ND-THF-950
- Place Style: Horizontal
- Type: Industrial Furnace
- Fuel: Gas
- Specification: Custom Design
- HS Code: 8514901000
- Certification: CE, ISO
- Range of Applications: Industrial
- Usage: Sand Casting
- Trademark: Nianda
- Origin: China
The equipment is mainly used for heating of copper rods. Maximum temperature is ≤1100ºC.
1.2 Main Characteristics
To save space, equipment adopts one end charge and the other end discharge. Discharging door is designed in a small size, thus can reduce energy consumption effectively.
Reasonable and reliable transmission device, hydraulic pushing machine, and perfect alarm detecting function ensures the equipment automatically and stably run. Copper ingot is free from deviation.
Dedicated high-quality combustion device and improved control system can realize automatic temperature control.
To increase thermal efficiency, the heat exchanger is supplied in this furnace, so to fully use of heat remaining in exhausted fume.
Working condition are recorded in the control system in Excel format.
The whole heating process for thermal recording parameters can be output to track the heating condition of furnace chamber.
Ingot running condition can be intuitively reflected in the monitoring system in PC.
Advanced pressure control system ensures furnace pressure remain at micro positive level.
2 Main Technical Parameter
Copper Round Ingot
Dimension of Ingot
Max. Production Rate
Production Rate Per Hour
Length of Furnace Chamber
Max. Gas Consumption
Effective Dimension (L*W*H)
Temperature control accuracy
Fume Exhausting Method
From Furnace Roof
Combustion Pressure of Burner
Combustion Air Pressure
Pre-heat Air Temperature
This copper round ingot heating furnace consists of the feeding device, furnace shell, lining, furnace slide rain, hydraulic system, gas system, heat exchanger systems, door, PLC control system discharge system, and the computer control and so on.
3.1 Feeding Device
Copper ingot travels inside by pushing device. 3 rows of ingots are paralleled placed at supporting-sliding-rails, ingots will one by one forward move with pushing force by the hydraulic cylinder.
Feeding device also includes pusher system and the Front track.
Pusher system includes a fixed framework for hydraulic cylinder, cylinder and pushing head. Steel structure is welded together and fixed with foundation by expansion bolts.
Front track is made of casting steel rail; it is fixed with steel framework and linked with support-sliding-rails inside of furnace chamber.
3.2 furnace shell
Furnace shell adopts formed steel and high-quality steel plate and welded together. The reliable structure provides a sturdy and solid appearance. In order to ensure the strength and ease of transport, equipment is partially fabricated and assembled in buyer shop.
Furnace body is fabricated with high quality steel and steel plate processing. Segment junction parts are connected with bolts. To ensure adequate strength, after installation, function parts are molding welded together.
Furnace lining adopts compound structure, it is made of alumina-silicate fiber and fire-brick.
Top and two sides of wall adopts new energy-saving materials, pre-compressed fiber folding block are fixed on shell with special anchors. This structure has low thermal conductivity, low hot-melt, excellent chemical stability, thermal stability, thermal shock resistance and excellent tensile strength. Pre-compressed alumina silicate fiber blocks can bear temperature of 1260 ºC, the density up to 230kg/m3. To ensure the surface lower temperature, thickness of lining is 350mm, and thinness of roof fiber is 370mm.
Bottom lining: it is made of fire-bricks. Total thickness of bottom lining is ~380mm. Compositing masonry structure, lowest layer: adopts diatomite insulation firebrick, Middle layer: light weight fire-brick, top layer: 1.3 light weight firebrick. This kind of structure can reduce furnace deadweight, furnace can be heated up quickly, with longer service life.
At discharge end, two sides of port and bottom is made of steel-fiber castables, so to ensure furnace port has adequate strength and good heat resistance performance.
3.4 Inside Sliding Track
It consists of supporting rack, rolling wheel, and sleeper (for bear the rail.) sleeper is made of CrMnN castings, supping rack of track is made of 3Cr24Ni7Si2N heat resistance castings. Each rail is partially fabricated, with interval of 25mm between each rail. For rail can be fee expansion, one end of rail is fixed on the sleeper and the other end is rest on the slot of sleeper by clasping material. Rolling wheel in preheating zone is made of 3Cr24Ni7Si2N heat resistance material, rolling wheel in heating and soaking zone adopts Cr25Ni20 material. Middle of rolling wheel is formed as V-shape, so to ensure ingot can travel on it free from falling down .
3.5 Hydraulic System
It consists of hydraulic station, hydraulic cylinder, and control system.
The hydraulic System has over-voltage protection and unloading functions, load capacity with automatic adjustment, can save energy. it has compact structure, reasonable arrangement, with a novel appearance. Components of the system are easy for handling, installation and adjustment; indicating label is fixed on oil tank. The hydraulic is reliable and smooth running, free from impact and noise.
To avoid incident, motor of oil pump is covered with protecting hood. Besides, the cut-off valve is designed at oil suction outlet, so that oil tank could not be emptied if lack of oil.
