[ Abstract ] This paper briefly describes the application of heat treatment and energy saving in actual production, and analyzes the methods and methods of heat treatment and energy saving in technology and management. The heat treatment technology achieves the goal of energy saving, emission reduction, high quality and high efficiency.
Keywords: heat treatment energy saving, process flow, system, management production
Shuangniu (Xiamen) Machinery Co., Ltd. is a manufacturer of production engineering machinery. Many parts of the machinery industry are subject to heat treatment to achieve the designed mechanical conditions, give full play to the performance of materials, ensure product quality, and improve the grade of mechanical parts. Competitiveness in the market. Our company officially established the Heat Treatment Division at the end of 2005. In the initial stage of the planning, the heat treatment equipment layout, process flow, power supply equipment and quenching cooling system were optimized and arranged in the form of documents in accordance with the principle of energy saving and emission reduction. .
The heat treatment energy saving mentioned here is mainly composed of several factors:
1): Whether the heat treatment process is effective to allow the processed workpiece to meet the technical requirements of its design, and at a lower cost.
2): Whether the heat treatment equipment has been effectively and reasonably used in operation, such as continuous production, and the equipment waiting time is reduced. There is no additional heat loss.
3): Heat treatment operators, process technicians, and production management personnel are well communicated, and everyone can be effectively managed and organized.
1. Heat treatment process:
In the traditional process calculation time: T = K * A * D in the T is the heating time, K is the furnace loading coefficient, A is the heating coefficient, D is the effective thickness of the workpiece, in fact, in actual production, generally based on past work The experience and the effective thickness of the workpiece to calculate the holding time, in large quantities based on actual experience or to observe the fire color of the workpiece, which is mainly reflected in carbon steel and low alloy steel, because carbon steel has no alloying elements and carbides. It does not need to keep the austenitizing process for a long time. Low alloy steel has a heat transfer coefficient similar to that of carbon steel, so the heat transfer time of the workpiece is mainly determined by its effective size. For a single piece of workpiece in production, when the furnace temperature has reached the process setting value, When the surface of the workpiece has reached the process temperature value, the workpiece has been sterilized. Do not add additional insulation time. This is what we often call “zero†insulation heating. For mass production, we generally heat the furnace first, then put it into the workpiece after the temperature is reached, and when the furnace temperature reaches the process time again, add a certain homogenization time, which can shorten the process cycle relatively, save energy and reduce cost.
Alloy structural steel (40Cr, 35CrMo, 42CrMo), etc., because some alloying elements are added to the material, we need to make the carbide homogenization in the heating process for a certain time, so it is a little more than carbon steel. Time, generally we have to be about 60%-80% of the traditional process time, this can shorten the heating time of the steel at high temperature, the deformation is also relatively reduced, the austenitic grains are relatively small, can be obtained after quenching The fine martensite structure has a certain improvement in its mechanical properties, which is what our heat treatment workers want to achieve.
2, the parts are loaded
1): In actual production, when the number of workpieces is limited, it is not cost-effective to arrange the furnaces separately. In this case, we can put different workpieces and different materials in the same process parameters. Mixing a furnace, such as Cr12MoV and 8407 or H13, 40Cr and 42CrMo are the same. The quenching temperature is about the same, so that the furnace capacity can be satisfied. Similarly, when the tempering temperature is the same, different parts and different materials can be mixed together, and the tempering time can be based on the longest tempering time. carried out.
2): Heat treatment fixtures, in fact, many of our products are not nearly the same, but the amount is not a lot, but in order to reduce the amount of deformation, sometimes increase the heat treatment tooling, so I often do not use heat-resistant stainless steel, most of them have ordinary low-carbon steel Instead, the main reason is that the price of the material is low, and there are not many.
3. Heat treatment cooling medium
Since many of the mechanical parts of our company are alloy structural steels, when considering quenching media. I choose to use aqueous solution, aqueous solution quenching to avoid large-diameter medium-carbon low-alloy steel in heat treatment with oil hardness hardness may not reach, water quenching easy to crack, water-soluble synthetic quenching liquid is especially suitable for low, medium carbon steel induction and Large-scale quenching, water-soluble synthetic quenching liquid is especially suitable for low- and medium-carbon steel induction and large-piece quenching. By adjusting the concentration, etc., different cooling rates can be obtained. The quenched workpiece is bright and has short-term anti-rust effect, and can be directly tempered without cleaning. , no fumes. No fumes, no burning, no fire hazard, improve the working environment. It is not easy to age, deteriorate, and has a long service life, compared to oil. The cost is also relatively small.
4, tempering process: tempering process is to determine the residual heat of the furnace to be used according to the tempering temperature of the part. The general rule is that the tempering temperature of the part is lower than the residual heat temperature of the furnace by about 300 degrees, so that the furnace is quickly after the workpiece enters the furnace. The tempering process temperature setting value is reached, and multiple tempering is better than one tempering. Therefore, in the mass production, the second tempering results in better tissue performance than a tempering, and the cost is also reduced accordingly.
