Application of Frequency Converter in Aluminum Melting Furnace

With the rapid development of the domestic aluminum processing industry, aluminum processing enterprises have made significant progress, and competition in the product market has become increasingly intense. To stay 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 enterprise growth. Therefore, it is crucial to implement energy-saving measures that offer substantial economic returns, low investment, fast return on investment, and scalability for large-scale production. In this context, the casting and rolling plant carried out an energy-saving and environmental protection transformation of the four reverberatory furnaces used in the continuous casting and rolling process. The continuous casting and rolling system primarily consists of a smelting furnace and a casting mill. The quality of the metal melt in the smelting furnace directly affects the final quality of the cast-rolled sheet. Excessive or uneven temperatures can lead to coarse grain structures, unstable melt temperatures, and hydrogen absorption in the liquid metal. Additionally, improper control of the melting process may result in incomplete combustion, over-burning, and increased environmental pollution. Ensuring stable operation and high-quality output is therefore critical for the entire process. In the casting and rolling plant, aluminum raw materials are melted using heavy oil combustion. The flame size depends on the flow rate of the heavy oil and the air supply. However, due to the high viscosity of heavy oil, steam insulation is required, making the system unstable. This leads to fluctuating pressure and inefficient combustion, resulting in black smoke, incomplete burning, and higher energy consumption. To address these issues, the plant implemented frequency converter technology to control the heavy oil pumps of the four melting furnaces. By adjusting the pump speed based on temperature and pressure signals, the system achieves optimal pressure and flow control, significantly improving efficiency and reducing energy waste. The pressure loss in the oil supply system is mainly caused by friction along the pipeline and local resistance. Fluctuations in ambient temperature and frequent valve adjustments further complicate the stability of the system. Maintaining consistent pressure is essential for smooth operation and energy savings. The use of frequency converters allows for precise control of the pump speed, eliminating the need for manual valve adjustments and reducing energy loss from pressure fluctuations. After implementing the frequency conversion system, the performance of the heavy oil pumps became more stable and efficient. The motor speed was reduced from 1400 rpm to 504 rpm, significantly lowering energy consumption while maintaining the required pressure and flow. This not only improved the combustion efficiency but also extended the lifespan of the equipment and reduced maintenance costs. Additionally, the system allowed for automatic control, minimizing human error and ensuring consistent performance. The benefits of using frequency converters include energy savings, soft motor starting, no inrush current, and reduced mechanical stress. The system offers a wide speed range, high precision, and built-in protection features that enhance reliability and safety. Overall, the implementation of variable frequency technology has proven to be a highly effective solution for energy conservation in the aluminum processing industry. This transformation has not only improved operational efficiency but also set a new standard for energy-saving practices in the sector. It serves as a valuable reference for other similar facilities looking to modernize their processes and reduce environmental impact. As technology continues to evolve, further innovation and application of advanced control systems will be essential to remain competitive in the global aluminum market.

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