To ensure reliable operation, valves and auxiliaries of the hydraulic system are imported from abroad. Oil tank which made of stainless steel is seamlessly welded in compact rectangle structure; this structure is easy for clean and transportation, also it is suitable for harsh environments.
To reduce shock during working process, outlet of oil pump is added with anti-vibration absorber; oil pump pressure outlet connects with the main pipeline with flexible high pressure hose.
Oil flowing direction are marked on the pipe line, those marks is consistent with the hydraulic schematic diagram.
Oil pump rotating direction is also indicted on the general drawing, code of solenoid valve is consistent with the hydraulic schematic diagram.
Oil temperature is controlled from 20ºC to 55ºC, and will not be over than 60ºC. Oil level is inspected by the oil meter. If oil is reached limited level, it will send out alarm signal.
Inlet and outlet of oil tank and cylinders are equipped with pipe joint.
To ensure perfect sealing, sealing of All components of the hydraulic system and its binding site are imported from abroad. the pressure does not produce oil leaking all the electromagnetic control valve and the signal lines are concentrated in the terminal box of the terminal block.
3.6 Combustion System
It consists of gas pipe line, burner system and combustion pipe line.
Gas pipeline: Gas mains start from the workshop supervisor Road, interfaces, with the main channel manual valves, pressure gauges, flow meters, valves, pressure switches, pressure switches, electric shut-off valve, pressure gauge, elution valves and piping.
Gas branch pipeline is connected to each burner with the main gas line. Branch line is mounted with manual valve, electric valves and proportional valves. Manual valve is designed for the burner gas flow control, proportional valve will regular air/gas flow rate automatically.
Combustion Air Pipe:the combustion air pipe is connected with a heat exchanger and then divided into 5 heating zones. Each main pipe line is mounted with actuator + air butterfly valve for centering control combustion air volume of each zone. Branch pipe is equipped with manual air butterfly valve and corrugated pipe. Manual air butterfly valve is supplied for control air flow volume, and corrugated pipe is used to protect the burner.
2 sets of gas leak detectors are located at top of furnace. Any one of the gas leak detection device detects the signal will be given to the control system, so that the control system gives the command to cut off the gas main pipe line, thus to ensure the safe use of gas.
3.7 Heat Exchanger System
To save energy, the heat exchanger is equipped with the furnace. it is made of stainless steel tube by a professional factory manufacturing. Fume inlet, fume outlet, heated air inlet and heated air outlet are designed with the heat exchanger.
When the secondary air through the heat exchanger using heat from flue gas to preheat, preheat the secondary air after the burner will burn more fully, and to effectively reduce the temperature of flue gas and reduce the heat loss. The heated air can be reached to 200~300ºC after heat exchanger.
There is an electric actuator mounted at outlet of heat exchanger. , through furnace pressure sensors adjust fume expelling volume, thus to control the furnace pressure. To prevent heat loss, hot air to each burner from the air pipe are coated with aluminum silicate fiber, and then covered with a galvanized sheet for decoration purpose.
Anti-explosion exhaust pipe systems are installed to ensure safe operation of equipment. Besides, the furnace is equipped with a furnace pressure control system , it can automatically adjust the furnace pressure the amount of exhaust valves open, so that the furnace pressure is controlled under positive level.
3.8 Furnace Door
The furnace adopts one end charge and the other end discharge. Discharge door is controlled by speed reducer; automatic adjustment of the door operation. Door motor power is 1.5Kw. Discharge door is made of heat resistance cast iron. Door is lined with full fiber.
3.9 Unloading System
the discharge system adopts roller structure. Copper rod will be slide out our furnace chamber along at the slope at the end of the door. (the discharge table is prepared by the users themselves).
3.10 PLC PLC and PC control system
PLC (Siemens S7-200 series) is the core in the control system. All data are set through PLC.
Main Function of PLC control System:
Combustion control: it includes burner ignition, flame inspection, small/large flame adjusting, Burner failure alarm, blowing before igniting, and data checking/control. Etc.
Temperature control: temperature in each heating zone is adjusted accordance with pre-set working process, and is stored in recorder.
Power supply control: (fan, furnace door, pushing machine, etc.)
Interlock protection control: (working procedure interlock, gas supply interlock, etc.)
e. Combustion Control System
The combustion control includes the following function: proportional regulating of each burner, burner igniting flame adjusting, flame detecting, burner failure alarm signal, gas pipe purging before fire, pressure setting, and flow volume setting. Etc.
Its main function is for inspection and management the heating furnace:
Its main functions are as following:
Burner working conditions are indicated in liquid crystal display in picture form. (For instance: burner normal running, burner flame out ...failure, etc)
Working Conditions of the whole system are indicated in liquid Crystal Display in analog. (For example: furnace door fully opening, furnace door completely closed etc)
Data Display function.(for example: pre-set temperature, actual temperature, exhausted fume temperature etc. )
Working process is pre-set and stored in master computer. Operator can check and print those data at any moment.