معدات كيميائية أخرى Complete Salt Bath Heat Treatment Plant

Preis: Contact us for price
DESCRIPTION
Complete salt bath heat treatment line for preheating
drying
carburizing
hardening
annealing
quenching
tempering (incl. bainite treatment) and washing of metallic parts. Usable batch size: Ø 800 x 1200 mm. Includes switchgear with Siemens S7 PLC
WinCC flexible visualization
batch data archiving and energy/load management
plus a dust extraction filter system. Positions refer to installation plan Rev. 4
SCOPE OF SUPPLY
1. Electric Shaft Furnace
type ESO-80/120 – 3 units (Pos. 3
4
16)
Usable diameter: 800 mm
Usable depth: 1,200 mm
Nominal temperature: 500 °C
Rated power: 50 kW
Electrical connection: 400 V
3/N/PE ~ 50 Hz
Compressed air requirement: 6 bar
Application: shaft furnace with air circulation for preheating and drying
Housing: welded sheet steel construction reinforced with steel profiles
Usable space: air guide cylinder with annular base
heated electrically by meandering resistance wire coils
Air circulation: fan built into the furnace floor
indirectly driven by a flange motor
draws air from the usable space and blows it in a broad stream upwards outside the air guide cylinder through the heating coils
Lid: raised mechanically by a pneumatic cylinder
2. Natural Gas-Fired Crucible Salt Bath Furnace
type GSOT-80/120 – 4 units (Pos. 5–8)
Clear crucible diameter: 800 mm
Clear crucible depth: 1,200 mm
Crucible capacity: 540 l
Nominal temperature: 750–950 °C
Rated power: 200 kW
Burners: 4 x Kromschröder BIC 65
ionization flame monitoring
direct ignition
IFD244 burner control
combustion air blower with distribution line incl. throttle valves
Control mode: high / low / off
Gas flow meter: DE25R25-40B with interface
Fuel: natural gas H
Gas flow pressure: approx. 70 mbar (operating range 65–75 mbar)
Max. exhaust gas temperature at exhaust outlet: 600 °C
Exhaust connection: Ø 250 mm
Electrical connection: 400 V
3/N/PE ~ 50 Hz
Application: carburizing
hardening or annealing of metallic parts in a salt bath
Housing: welded sheet steel construction reinforced with steel profiles
designed for all mechanical and thermal loads
Usable space: special crucible
its raised edge resting on the top of the furnace casing
Insulation: high-quality insulating bricks and lightweight firebricks
Heating: 4 burners arranged around the crucible
heating the combustion chamber tangentially around the crucible
Exhaust: routed from the combustion chamber through an exhaust pipe into an air preheater
which heats the combustion air (typically 15–20% energy saving compared to unheated air)
draft interrupter after the air preheater
connected to the exhaust pipe to the chimney
Ring extraction for removal of salt vapors
3. Electric Thermal Salt Bath (Tub Type)
type ETOW-100/120/150 – 1 unit (Pos. 9)
Clear tub length: 1,600 mm (usable length 800 mm)
Clear tub width: 1,000 mm (usable width 800 mm)
Clear tub depth: 1,500 mm (usable depth 1,200 mm)
Usable salt capacity: approx. 2,240 l
Max. nominal temperature: 450 °C
Nominal heating output: 105 kW
Cooling fan: volume flow 0.71 m³/s
pressure difference 1.86 kPa
Stirrer: three-phase motor with extended shaft
1,420 rpm at 50 Hz
mixing blade D=148 / M16
Electrical connection: 400 V
3/N/PE ~ 50 Hz
Application: quenching or tempering of metallic parts in a salt bath
bainite treatment of a batch also possible
Housing: welded sheet steel construction reinforced with steel profiles
with built-in insulation
Usable space: tub with its edge resting on the furnace housing
Heating: meandering resistance wire coils arranged around the tub
Stirrer mounted on a console at the end of the tub opposite the operator
Continuous desludging for filtration of the molten salt
mainly carbonate removal
uses customer-provided equipment
operated with compressed air
must be emptied cyclically (at the edge of the tub)
Enclosure with salt vapor extraction
pneumatic double swing doors at front and rear (in charging direction)
opened and closed by the operator via a diverter valve
Viewing window at eye level for precise positioning of the batch
Slot in the enclosure ceiling for the hoist rope/chain
Cooling fan cools the tub from the outside if adding warm parts heats the salt bath above the set temperature
warm air discharged through an exhaust vent
4. Electrically Heated 3-Stage Wash Tank
3x100x125x150 – 1 unit (Pos. 11–14)
Usable width: 3 x 800 mm
Usable length: 3 x 800 mm
Usable depth: 3 x approx. 1,200 mm
Volume: 3 x approx. 1,900 l
Nominal temperature: 70 °C (basins 2 and 3)
Heating capacity: approx. 60 kW (2 x 30 kW
basins 2 and 3)
Electrical connection: 400 V
3/N/PE ~ 50 Hz
Stirrers: 3 x hollow shaft motor with extended shaft
1,500 rpm at 50 Hz
shaft material 1.4571
secured stirring element D=160 in material 1.4401
Circulation capacity: approx. 324 m³/h
Application: washing salt residue off metallic parts
batch can also be quenched in water in the first wash stage
