Wuxi Wondery Industry Equipment Co., Ltd
Wuxi Wondery Industry Equipment Co., Ltd
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1. General Introduction
The aluminum alloy reverberatory aluminum melting Furnace has a compact structure for both melting and heat preservation function.
The melting pool is formed by once-forming non-stick aluminum casting material, which has the feature of high strength, easy
to cleaning and long service life. The furnace employs famous burner brand, which has automatic ignition, temperature control
and over temperature alarm devices.
2. Technical Parameters
| 2.1 Model: WDL-RJL-2500; 2.2 Furnace capacity: 6000kg; 2.3 Melting rate: 2500kg/hour (at continuous working method); 2.4 aluminum liquid temperature: 720℃; 2.5 temperature control accuracy: ±10℃; 2.6 Fuel: natural gas, value 8600Kcal/M3 gas pressure: 5-8KPa (50-80mbar); 2.7 power supply: 380V 50HZ 17.5KW; 2.8 compressed air: 0.5-0.7Mpa 1.5m3/h (with drying and oil water separation) 2.9 aluminum liquid outlet height: 1650mm; 2.10 outlet method: pneumatic stopper type outlet; 2.11 Gas consumption: 1) less than 65N3/ton aluminum (following conditions should be met:the content of scrap in the returned material is less than 5%, especially when there is no scrap easily oxidized; the ratio of melted material is 50% for the returned material (density 400-500kg/M3) and 50% for the ingot; the temperature of molten aluminum liquid after melting is 750°C.) 2) Less than 58M3/ton aluminum (continuous operation, no oily and watery material, no aluminum scraps, 30% of aluminum scrap melting furnace material (density 400-500kg/M3), 70% of aluminum ingot; molten aluminum liquid temperature, based on 720℃) 3) Less than 55M3/ton aluminum (100% for ingots in continuous operation; aluminum liquid temperature after melting based on 720°C.) Calculation time is timed after the material is put in, and the input raw material per hour is greater than or equal to the melting volume per hour. When the aluminum liquid temperature is reached and the aluminum liquid is discharged, the water output reaches the melting efficiency specified by the equipment, and the minimum 3 hours is a statistical cycle, take the average value as the unit energy consumption standard. 2.12 aluminum ingot: R14 or ADC12, average weight: 8kg or less; 2.13 max aluminum liquid temperature: 750°C; 2.13 melting chamber filling rate: 50% (scrap mateiral unbundled); 2.14 Maximum size of recycled material: must be smaller than the inside dimensions of the material cart; Note: The above parameters must meet the following conditions: A) The aluminum melting furnace should be in a stable state of continuous operation for more than 6 hours. B) The average fuel consumption of 3 hours in continuous melting is the calculated value. C) The actual calorific value of fuel is 8600Kcal/NM3. D) The industrial metal melting furnace and accompanying equipment are in normal operation. E) The energy consumption of degassing, slag removal and holding time is not included in the energy consumption range. |
3.1 The combustion system consists of a fan, butterfly valve, ball valve, pressure switch, pressure gauge, solenoid valve,
UV detection, metal hose and burners. The melting chamber burner is of a long flame type and the holding chamber burner
is of a flat flame type.
3.2 The combustion system is set up with various detections to ensure the normal operation of the equipment: A. UV detection,
to detect whether the burner ignition is successful; B. Liquid level detection, when the aluminum liquid inside the furnace reaches
a high level, the burner will run at reduced power; C. Pressure detection, when the pressure in the piping system is abnormal,
the system issues an alarm.
The gas fired metal melting furnace employs a combination of several electrical components for the control of
temperature objects, thus ensuring the safe and reliable operation of the controlled equipment. The main functions
of the electrical control system are: automatic controller, sensor, transmitter, actuator (final controlling element),
input-output interface (I/O interface)
and other components of the closed-loop control.
Non-linear and time-varying temperature control, fast response time and high accuracy. Control system stability
and adaptability.
