In the forging process, the heating furnace plays a vital role. Different types of heating furnaces have their own unique characteristics and application scenarios. Next, let us enter the world of forging heating furnaces and learn about their types and characteristics!
First of all, we have to clarify what a forging heating furnace is. Simply put, a forging heating furnace is a device used to heat metal materials to a suitable forging temperature. According to different heating methods, structural forms and application requirements, forging heating furnaces can be divided into many types.
Chamber Heating Furnace
What is a chamber heating furnace?
Chamber heating furnace, this equipment plays a pivotal role in industrial production and laboratory research. Its essence is a closed heating space, which relies on heating elements, such as resistance wires or electric heating tubes, to effectively provide the necessary heat energy, so that the indoor temperature can accurately reach the level required by the user.
Speaking of its structure, the chamber heating furnace is mainly composed of two parts: one is the heating chamber, and the other is the control system. The heating chamber part is usually made of materials that can withstand extremely high temperatures, such as ceramics or specific metals, to ensure that the equipment can operate stably in a high temperature environment. The control system can be said to be the "brain" of the entire heating furnace. This system is not only responsible for real-time monitoring of the temperature in the furnace, but also fine-tuning the working state of the heating elements through high-precision equipment such as temperature sensors and temperature controllers to ensure that the temperature in the furnace is always maintained at the set value.
Chamber heating furnaces are widely used in many industries due to their high flexibility and precision. Whether it is heat treatment in metal processing, in the manufacture of ceramics and glass, or sample testing in chemical laboratories, it can provide a stable and controllable thermal environment. According to specific needs, chamber heating furnaces have also derived a variety of types, such as box type, tube type and tunnel type, each of which is optimized for specific application scenarios.
Improvement of refractory materials for chamber heating furnaces:
High-strength refractory castables are good lining materials for forging heating furnaces, which improve the life of the furnace, reduce energy consumption, and achieve good economic results. In the design, the furnace structure of the chamber heating furnace is improved as a whole. The improvement steps are as follows: the reservation of the furnace top, furnace wall, furnace bottom, and expansion joints.
① Furnace roof
The furnace roof of the chamber heating furnace is exquisitely designed and sturdy. It adopts a composite flat furnace roof structure. In order to ensure the stability and high temperature resistance of the furnace roof, 48 high-aluminum hanging anchor bricks are carefully buried inside the furnace roof, and the length of each brick is precisely controlled at 460mm. These anchor bricks are closely combined with the refractory castables to form a solid whole. Among them, the thickness of the casting layer formed by the refractory castables reaches 300mm, which further enhances the durability of the furnace roof.
In the structural design of the furnace roof, a metal hanging system is adopted. In this system, the hanging bolts are closely connected with the metal hanging beams to ensure the uniform distribution of the hook force, so that the entire furnace roof can be in a stable hanging free state. This design not only ensures the overall force balance of the furnace roof, but also provides convenience for future maintenance and overhaul.
In order to improve the insulation effect of the furnace, a 70mm thick layer of refractory fiber is specially covered on the upper surface of the furnace roof. This material is not only resistant to high temperatures, but also effectively reduces the loss of heat energy, thereby significantly enhancing the thermal insulation performance of the furnace and providing a stable guarantee for the high temperature environment in the furnace.
② Furnace wall
The furnace wall design of the chamber heating furnace fully considers durability, thermal insulation effect and energy efficiency. The furnace wall adopts a composite structure and is reinforced by δ=8mm steel plates on all sides, which not only increases the mechanical strength of the furnace wall, but also improves the overall safety. On the inside of the steel plate, a 40mm thick refractory fiber is tightly fitted. This material has excellent high temperature resistance and thermal insulation properties, effectively reducing the heat loss in the furnace.
On the inside of the refractory fiber, 114mm lightweight refractory bricks are laid to further enhance the refractory performance of the furnace wall. The inner lining of the furnace wall is cast as a whole with high-strength refractory castables, and the thickness of the casting layer reaches 300mm, ensuring the firmness and durability of the furnace wall. During the casting process, the burner hole is cleverly reserved, and after the castable solidifies, the fired bricks can be embedded in it. The tiny gap between the burner brick and the castable is tightly filled with fine powder to ensure the airtightness and thermal insulation effect of the furnace wall.
It is worth mentioning that this one-time cast furnace wall has superior impact resistance and significantly improved thermal insulation effect compared with the traditional brick furnace wall. Such a design not only reduces the heat dissipation loss of the furnace wall, but also effectively saves energy, fully reflecting the modern industry's unremitting pursuit of high efficiency, energy saving and environmental protection.
