As a core equipment in steel manufacturing, heating furnaces are critical to balancing production efficiency, cost control, and environmental compliance. Our energy-saving heating furnaces integrate six cutting-edge technologies to solve industry pain points—delivering tangible value for green and efficient operations.
I. Overview of Core Technical Advantages
The energy-saving heating furnace leverages six integrated core technologies: Full Fiber Furnace Roof, Intelligent Combustion System, Hydraulic System Potential Energy Recovery, Digital Operation & Maintenance Platform, Waste Heat Recovery, and Walking Beam Thermal Insulation Technology. Through synergy in material upgrading, intelligent control, energy recycling, and digital management, it addresses key challenges of traditional heating furnaces (high energy consumption, complex operations, poor maintainability, and limited capacity)—driving dual improvements in carbon reduction and production performance.
II. Detailed Analysis of Key Technologies, Problem-Solving & Effects
(1) Full Fiber Furnace Roof Technology
1. Technical Advantages
Adopts internationally advanced pure fiber precast blocks and spray coatings, replacing traditional materials (anchoring bricks, plastic refractory, castable). Features modular design, high-temperature resistance, strong erosion resistance, superior thermal insulation, and supports factory prefabrication with on-site rapid assembly.
2. Core Problems Solved
- Heavy traditional furnace roofs cause high heat loss (3.88%-3.89% of total heat), leading to excessive fuel waste.
- Long on-site casting cycles and difficult maintenance disrupt continuous production.
- Severe heat dissipation degrades the furnace area working environment.
3. Practical Application Effects
4. Case Verification
A bar production line retrofitted with this technology achieved a 35.7% reduction in specific gas consumption (from 261.5 m³/t to 168 m³/t) under 1190℃ tapping temperature and 74% hot charging rate. A special steel line saw 21.8% lower gas consumption and 17.9% higher tapping capacity (140 t/h → 165 t/h).
(2) Intelligent Combustion System
1. Technical Advantages
Based on improved dual-cross limiting control for furnace temperature and air-fuel ratio, it builds a tapping temperature-oriented optimized process control system. Integrates steel temperature tracking, furnace temperature setting, and rolling delay decision models—enabling unmanned heating and closed-loop rapid temperature control.
2. Core Problems Solved
- Manual temperature setting leads to large fluctuations (±30℃ tapping deviation) during rolling delays, causing severe oxidation loss.
- Inaccurate air-fuel ratio adjustment wastes fuel and compromises steel temperature uniformity.
- Lack of heating process traceability hinders quality problem troubleshooting.
3. Practical Application Effects
4. Case Verification
A steel mill maintained stable temperature control during 20-minute rolling delays with minimal overheating. Multiple applications achieved ≥98% intelligent operation rates—reducing fuel consumption and lowering rolling scrap rates via improved steel temperature uniformity.
(3) Hydraulic System Potential Energy Recovery Technology
1. Technical Advantages
Recovers gravitational potential energy from descending walking beams via energy storage devices, converting it into reusable hydraulic energy while absorbing load fluctuation shocks.
2. Core Problems Solved
- Traditional hydraulic systems waste potential energy during walking beam descent.
- Load fluctuations cause equipment shocks, shortening service life and increasing spare parts costs.
3. Practical Application Effects
- Saves ~60% energy vs. conventional equipment; cuts pump set power consumption by ≥50%.
- Enhances operational stability, reduces spare parts usage, and extends equipment lifespan.
- Cushions load shocks, lowers failure rates, and ensures continuous production.
(4) Digital Operation & Maintenance Platform
1. Technical Advantages
IoT-based 3D visualized O&M platform that real-time collects multi-dimensional data (gas composition/flow/pressure, furnace/steel temperature). Integrates fault early warning, diagnosis, digital spare parts management, and predictive maintenance—enabling closed-loop heating furnace management.
2. Core Problems Solved
- Lack of real-time monitoring leads to delayed fault detection and prolonged downtime.
- Experience-dependent O&M lacks data support, resulting in improper maintenance timing.
- Chaotic spare parts inventory causes shortages or overstocking.
3. Practical Application Effects
- Improves fault warning response speed by ≥50%; reduces line failure rates; boosts capacity by 10%-15%.
- Optimizes operating parameters via data analysis to unlock additional energy savings.
- Intelligently plans spare parts inventory, cutting capital occupation and costs by ≥20%.
- Extends equipment life and reduces comprehensive O&M costs by ~30%.
(5) Walking Beam Thermal Insulation Technology
1. Technical Advantages
Uses high-efficiency thermal insulation materials and optimized structural design to minimize walking beam heat loss and maintain stable furnace temperature.
2. Core Problems Solved
- Poor insulation of traditional walking beams causes uneven furnace temperature and reduced heating efficiency.
- Heat leakage increases ambient temperature and burdens the cooling system.
3. Practical Application Effects
- Improves furnace temperature uniformity by ≥10% vs. traditional designs, ensuring consistent heating quality.
- Reduces heat leakage, cuts cooling system energy consumption by ~10%, and improves workplace conditions.
III. Comprehensive Synergistic Benefits
The six core technologies work in tandem to deliver energy saving, quality improvement, efficiency enhancement, and cost reduction:
- Energy Saving & Carbon Reduction: 15%-38% comprehensive energy savings (≥30% per ton of steel in top-performing projects) + reduced CO₂ emissions—aligning with global environmental regulations.
- Quality Upgrade: Tighter tapping temperature precision, uniform steel heating, and ~10% lower oxidation loss—boosting product consistency.
- Efficiency Boost: 10%-20% higher furnace capacity, ≥30% shorter construction cycles, and reduced downtime—accelerating production throughput.
- Cost Control: Lower fuel, labor, spare parts, and O&M costs—delivering strong return on investment (ROI).
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📧 Email: hengyuan6@hotmail.com
