Heat Treatment Furnace for All Sizes LPG Cylinder Production Line

                                     Technical Parameter for gas heat treatment furnace
 

Execution standard reference for National industrial furnace production, installation and inspection:

Introduction for this equipment:
Continuous cylinder heat treatment nature gas heat treatment furnace is widely used for heat treatment of steel cylinder. The heating of the furnace is divided into two sections. One section is the heating section (horizontal); the second section is the high temperature section (horizontal).
 
Parameter and requirements:
1.Continuous heat treatment furnace: total length for this machine is 20 meters(furnace is 15 meters, loading & unloading holder is 5 meters). The furnace is welded by high quality section steel, the furnace is lined with high temperature resistant high alumina refractory firebrick, insulation layer is made of fiber and other thermal insulation materials. Overall, the high temperature furnace is light and of good insulation performance.
2.Application: Cylinder normalizing heat treatment
3.Specification: ISO Standard, cylinder weight:6kg/pc, 12.5kg/pc,25 and 52kgs Diameter of cylinder is from DN200-400mm
4.Working efficiency: 200pcs/hour
5.Entrance temperature: 30ºC
6.Cylinder heating temperature: 900ºC±25ºC
7.The max. working temperature of the furnace body: ≤1000ºC
8.The temperature rise of furnace body surface is according to China industry standards.
9.Parts of the furnace:
10.Horizontal furnace body: 1 set
11.Loading and unloading chain mechanism: 1 pair
12.Nature gas control system(record containing): 1 set
13.Flue gas and heat exchange system: 1 set
14.Fuel type: nature gas 
15.Fuel calorific value: 8500 Kcal / kg
16.The form of combustion apparatus: high-speed fuel burner
17.Heating quantity and thermal load distribution: 8 pcs gas burner
18.No. of burners in heating section:4 pcs burners, 230KW/pcs
19. No. of burners in the front of temperature holding section : 2 pcs burners, 230KW/pcs
20. No. of burners in the back end of temperature holding section : 2pcs burners, 150KW/pcs
21.Power supply: 20KW, 380V, 50Hz 
 
Burner and control system:

1. High speed gas burner and ratio control system

Continuous cylinder heat treatment furnace requires the equal heat supply, equally loading the cylinder, and needs to provide large heating load changes, so we choose ratio burning control system. The sleeve tube on the burner nozzle will form a high speed jet steam when burning, can stir up the inside atmosphere and equally supply the heat. The heating of each burner nozzle is ratio control.
In the ratio control system, the burner nozzle will automatically adjust the heating according to the temperature in the furnace, the power, mixture ratio, spraying speed will be adjusted to a best condition, which will effectively improve the burning capacity and reduce the pollution. Through the cooperation of the several burner nozzles, the heat flow will be uniformly distributed in the furnace, which will improve the heating quality of the cylinder and temperature uniform. We also choose controller of high resolution and suitable power burner nozzle to reach a high linearity of the system. That kind of control system is widely used in metallurgy and machine heat treatment industry.

 2. Working station control system

That system has the feature of expansibility, adopts the control system: one gauge- one burner nozzle or one gauge- multi-burner nozzles. The instrument adopts Japan conductive company SRS3 type intelligent temperature control instrument. Through connect the signal of actual temperature in the furnace and then calculate by computer to control the on/off and size of the every burner nozzle, meanwhile , every burner nozzle working condition can automatically go on according to the pre-set curve. And it will show the temperature control point and its temperature and the curve(also has paperless recorder), show the working condition of the burner nozzle, and failure warning.
The specific principle: the thermocouple will detect the temperature signal of very section furnace, then feed back to temperature instrument to check the tolerance between the pre-set temperature and actual temperature, then control the burner nozzle output through ratio control.

 3. Alarm system and safety interlock device

Since the fuel is nature gas, which is dangerous, so the safety system is necessary. All the nozzles are equipped with auto ignition device and flame detection device, will output the warning signal when flame is out, the auto ignition device and flame detection device will cut sown the solenoid valve, meanwhile there is indicator light will tell which nozzle is down and start and stop the interlock device. Audible and visual alarm will alarm to remind the operator to deal with the failure in time. There will is real-time monitor and failure record in our electric system.

 4. Electric equipment: Japanese conductive meter, Chit or Delixi low pressure electrical appliance, the cable wire is from inland famous brand.