5, equipment maintenance and maintenance: we must regularly repair equipment in the production, check the furnace, the sealing of the furnace door. The instrumentation and instrumentation related to the distribution box should be regularly calibrated and maintained to reduce the loss caused by the shutdown caused by the electrical failure. All relevant operating equipment, such as trolleys, maintenance of the vehicle reduces the inconvenience caused by the inconvenience of entering and leaving the furnace.
6. Control of heat treatment quality: In fact, when the workpiece is heat treated, it is energy-saving. If a workpiece is not subjected to effective and reasonable heat treatment, the time limit of the part will not be long. It is necessary to manufacture new parts in the early stage of failure. The parts are replaced, which in turn will consume raw materials and machining time, and other related costs. Effective and reasonable heat treatment can double the service life of the workpiece. Therefore, the quality of the heat treatment can avoid the early failure of the workpiece, and can avoid a series of procedures such as heat treatment of the workpiece (normalizing, re-quenching, correcting, de-stressing and tempering). Therefore, our country had a slogan in the 1970s: "Do a good job of heat treatment, and a few parts."
Heat treatment energy saving is often related to process management, reasonable arrangement of work, reduction of furnace shutdown time, and the heating period of the furnace is placed in a time-consuming period of low electricity consumption. In many cases, the execution of the process is related to management, and the company must strictly formulate the process specifications and Equipment operating standards, and related technical standards. In the production arrangement, it is necessary to batch-load full-load production as much as possible, and it is not enough to install the furnace, and prepare for the heat treatment in advance. Regularly check the operation of each equipment in the heat treatment.
in conclusion
Actively improve the business level, operation level and related work awareness of heat treatment personnel, and improve the working attitude of heat treatment personnel. Because many times the final determining factor is still "people." In the case where the relevant hardware cannot be changed, the working attitude as a person is software. We can formulate relevant systems, implement rewards and punishments regulations, count and evaluate energy consumption in production, and carry out rectification management for bad.
Energy conservation and emission reduction are in a very important position in our work. How to save energy, improve production efficiency, reduce costs, and establish our own brand in the market competition. The improvement of production and technical management level is an important measure to implement the development of science and technology and the development of enterprises. The awareness of energy conservation starts from me, starting from now, starting from the bit by bit at work. The heat treatment technology achieves the goal of energy saving, emission reduction, high quality and high efficiency. It also makes the product quality and quality control in the market at a certain level.
1. Product introduction
Coal-based columnar net gas Activated Carbon is cylindrical, tasteless non-toxic; as high quality anthracite the raw material, by process of crushing, mixing, extrusion, molding, drying, carbonization, activation and made. It has reasonable pore structure, good adsorption properties, high mechanical strength, able to withstand the high temperature, high pressure and not easily broken, easy to regenerate, and low cost characteristics. It is widely used in sewage treatment, gas treatment, solvent recovery, desulfurization and denitrification, nitrogen making machine, air separation equipment, paint shop and other fields.
2. Application
a.Coal columnar net gas activated carbon used for purification, such as chemical raw materials, pharmaceutical chemical synthesis gas, industrial gas, nitrogen, chlorine, hydrogen chloride, ethylene hydrocarbons, ozone, ethane, butane, cracking gas, carbon dioxide and hydrogen used in beverage; atomic facilities exhaust inert gas and remove the pollutants; also separate and purify mixed gas. It also can be used for gas masks and protective equipment disinfection and filtration.
b.Coal columnar net gas activated carbon is mainly suitable for industrial waste treatment, such as waste gas power plant, chemical plant gas, coking plant, smelting plant, oil plant. Coal columnar net gas activated carbon rely on the good adsorption capacity, developed gap, high iodine value can make a cleaning purpose.
3. Adsorption purification principle and process
The physical properties of coal-based activated carbon introduction: it is cylindrical black particles; the physical, chemical properties analysis of carbon is a porous carbon, the highly developed pore structure makes it has large surface area, so it is easy to full contact with toxic and harmful gases in the air (and harmful impurities), so this highly developed capillary and pore structure formed a powerful adsorption force field, which gives the unique adsorption properties of activated carbon.
Adsorption: the organic waste gas passes through the filter removed the solid particulate material, from the upper to the lower into the adsorption tank. The organic matter is captured, absorbed and concentrated by the activated carbon, and the purified air is discharged from the lower part of the tank through the main fan into the atmosphere.
Stop: when activated carbon adsorption reached saturation,it stops to inhalation waste gas; and then blowing up into the steam through the activated carbon bed, which expelled the organic matter from the activated carbon, and the subsequent restoration of desorption, activated carbon activity is recycled.
Hot air drying and cooling: the activated carbon layer after desorption remains 80%-90% steam condensate which can in reducing carbon layer activity; therefore using the hot air to dry, close the steam valve, and then through the air cooling at 25 DEG C, activated carbon can be recovered into the circulation.
Columnar Net Gas Activated Carbon
Columnar Net Gas Activated Carbon,Columnar Activated Carbon,Pellet Activated Carbon For Gas Mask
Ningxia XingKai Silicon Industry Co., Ltd. , http://www.xingkaisic.com