The programmable controller PLC of the aluminum scrap melting furnace interacts with the HMI for internal execution of
logic operations, sequential
control operations, and analog outputs, providing an ideal solution for easy control of the furnace temperature.
4.1 Strong environmental tolerance
Based on its strong tolerance to environmental conditions, the protection level is high, including the operating
temperature and storage temperature is wider.
4.2 powerful function: touch screen support data and alarm record archiving function, powerful smart temperature
management trend display function, there are powerful and rich communication capabilities, integrated Ethernet
communication interface, USB port, RS-485 communication interface, accessory serial port (RS232/485 SB signal
board), EM expansion module. modbus slave protocol command. micro SD card slot, CPU sensor power terminal.
5. Main Components List of Aluminum Melting Furnaces
|
No. |
Name |
Model | Quantity |
| 1 | PLC controller (Siemens) | S7-200 SMART CPU SR60 | 1 |
| 2 | PLC analog input module | S7-200 SMART EM AT04 | 1 |
| 3 | PLC analog output module | S7-200 SMART EM AQ02 | 1 |
| 4 | Touch Screen (Siemens) | SMART 1000 IE | 1 |
| 5 | Miniature Circuit Breakers Schneider | IC652P C10A | 1 |
| 6 | Motor Circuit Breakers Schneider | GV2-ME12C | 1 |
| 7 | AC Contactors Schneider | LC1D12M7C | 1 |
| 8 | Intermediate Relays Schneider | RXM2LB2P7 | 5 |
| 9 | Push Button Switches Schneider | XB5AW33BIC | 2 |
| 10 | Emergency Stop Switch Schneider | XB5ASS542C | 1 |
| 11 | Signal Lights Schneider | XB2-BVM3LC | 3 |
| 12 | Photoelectric Sensors OMRON | E3Z-T61 2M | 2 |
| 13 | Heavy Duty Connector | HDH024-01 | 2 |
| 14 | Flame detector (ion detection rod) | M14 | 1 |
| 15 | Ignition Program Controller (Honeywell) | TBC2800/A10000 | 2 |
| 16 | Ignition transformer (Zhe I) | BGY004-8/GS25P 220V | 2 |
| 17 | Magnetic switch | CS1-U | 1 |
| 18 | Proportional motor actuator (Honeywell) | M7284A1004 (AC 220V 7284) | 2 |
| 19 | Gas ignition and combustion solenoid valve (Japan CKD) | AB4103-07 (AC 220V) | 2 |
|
20 | Gas melting combustion solenoid valve (Honeywell) | DN80 (AC 220V) |
2 |
|
21 | Gas Hold Burn Solenoid Valve (Honeywell) | DN40 (AC 220V) |
1 |
| 22 | Flame detector FIREYE | UV1AL-6 | |
| 23 | Pressure Reducing Valve Italy Fite | DN65 | 1 |
| 24 | Manual Butterfly Valve Best | (DN80 thread with scale) | 1 |
| 25 | Gas Master Valve (Honeywell) | DN80 (AC 220V) | 1 |
| 26 | Gas pressure switch (Dungs) | A2210 (Low pressure alarm) | 1 |
| 27 | Gas pressure switch (Dungs) | A2310 (High Voltage Alarm) | 1 |
| 28 | Air pressure switch (Dungs) | A2310(Low pressure alarm) | 1 |
|
29 | Material detection device in the furnace tower (Omron system) | E3JK-5M (220V) |
1 |
|
30 | Holding room liquid level detection device (Omron system) | 61F-GP-N |
1 |
| 31 | Furnace lid cylinder (Taiwan Airtac) | SC125X800STCM1 | 1 |
| 32 | Drain port air cylinder (Taiwan Yadec) | SC80×200-CA-CB | 1 |
| 33 | Low voltage components | OMRON, Schneider, etc |
Notes: The components brand for the components of the aluminum casting furnaces
might be changed to equivalent ones without noticing the customer due to unavailability of current ones.