 5. Burner: ignition controller, press switch, solenoid valve are from UAS Honeywell11 or German Krom, the hand valve and dish valve are from inland famous brand.

 

Main material details:

1. The shell is welded by section steel and steel plate(high quality steel)

2. Insulation fiber: Shandong

3. High temperature refractory clay: Hangzhou 

4. High temperature refractory brick: Hangzhou

5. Electric Appliances: CHNT or Delixi 

6. The fuel burner: local brand

7. Thermocouple: Hangzhou

8. Conveyor transmission chain: Hangzhou 

Frequency heating principle:

Frequency heating is using frequency power to change 380V, 50Hz power current into the suitable frequency current by rectification and contravariant. Input this current into resonant tank composed by the heating furnace, to make the furnace coil produce alternating magnetic field, while the pre-heating metal material stay in the alternating magnetic field, the material will produce the alternating current and heating by itself, high hot efficiency and low energy consumption.

Feature:

Frequency induction heating power factor≥96%, has automatic impedance adjustment function, the performance of energy saving is obviously.

Power output is steady, heating temperature is easy to control, good consistency to improve the heating quality.

Good diathermancy, magnetic field has a good permeability to the metal workpiece, it's not heating conduction, so the temperature difference of workpiece movements is small and improve the products' quality.

Temperature measuring system closed-loop control heating power, the precision of temperature is high.

Automatic impedance adjustment and automatic frequency adjustment function, inspecting system impedance transformation caused by the cylinder from cool to hot during the whole heating process automatically. Adjusting the output parameter automatically and making the whole heating process stay in energy-efficient state, saving more power. 

Heating process requirement:

9KG, 14KG LPG cylinder production line:

Workpiece size: 9KG, 14KG LPG cylinder

Heating temperature: 780 - 900°C (The heating temperature sets according to the technology demand, adjustable)

Mixed production line heating speed: 14 second/per cylinder

Productivity: 2000 pcs / 8 hours

User required equipment power calculation:

9KG, 14KG LPG cylinder production line:

Size: BPS-550 frequency power. GT-9, 14/550 name: 9KG, 14KG LPG cylinder frequency heat treatment furnace.

Power: 550KW

Composition of cylinder heating treatment equipment:

1. BPS series frequency power: one set

Size: BPS-550

Rated power: 550KW

Shunt capacitor: one set (under the furnace)

Power factor: Full power state arrive more than 96%.

A. Advanced control system:

The frequency power uses intelligent control system, it is a new SCR generation control system designed by absorbing the advance frequency heating technology both Chinese and foreign and special requirement for cylinder. The intelligent control system uses line unit design, all working units have luminotrons to display working state, the calculation of control system is processing in the special CPU module. It is reliable, steady and easy to maintain.

B. Adjustable power output:

During the power of equipment is 0 - rated power can be adjusted continuously, increasing the power adjustment output function, the low power of 9KG cylinder operation can guarantee the best working state, to ensure the commutating voltage reach 500V, improve the heating efficiency and save the energy consumption.

C. Complete protection function:

Not only equip with over-voltage protection, over-current protection, voltage restriction, current restriction functions, but also the intelligent protection system has the reliable release circuit while using the over-voltage high voltage, improve the frequency power running steady greatly, and has the over-temperature alarm function of cooling water temperature.

D. Obviously energy saving:

Retain all original functions in the intelligent control system, The unique design of the regulating function of impedance in the working process of the equipment according to the furnace workpiece (charge) impedance changes during heating (the inherent characteristics of the workpiece, the burden is in the process of heating) the working parameter adjustment of inverter power supply, the working efficiency is the highest in the state, so the high efficiency, energy saving, time saving. Frequency power intelligent impedance adjustment function, intelligent protection function is the domestic unique technology

E. Reliable starting system:

Zero voltage sweep frequency starting mode without impact, and the impedance adjustment function in the intelligent control system, making the essence of starting ability of frequency power has been greatly improved.

F: Automatic testing frequency output:

Intelligent control system, testing the change of system inductance caused by the cylinder temperature changing during the heating process automatically, adjust the output parameter in real time, making the whole heating process stay in high efficiency state and saving energy.

G: Simple troubleshooting:

Digital intelligent control system has fault display function, easy to find the fault, you can find the fault of the intelligent system without inspecting the equipment. Easy to maintain.