③ Furnace bottom
The furnace bottom design of the chamber heating furnace fully considers wear resistance and durability, and steel fiber reinforced castables are selected for integral casting to form a solid pit surface structure. The working layer thickness of the furnace bottom reaches 280mm, ensuring sufficient strength and wear resistance. In order to further improve the stability and thermal insulation effect of the furnace bottom, 210mm thick refractory clay bricks and lightweight refractory clay bricks are laid under the working layer. These refractory materials are not only resistant to high temperatures, but also can effectively insulate heat and protect the furnace bottom from high temperature erosion.
In the lower temperature part of the furnace bottom, some clay bricks are cleverly laid, and these bricks extend all the way to the ground level, providing stable support for the furnace bottom. In addition, each heating chamber has carefully reserved 3 flue holes, which are connected to the main flue to ensure the smooth discharge of flue gas in the furnace. It is worth mentioning that all flues are built with refractory bricks, which not only enhances the fire resistance of the flue, but also improves the safety of the entire furnace bottom.
④ Connection between the furnace top and the furnace wall
The connection between the furnace top and the furnace wall of the chamber heating furnace is designed to be both scientific and exquisite. The furnace wall does not bear the weight of the furnace top, so that the furnace wall can expand more freely due to heat, and a 20mm gap is deliberately left between the two to accommodate this expansion. In order to ensure that the flame will not burst out from the joint between the furnace wall and the furnace top, the designer cleverly overlaps the furnace top and the furnace wall by at least 150mm.
In order to further isolate the flame, clay bricks are laid on the side of the furnace top. This material is not only resistant to high temperatures, but also can effectively prevent the spread of flames. At the same time, clay bricks are used for wet masonry above the clay bricks. This method can ensure the close combination between bricks and reduce gaps. More importantly, this wet masonry method can also cover the gaps between the furnace top castables and the refractory clay bricks and refractory fiber fillers, thereby effectively preventing the flames from escaping through these gaps and ensuring the safe operation of the heating furnace.
⑤ Expansion joints
In the design of refractory materials for chamber heating furnaces, the setting of expansion joints is particularly important. In order to ensure that the furnace body can expand freely during the heating process and avoid excessive thermal stress, the designer carefully left expansion joints at the four corners of the furnace wall, the center of the middle partition wall, and the joints between the partition wall and the front and rear walls. The width of these expansion joints is strictly controlled between 3 and 4 mm, which not only ensures the free expansion of the furnace body, but also avoids heat loss caused by excessive gaps.
As a filling material, combustible corrugated board is selected, which will gradually burn and consume during the heating process of the furnace body, thereby further ensuring the effectiveness of the expansion joints. It is worth noting that no expansion joints are directly left in the furnace top part. Instead, 20mm refractory fibers are laid around the working layer of the furnace roof. This material is not only resistant to high temperatures, but also has good flexibility, which can effectively absorb the expansion of the furnace roof during heating, thus replacing the traditional expansion joint setting. This ingenious design not only ensures the safe operation of the furnace body, but also improves the overall insulation effect.
⑥ Construction
The construction of refractory materials for chamber heating furnaces is a process that requires highly professional and delicate operations, especially the construction of high-strength refractory castables, which is significantly different from the construction method of ordinary refractory castables. Therefore, it must be operated in strict accordance with relevant construction regulations.
Before construction, a series of preparations need to be carried out. First, install the membranes on the burners, flues and furnace doors, which is an important step to ensure the smooth progress of subsequent construction. Next, support the furnace wall formwork and ensure the tight connection between the hole membrane and the furnace wall formwork. When the furnace bottom castable construction is completed and reaches a certain strength, the furnace roof formwork can be supported.
After the support is completed, the work of hanging anchor bricks needs to be carried out. During this process, it is necessary to ensure that the gap between the lower end of the anchor brick and the formwork is controlled within 0~5mm, and the support of the formwork must be firm and reliable, and there must be no looseness.
As a finished material, the mixing and pouring process of high-strength refractory castables also needs to be strictly controlled. It is necessary to use a forced mixer to evenly mix the materials. When mixing, first load the materials into the mixer for 1 minute of dry mixing, then add 6.5%~7.2% of water for 3~4 minutes of wet mixing to ensure that the materials are fully mixed before discharging. It should be noted that the mixed materials poured out of the mixer must be used within 30 minutes to ensure the construction quality and the best performance of the materials.
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