Housing: welded stainless steel sheet construction reinforced with steel profiles
Basin 1 (Pos. 11): unheated
with cooling plates to be connected by the customer to an existing cooling water circuit
removes heat from quenching the parts
Basins 2 and 3 (Pos. 12
13): washing stages for final cleaning
heated by replaceable heating cartridges
Insulation: high-quality insulating panels
Stirrers mix the water and speed up removal of salt particles from the batch
Water flow: fresh water fed into basin 3
cascades over basin 2 into basin 1
salt concentration is highest in basin 1
which overflows into a pumping station (Pos. 14) leading to the wastewater tank
5. Switchgear and Control System – 1 unit (Pos. 20)
Depth: 600 mm
Supply: 400 V AC
3L/N/PE
Current: approx. 650 A
Power: approx. 420 kW
Control voltage: 24 V DC
Auxiliary voltage: 230 V AC
Cabinet cooling: 2 roof-mounted cooling units
Designed exclusively for operating the plant components in this offer
Resistance heaters controlled according to their power by Eurotherm EPower thyristor controllers in a 2-phase energy-saving circuit
with upstream safety contactors
EPower controllers with "load current management" option
transmit performance data to the central control system
Safety temperature limiters on the GSOT gas-fired salt baths and the thermal salt bath
Gas meter with M-Bus interface connected to the control unit
gas consumption data transmitted to the central control system
PLC: Siemens Simatic S7-317 PN/DP
controls and regulates all plant components
Audible and visual alarm at the end of the set heat treatment process
Visualization: PC with Siemens WinCC flexible
Order management and batch data archiving: PMQUALITI
prepared for batch analysis
Processing of energy consumption and load management data
6. Air Cooling / Salt Draining Station – 1 unit (Pos. 10)
Clear diameter: 800 mm
Clear depth: 1,200 mm
Application: cooling the batch and draining salt residues
Construction: welded sheet steel reinforced with steel profiles
Pull-out salt collection tray in the bottom
must be cleaned cyclically
7. Water Drip Station – 1 unit (Pos. 15)
Clear diameter: 800 mm
Clear depth: 1,200 mm
Application: draining water from the batch after washing
Construction: welded sheet steel reinforced with steel profiles
Watertight drip tray at the bottom
8. Loading / Unloading Stations – 3 units (Pos. 1
2
17)
Clear diameter: 800 mm
Clear depth: 1,200 mm
Application: preparing and setting down the batch before or after heat treatment
Construction: welded sheet steel reinforced with steel profiles
9. Wastewater Tank 5 m³ – 1 unit (Pos. 18)
Round tank (agitator tank) made of black polyethylene (PE-100)
Usable capacity: approx. 5,000 l
Diameter: approx. 1,600 mm
Height: approx. 2,650 mm
Design: double-walled round tank with lid
collects the saline wastewater from the 3-stage wash tank
Plastic tank
no drain valve
DN 500 manhole in the lid
complete with cover
seal and stainless steel quick-release fastener
DN 50 loose flange nozzle for filling
DN 50 loose flange nozzle with internal 90° suction bend
on the side of the tank cylinder
for extraction
DN 100 vent designed as a 180° bend
incl. insect screen
permanently welded into the lid
Galvanized steel agitator crossbeam on the lid
mounting point for an agitator (max. 100 kg)
arranged off-centre (therefore no flow breakers)
2 lifting eyes
4 galvanized steel foot anchors for fixing the tank on a customer-provided foundation
Operating conditions: max. density 1.1 kg/dm³
max. operating temperature 30 °C
pressureless
10. Dust Filter
VARIO 5.2 Multitube Surface Filter – 1 unit (Pos. 21)
Housing
Sturdy welded sheet steel construction
Inspection openings
Support structure in sheet steel or steel profile design
Filter elements
Multitube surface filter
Filter medium: high-quality polyester fine fiber needle felt
High separation efficiency
Very good regenerability
even with oily and moist dusts
Robust and durable
Temperature resistant up to 70 °C
Clean gas emissions typically
Environmentally friendly
recyclable
Installed on the raw gas side
Filter cleaning
Continuous compressed air pulse cleaning during operation
Constant airflow
Fan unit
Top-mounted fan with direct drive
Sturdy design
very quiet
Drive motor with built-in temperature monitoring
Disposal
Dust collection containers
Electrical control
Supplied loose with the unit
For automatic operation of the entire system
High-quality components
Frequency converter with integrated PID controller for vacuum control
Designed according to VDE guidelines
Technical data
Volume flow: 12,000 m³/h
Temperature: 20 °C
Number of filter elements: 28
Filter area: 126 m²
Compressed air requirement: 183 Nl/pulse
Power: 22 kW
Dimensions (L x W x H): 2,400 x 1,540 x 4,300 mm
Dust collection containers: 3 x 40 l
Finish: RAL 7035
Electrical connection: 400 V
3/N/PE ~ 50 Hz
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