2. Heating normalizing furnace

It is made up of rectangular copper tube, which is optimized by computer. Aluminum alloy and insulation support, strong, long life. It consists of preheating section, heating section and insulation section

A: Pre-heating furnace: 1 set; length*width*height: 450*700*700mm

It consists of a metal material bracket, an efficient refractory material and a heat insulating material, no energy consume and heavy. Using the heat energy spillover the furnace for pre-heating.

B.  Heating furnace: 3 sets (integrated design); length*width*height: 1350*700*700mm

Power: 550KW

Furnace voltage: 750V

Dimension (length*width*height): 1350*700*700mm

It is made up of rectangular copper tube, which is optimized by computer. Aluminum alloy and insulation support, strong, long life. Three sets heating furnace use integrated design, it can heat multiply cylinders at the same time. Compare with old type single cylinder heating furnace, the new design can still guarantee the heating time for each cylinder to ensure the heat treatment quality after shorting the heating time.

C. Heat holding furnace: 2 sets

Dimension: 1400*700*700

It has the advantages of high efficiency, good heat preservation effect and long service life, which is composed of a metal material bracket, an efficient refractory material and a heat insulating material. The heat holding furnace including two parts.

D: Cylinder feeding system:

Consists of structural steel, stainless steel, pneumatic cylinder, etc. After completing the cylinder into the furnace heating and heating into the holding furnace. The method of cylinder feeding into heating furnace is pushing by the feed mechanism equip with the heating equipment. At the same time the deed mechanism on the other end of the heating equipment pushing the annealing cylinder into cylinder unloading conveyor.

E: Operation control system:

Setting heating process (set heating time and heating temperature), automatically control heating temperature and propulsion system. The electric control system sends out the instruction to complete a series of actions, such as pushing the cylinder into the furnace, heating, measuring temperature, and unloading cylinder, to ensure the whole process working as the setting parameter. Process requirements set on the touch screen, pushing the cylinder into the furnace, heating, temperature, unloading cylinder of a series of actions by the PLC control. The heating process parameters of each cylinder are recorded in the touch screen, and the temperature recording data can be extracted through the U disk. It can print the heating process parameter of all cylinders or check some printed cylinders. It can be operated by the operation table printer or print by U disk. During working touch screen display setting heating temperature, cylinder temperature, display and record the maximum cylinder temperature. Display and record the number of heating cylinders. For the occasional unreasonable data can be modified later.

It can also be provided with a heating speed, so that the pushing mechanism can push out the cylinder according to the set speed. 

3. Closed loop temperature control system:

It consists of Infrared temperature measurement signal sampling sensor, temperature control system, etc. Reliable, high precision, strong anti-interference ability.

Temperature measuring range: 50~1200°C

Precision: ±1%

During working the heating temperature is set according to the requirement of heating process. When the cylinder reaches the set temperature, the control system sends out the material pushing signal, and the pushing mechanism pushes out the cylinder which reaches the setting temperature to enter the heat holding furnace.

The infrared sensor is installed on the special bracket, equips with protective cover.

Feature:

A: When each cylinder is heated, it is in the monitoring of the heating temperature control system, the consistency is good, and the heating quality is ensured, and the energy loss caused by the failure of the heating and the defect of the product quality can be avoided.

B: Closed loop temperature control system, can prevent burning, waste, reduce power consumption.

C: Dual control of heating temperature and power, with over temperature automatic power regulation and over temperature shutdown protection function. 

Control cabinet        
                                                                                     


Burner nozzle

FAQ:

LPG cylinder manufacturing equipment
Q: What size of LPG cylinder your machine can produce?
A: 6kg, 12kg,15kgs and 50kgs LPG cylinder for cooking and other size according customers' requirement.

Q: Can you design machines according LPG cylinder technical drawing?
A: Sure, please send your technical drawing to us.

Q: What are the benefits to choose your machines?
A: Our machines are strong and reliable for long term industrial manufacturing

To enable me give you correct proposal for correct machines, please tell me following details:
We need to know following information to quote you correct machineries:
1.Technical Drawing of the cylinders you want to make?
2.What size of cylinder you want to produce?(6kg, 12kg)
3.What diameter and thickness of the cylinder you want to make?
4.Are you new in this area or you already have some machines in the workshop?
5.Capacity you require, i.e. how many pieces and sizes you want to make per day?