Application of Frequency Converter in Aluminum Melting Furnace

With the rapid development of the domestic aluminum processing industry, aluminum manufacturing companies have made significant progress, and competition in the product market has become increasingly intense. To remain competitive, companies must focus on improving product quality, reducing production costs, minimizing environmental impact, and enhancing equipment automation. These factors have become essential for sustainable growth. Therefore, it is crucial to implement energy-saving measures that offer substantial economic returns, low investment, fast payback, and scalability. In this context, a casting and rolling plant initiated an energy-saving and environmental protection transformation project for four reverberatory furnaces used in continuous casting and rolling processes. The continuous casting and rolling process primarily consists of a melting furnace and a casting mill. The quality of the molten metal produced in the furnace directly affects the final quality of the cast-rolled sheets. Excessive or uneven temperatures can lead to coarse grain structures, hydrogen absorption, and unstable melt conditions. Additionally, improper control of the smelting process may result in incomplete combustion, increasing both environmental pollution and damage to equipment. Ensuring stable and efficient operation is vital for improving product quality and maintaining a smooth casting and rolling process. In the casting and rolling plant, heavy oil is used as the fuel source for melting aluminum. The flame size depends on the flow rate of the heavy oil and the amount of combustion air. However, due to the high viscosity of heavy oil, steam insulation is required, which makes the system unstable. This leads to frequent fluctuations in pressure and flow, resulting in issues such as poor atomization, black smoke emissions, and inefficient combustion. To address these challenges, the plant implemented frequency converters to control the heavy oil pumps of the four melting furnaces. By adjusting the pump speed based on temperature and pressure data, the system achieves optimal performance and energy efficiency. The pressure loss in the heavy oil supply system is mainly due to friction along the pipeline and local resistance caused by valve adjustments. Fluctuations in ambient temperature and operational requirements further complicate pressure stability, leading to inconsistent burner performance. Maintaining stable oil pressure is essential for energy-efficient operation and consistent combustion. The use of frequency conversion technology allows for precise control of flow and pressure without relying on valve adjustments, thereby reducing energy waste and improving overall system efficiency. After implementing the frequency converter system, the plant observed remarkable improvements in performance and reliability. Energy consumption was significantly reduced, and the motor life was extended due to soft starting and reduced mechanical stress. The system also improved the working environment for operators, reduced manual intervention, and enhanced the accuracy of the smelting process. In conclusion, the application of frequency conversion technology in the smelting process has proven to be a highly effective solution for energy savings and cost reduction. As the aluminum industry continues to evolve, adopting advanced technologies like variable frequency drives will play a critical role in maintaining competitiveness and sustainability. The success of this transformation provides valuable insights for other facilities looking to improve their energy efficiency and environmental performance.

Sectional Sofa

Couch With Chaise,Sectional Couch,Modular Couch,Modern Sectional Sofa

Mexarts Household Products Co., Ltd. , https://www.mexartsglobal.com