Aluminum Billet Production Line

I- 10TONS Rectangular solid aluminum melting furnace

1. Usage

This machine is used for melting nonferrous metals (aluminum) 

1- The capacity is 10 tons

The shell of furnace is 8mm steel plate, furnace wall is 14# channel steel.

2- The thickness of fireproofing of furnace wall is 568mm. The thermal insulation material is silicate insulation board and high strength light-weight insulating brick. Furnace hearth slag line and working layer of furnace bottom are used by Grade I aluminum bricks, and other parts are used by Grade III aluminum bricks. The furnace door and the fire mouth are made of high quality low cement and high strength castable.

3- Furnace door is cable-stayed type

4- Supply range: the drawing of civil foundation, layout chart, furnace body, furnace door, and lifting device. And foundation, oven , oven materials and draught fan are outside of offer

5- The life of furnace body is more than 3 years.

6- Guarantee: within one year since B/L, excluding quick-wear parts and pneumatic element.

7- Quick-wear parts list: Furnace door and furnace mouth fireproofing.

2. Main technical parameters

Name

Data

Furnace type

Rectangular stationary type

Capacity

More than 10 tons

Max. depth of aluminum water

About 500mm

Number of furnace door

1

Door operation

Power driven

Max. temperature

860℃

Normal operation temperature

720-800℃

Al water discharge type

Manual

Discharge hole diameter

About 60mm

Discharge mouth number

1

II- NATURAL GAS Burner System 

Description

Efficient regenerative burner system is used in pairs. It should be reversed on time. When one nozzle is burning and heating, another nozzle is doing energy storage.

Feature

Good configuration and intelligent control

Electronic ignition, wind/gas ratio adjustment, flameout alarm, automatic closing solenoid valve

Automatically adjust flame size according to the furnace temperature

Electronic ignition, flame detection, flameout alarm and gas pressure detection

Use Honeywell flame detector to monitor the flame in real time, turn off the fire alarm and immediately turn off the gas valve and sound and light alarm to ensure the safety of combustion

Quick shut-off solenoid valve opens and closes combustion gases

Intelligent control system to promise working in best economic.

Servo motor adjusts butterfly valve and automatically adjusts according to furnace temperature

Easy and safety operation

2 Technical data

Name

Data

Fuel type

Natural gas (8500kcal/m³)

Burning capacity

320m³/h

Calorific value

1.6 million kilocalorie/hour

Length of flame

800-1200mm

Diameter of flame

400mm

Flame temperature

1100-1250℃

Natural gas pressure

15Kpa

Power supply

380V, 3phase, 50Hz.

3 Configuration list

Name

Brand

Air burner

Equipment factory

Servo motor damper adjustment device

Honeywell

PLC

Mitsubishi, Japanese

Ignition device

SANYO, Japanese

Flame detector

Honeywell

Gas control pipe line

Equipment factory

Manual regulating valve

Zhejiang

Electric rapid closing stop valve

Beijing

Pressure gauge element

Japan

Leakage detecting device

Japan

Total junction box

Equipment factory

Air blower

Nantong 

Air duct pipes

Nantong

III- Hot pot billet casting die

I Description and technical

1- The casting mold is consists of crystallizer (including starter head), casting water tank, metal split, ingot guidance support table (ingot guidance rack) and so on. 

All casting tooling which contacted with water are treated with anti-corrosion treatment. 

Processing part is smoothed, no burr, and disassembled the casting platform after cleaning, and clean the steel sheet inside and outside the water tank by a high-speed sand blasting machine. The water tank can avoid to trust for more than 10 years after being treated with galvanizing and high temperature antirust paint.

2- Technical

Billet size: Φ178mm

Bending curvature: ≤10mm/m

Casting water: 300-400m3/h

Casting pressure: 0.8-3kgf/cm3

3- The material of crystallizer is three high graphite, which is promise good cooling and small friction.

4- Casting water tank

It’s made of square tubes and steel plate. The thickness of steel plate is 35mm and 16mm. There is 8 holes for cleaning.

5- Aluminum liquid dispensing system

It’s made of dispensing tray, transfer conduit, distribution chute and pressure plate. These parts are high strength, long life, high thermal insulation properties and so on.

II Φ178 aluminum alloy billet casting die, 24pcs each casting

1- Upper die disc 2650 x 2200mm. Upper plate thickness is 25mm, lower plate thickness is 14mm.

2- lower die disc is 1950mm×1950mm×720mm, it adopts Q235 steel plate( 16mm and 10mm), and quadrangle is Φ76 seamless steel pipe column

3- Crystallizer is 24pcs, high strength duralumin alloy, and lining is High density graphite ring.

4- Liquid separate disc: 12pcs

5- Honeycomb duct: 24pcs

6- Main runner channel: 1pcs

7- Dummy bar head: 24pcs, casting iron.

IV-Hydraulic turnover device

Supply range:

1- Hydraulic: 1 pcs 

2- Hydraulic arm: 2 pcs

3- Hydraulic oil cylinder: 2 pcs 

4- Oil pipe

5- Valve

6- The capacity of hydraulic arm is more than 10tons.

V-Wire rope transmission type casting machine (15 tons)

The stroke of hoisting machine is more than 8 meters, with inverter frequency control, and the speed regulation range is 30-450mm/min. The capacity of casting machine is 20 tons and the motor power is 7.5kW. The winch has manual lowering device and spring-assisted starting device.

Structure

Worm speed reducer, gear reducer and stepless speed regulation motor

Variable-grequency and variable-speed motor

5.5kW

175 type worm speed reducer

Speed ratio: 60:1, 1 set

350 type gear reducer

Speed ratio: 31.4:1, 1 set

Wire rope reel

1

Braking device

1

Steel wires

16 mm x 100m

Guide roller

6pcs

Carrying roller

4 pcs

Adjusting screw rod for steel wires

4 pcs

Lifting platform

1 set

Electric cabinet

1 set

VI -Water pump

Model

IS200-150-400B

Flow

346m3/h

Throw of pump 

38m

Motor power

55kW 

VII- Billet cutting machine

Model 

LH-90

Power

15kW

Rated voltage

380V, 50Hz

No-load speed

1500rpm

Cutting blade

600 x 40 x 2.8mm

VIII- LHDC-700-90KW Low pressure jet pulse dust remover

I Description and technical

This system includes smoke collection device, bag dust collector host, wind motor system, smoke exhaust pipe system and electrical control system.

Air volume is controlled by automatic.

The effective suction hood end face design is 3000mm × 2500mm, and the end face wind speed is not less than 1.2m / s.

No.

Item name

Data

1

model

LHDC-700

2

Airflow dealer

60000-65000m3/h

3

Flue gas temperature at inlet

＜130℃

4

Inlet concentration

＜10g/Nm3

5

Outlet concentration

＜50mg/Nm3

6

Deashing method

Offline

7

Filtered net area

685m2

8

Design filter wind speed

1.2m/min

9

Air leakage rate

＜3%

10

Resistance loss

＜1500Pa

11

Design dielectric strength

-6500Pa

12

Room number

3 rooms

13

Filter-bag numbers

504bags

14

Filter-bag size

Φ134*3200

15

Filter-bag material

Room temperature 130℃

16

Pulse valve specification number

3inch x 12pcs

17

Installation method

Parallel

18

Ash discharge valve mouth

260*260

19

Compressed gas pressure

0.25-0.35MPa

20

Main motor

G4-73-12D-90KW

21

Deduster framework

Φ124×3200

22

Deduster filter-bag

Φ134×3200

23

Pulse valve

3inch

24

PLC

Mitsubishi