Induction Furnace VS Gas Furnace

Induction Furnace VS Gas Furnace

Induction Furnace

Induction furnace is an electric furnace that uses the induction electrothermal effect of materials to heat or melt materials. The basic component of an induction furnace is an induction coil wound with a copper tube.

AC voltage is applied to both ends of the induction coil to generate an alternating electromagnetic field. Conductive materials are placed in the induction coil, and eddy currents are generated in the materials due to electromagnetic induction, and the electrical energy is converted into heat energy to heat the materials by the action of resistance; therefore, it can also be regarded as Induction heating is a direct heating resistance heating.

The characteristic of induction heating is that the electric heating power (current distribution) transformed in the heated material is very uneven, the surface is the largest and the center is the smallest, which is called the skin effect.

Induction Furnace Series Heating Furnace Features:

(1) Fast heating speed, high production efficiency, less oxidation, and decarburization, saving material and forging die costs.

Since the principle of intermediate frequency induction heating is electromagnetic induction, the heat is generated in the workpiece itself. Ordinary workers can continue the forging task ten minutes after going to work with the intermediate frequency electric furnace, and there is no need for professional workers to burn the furnace and seal the furnace in advance. 

(2) The working environment is superior, improving the working environment of workers and the image of the company, with no pollution, and low energy consumption.

Compared with the coal furnace, the induction heating furnace will no longer be baked and smoked by the coal furnace under the scorching sun and can meet the requirements of the environmental protection department. At the same time, it can establish the company's external image and the future development trend of the forging industry. Induction heating is the most energy-saving heating method in the electric heating furnace. The power consumption of ton forgings heated from room temperature to 1100 ° C is less than 360 degrees.

(3) Uniform heating, the extremely small temperature difference between core and surface, and high-temperature control accuracy.

Induction heating furnace has the advantages of being small in size, lightweight, high efficiency, having excellent thermal processing quality, and a favorable environment. It is rapidly eliminating coal-fired furnaces, gas furnaces, oil furnaces, and ordinary resistance furnaces. It is a new generation of metal heating equipment.

In production, after each furnace of metal is smelted, the molten pool cannot be emptied, otherwise, it will dry up easily, and a part of the melt must be reserved as the starting melt for the next furnace. The temperature of the melting channel is higher than that of the molten pool, and it is also subjected to erosion of the melt flow, so the lining of the melting channel is easily damaged. In order to facilitate maintenance, the inductor of the modern furnace is made into an assembly that is easy to replace. The capacity of the melting channel furnace ranges from several hundred kilograms to more than one hundred tons. The melting channel furnace supplies power frequency power, and since the iron core made of silicon steel sheets is used as the magnetic path, the electrical efficiency and power factor are very high. The melting channel furnace is mainly used for melting cast iron, copper, zinc, brass, etc., and can also be used as a mixed melting furnace to store and heat the melt.

Gas Furnace

Gas furnaces are classified according to the gas production process and the quality of the gas produced

Gas furnace is an ideal secondary energy equipment for various heating furnaces and industrial kilns in machinery, metallurgy, chemical industry, light industry, building materials, glass, and other industries.

According to the gas production process and the quality of the gas produced, it is divided into the single-stage gas furnace, two-stage gas furnace, two-stage hot gas furnace, and two-stage cold clean gas furnace.

The single-stage gas furnace has simple equipment, consisting of only a water jacket, a furnace top device, and a slag discharge system. The gas produced is hot and dirty gas and is suitable for kilns with short transportation distances and low requirements for gas cleanliness.

The two-stage gas furnace is to add a dry distillation section to the upper part of the original gas generator. The two-stage gas furnace is to add a dry distillation section on the basis of the single-stage gas furnace. Bituminous coal is subjected to dry distillation, and the volatile content after dry distillation is 2-3%. The dry distillation product of coal is semi-coke or coke, and then the semi-coke or coke is vaporized to generate gas. The fuel is bituminous coal. It is divided into upper and lower gas outlets. The gas from the lower section of the gas outlet is the gas generated by the vaporization of semi-coke or coke after carbonization and does not contain tar. The gas in the upper section is dry distillation gas with high C and H compound content and carbonization crystals. Tar, the tar produced is produced by dry distillation at a temperature of 550-750 ° C. It is a light tar, similar to diesel oil. The output is about 3-4% of coal consumption, and the calorific value is about 10,000 kcal. It can be taken out or used as fuel oil. The gas produced by the two-stage gas furnace is relatively clean, the transportation distance is long, and the requirements for coal quality are not as high as those of the single-stage gas furnace. The gas produced by the two-stage cold gas station with a purified cooling device can be pressurized and transported long-distance according to the user's requirements. It is not limited by the site. The quality of the cold and clean gas is relatively clean. Chemical, ceramic and other industries.

Classified According to the Way of the Slag Discharge

According to different slagging methods, gas furnaces are commonly divided into two methods: internal slag discharge and external slag discharge. Among them, the external slag discharge gasifier is divided into two types: worm slag discharge and hydraulic ratchet slag discharge due to different transmission methods, which are more commonly used. The most important are these two ways of slag removal.

Classified by Coaling Method

According to the different coal feeding forms, the gas furnace is divided into three methods: single-channel single-drum, single-channel double-drum, and double-channel double-drum. The more commonly used method is single-channel single-drum.

Classified by Desulfurization Form

Different desulfurization forms, it is divided into dry desulfurization and wet desulfurization. According to different fuels of users and different requirements for hydrogen sulfide content in gas, different desulfurization processes are adopted to make the purified gas reach the minimum operating cost. National emission requirements, but also to meet user requirements. After the system is put into operation, the production is stable and the desulfurization effect is good. It reduces the emission of sulfide in the process of gas combustion, reduces environmental pollution, reduces the labor intensity of operators, and greatly reduces operating costs.

The Importance of Grate Selection

The grate is one of the core components of the gas furnace, which plays a very important role in the gas generation process. Correctly selecting a grate with excellent performance and applying it scientifically is the key to improving the gasification intensity of the gas furnace and reducing coal consumption.

A Grate with Good Performance Should have the Following Functions:

(1) The air distribution is reasonable so that the furnace section can achieve uniform air distribution.

(2) The ventilation area should be larger because there is only a large ventilation area (the ventilation area should be calculated based on the narrowest area between the furnace layers perpendicular to the inside of the vent, and the calculation based on the area of the furnace contacting fuel and ash is no problem. Scientific reason) grate can achieve high gasification intensity.

(3) It has the functions of slag receiving, slag guiding, slag pushing, slag breaking, and slag discharging.

(4) Long service life. The early grates were made of cast iron, which had a short service life and had to be replaced every 5 to 6 months. Most of them are made of cast steel and have a long service life. A good grate can be used for more than 2 years.