① After starting the aluminum melting furnace, the first task is to adjust the heating parameters. This link is crucial because it is directly related to the safety and efficiency of subsequent heating production. We must carefully calibrate various parameters to ensure their accuracy and stability. Only after the heating parameters are completely stable can we carry out normal smelting operations. Doing so can not only ensure the safety of the smelting process, but also ensure the quality of the aluminum liquid, laying a solid foundation for subsequent production links.
② Before starting the aluminum melting furnace, a series of key inspections must be carried out. First, carefully check whether the push and discharge devices are intact and operating normally, which is related to whether the materials can be smoothly in and out and avoid blockage or failure during the production process. Secondly, it is necessary to verify the stability of the circulating water system and the air pressure system, which is the infrastructure for the normal operation of the aluminum melting furnace. Any abnormality may affect the entire smelting process.
At the same time, it is also an essential step to calibrate the position of the limit switch and the manual automatic switch to ensure that they are in the correct position, so that the power can be cut off or the working mode can be switched in time in an emergency, thereby ensuring the safety of the operator and the integrity of the equipment.
In addition, the materials on the workbench need to be strictly audited to ensure that they meet the requirements of forgings. In particular, attention should be paid to the type, specification and quality of the materials to avoid using unqualified or unsuitable materials, so as to ensure the quality of the products produced.
Finally, special attention should be paid to the state of cooling water. Cooling water is essential for the normal operation of the induction furnace and can be said to be the "lifeline" of the induction furnace. Therefore, it is necessary to ensure that the parameters such as the flow rate, temperature and pressure of the cooling water are within the normal range, especially the outlet water temperature must not exceed 60°C to prevent the equipment from overheating and damaging or affecting the smelting effect of the aluminum liquid. These meticulous inspections can greatly improve the operating efficiency and production safety of the aluminum melting furnace.
③ In the process of charging the aluminum melting furnace, the correct placement of materials is crucial. In particular, large pieces of aluminum materials cannot be directly placed in the furnace, but should be properly processed first to ensure that they meet the smelting requirements. At the same time, special attention should be paid to the method when loading: it is recommended to place the irregular surface of the aluminum material as much as possible upward. The purpose of this is to avoid the aluminum material from getting stuck in the furnace lining during the smelting process, thereby ensuring the smooth progress of smelting. By taking these professional charging measures, we can effectively improve the efficiency of the aluminum melting furnace, extend the service life of the furnace lining, and provide strong protection for aluminum production.
④ When the aluminum melting furnace is in a cold furnace state for the first firing, we must adopt a cautious operation strategy. In order to avoid cracks in the refractory material of the furnace lining due to rapid temperature changes, we should not use the rated power for heating immediately. Instead, 60%-75% of the normal power should be used for low-temperature heating to ensure that the furnace lining material can be heated gradually and evenly. This preheating process is crucial, which can effectively reduce the thermal stress of the refractory material caused by the temperature difference, thereby protecting the integrity of the furnace lining.
When the furnace lining temperature reaches about 90°C uniformly, we can gradually increase the power to the normal process power level. Through such a progressive heating method, we can not only ensure the safe start-up of the aluminum melting furnace, but also lay a good foundation for subsequent forging operations. This professional operation method is designed to maximize the protection of the service life of the aluminum melting furnace and ensure the smooth progress of the production process.
⑤ In the aluminum melting furnace operation area, we must ensure that there are no two different specifications or types of billets in front of the furnace and on the workbench at the same time to maintain the clarity and accuracy of the production process. To ensure the standardization of material management, the staff in front of the furnace are responsible for properly storing the heated but unused billets in the feed box before leaving get off work, and marking their specifications and current status in detail, so that subsequent staff can accurately understand and handle these billets.
In addition, all billets that have been heated to a red-hot state in the induction furnace must be forged to avoid resource waste and potential safety risks. As an efficient electric heating equipment, the medium frequency heating furnace has the advantages of rapid heating, less oxidation and decarburization, excellent working conditions, and easy mechanization and automation. However, its adaptability to changes in billet size and shape is relatively limited.
Therefore, in actual operation, once the size or shape of the billet changes, such as length reduction or the addition of billets of different sizes, we must strictly follow the design requirements of the inductor to perform corresponding discharge and push calculations. This step is crucial, as it ensures that the billet obtains uniform heating quality, thereby effectively avoiding potential heating defects. Through this rigorous operation method, we can maximize production efficiency and product quality while ensuring the safety and reliability of the operation process.
⑥ In order to reasonably design the structure of the aluminum melting furnace to improve energy utilization efficiency, we need to comprehensively consider multiple key factors. The first is the selection of refractory and thermal insulation materials, the performance of which has a vital impact on the energy efficiency of the furnace. High-quality refractory and thermal insulation materials can effectively resist high temperatures, reduce heat loss, thereby reducing energy consumption and significantly improving the energy-saving effect of the furnace.
In addition, the design of the furnace structure is also crucial. A reasonable furnace structure can ensure uniform distribution and efficient use of heat, reducing energy waste. At the same time, advanced control systems can achieve precise temperature control and operation management, further improving energy utilization efficiency.
Finally, the optimization of the burner system is also a key link in improving the energy efficiency of the furnace. Efficient burners can ensure the full combustion of fuel, maximize the use of thermal energy, and thus reduce energy consumption.
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