Aluminum die-casting plant pot before purchasing a reference
Die casting factory in the choice of various types of melting furnace to buy before the specific targeting of all types of fuel oil using cost analysis and planning to buy melting furnace may extend various other expense research analysis:
1 diesel type crucible furnace
Diesel crucible furnace design are mainly used in furnace flue gas recovery by pipeline to the furnace surface to melt the aluminum, to accelerate speed of melting aluminum, and the general customers in the purchase of diesel crucible furnace using mainly the price is very low, often not considered in use may have other problems, such as:
( 1) when melting produced workshop foul the waste gas and the manufacture of high temperature workshop environment;
( 2) caused by aluminum in high temperature combustion melting loss is more than 3-5%;
( 3 ) side feeding side caused by production of Aluminum Die Casting liquid temperature to control aluminum soup unclean and casting adverse rate on the high side. And the use of cast iron pot is caused by iron castings;
(4 ) the high rate of non-performing caused production hours waste;
( 5) the purchase price upsurges successively diesel production cost increase caused by. In order to present diesel purchase price 6-6.5 element is calculated per kg aluminum melting cost about 1.17 yuan, and annual 8 cast iron pot purchase cost and repair cost considerable burning machine.
2 electric melting crucible furnace
Electric melting crucible furnace design application of electric heating melting aluminum crucible from outside, to 300kg electric melting crucible furnace purchase price of approximately 2-4 million yuan the price is very low, to 3ookg crucible furnace melting electric power carry at least 60Kw / h, estimates the crucible for melting 300kg full pot need about 3-3.5 hours, so this melting speed is too slow,
( 1) will cause the aluminum soup could supply use;
(2 ) if the application used in melting and casting feeding side will cause the temperature of molten aluminum to aluminum soup unclean and casting adverse rate will be high;
( 3) together with aluminum ingots often accidentally cause crucible impact rupture crisis, therefore we suggest that electric melting crucible furnace is preferably applied for holding furnace to use, if take fusion using electricity to 60 kwh / hour, using thermal insulation furnace using electricity for 30-35 degrees, if taken when melting to use every kilograms of aluminum melting electric production cost about 0.7 yuan.
3 diesel type centralized furnace
Diesel type centralized furnace is employed to design a set of combustion in a direct way to spray aluminum melting, a combustion engine is arranged in the side of the furnace or insulation chamber furnace cover directly burning aluminum soup to keep aluminum soup temperature, furnace lining material is divided into two kinds of design for the refractory brick into the cost comparison low, another lined by the casting refractory material for injection molding the high cost and long service life, general domestic stove manufacturers generally adopts refractory brick for two main reasons:
( 1) in the furnace body dumped because of low prices customers more easily accept.
( 2) furnace lining life of about 1-2 manufacturers can earn repair again. General concentration melting furnace for melting loss rate is about 3-5% so concentrate furnace to save energy and burning loss rate, mainly in the design of burner jet ignition and furnace lining refractory material and insulation material application and construction technology is in place, otherwise it will affect the service life of the furnace body and the energy consumption cost, general domestic production per hour melting 1 keep area 2.5 tons concentrated furnace price of about 28-35 million yuan, business ( the mainland property) or day import concentration furnace price of about 45-60 million yuan. And every kilograms of melting production cost about 0.75 – 0.85 yuan / kg, made concentration melting furnace about 0.9 – 1 yuan / kg.
Liquefied petroleum gas concentration furnace design and diesel concentration melting furnace design is substantially the same as the main focus, liquefied petroleum gas stove with special attention to furnace lining refractory material selection and construction technology of furnace body manufacturer is in place, or in the use of safety will make people quite concerns, again to watch for liquefied petroleum gas tank safe storage place and the factory pipeline configuration engineering staff is qualified or not careful, therefore the program using liquefied petroleum gas melting furnace using detailed accounting of plan cost is needed, because must first spending gas storage groove and plant piping engineering cost and security unit cost, and then in the purchase of liquefied petroleum gas on furnace and casting machine can use edge melting holding furnace to purchase another, Al Sheng Tonglai handling aluminum soup and other expense, according to the current aluminum die-casting plant generally take this kind of configuration, but do not consider the consequences, such as the furnace time concentration melting furnace must be repair, or order reduction, this time to reduce the production cost to concentration melting furnace short stop motion when found, die casting machine side insulation furnace can not be melted, so were unable to reach an effective cost reduction plan The project will focus on melting furnace shutdown, if this time the electric furnace is changed into non crucible type electric melting furnace, believe that your company will how to deploy without any menace from the “rear”, another proposal can use another way, if the production is not high we propose 1200 tons die-casting machine are respectively arranged above can be single sized liquefied oil gas concentration furnace as machine side furnace use, when production is reduced or the furnace body can be respectively used in need of repair, the province to other furnace and equipment such as: electric furnace, crucible furnace and the aluminum soup handling equipment, as for other small and medium-sized die casting machine, for example: 1000 tons die-castings machine can choose crucible type electric dissolving heat-insulated furnace as direct machine side furnace applied to lower production costs, every kilograms of melting cost only 0.25 – 0.35 yuan, use liquefied petroleum gas furnace melting aluminum environmental clean combustion and melting loss rate is low, approximately every kilograms melting cost is 0.3 – 0.39 yuan. The melting loss rate of about 2%-3%.
5 natural gas concentration furnace
Natural gas concentration furnace design and diesel concentration melting furnace design roughly the same, mainly natural gas concentration to pay special attention to the furnace body furnace lining refractory material selection and construction technology of furnace body manufacturer is in place, or in the use of safety will make people quite concerns, so in the choice of natural gas melting furnace is used to a detailed accounting of plan cost, it set the cost caused by higher costs than the liquefied petroleum gas, natural gas use when you choose, you must first consider plant piping configuration area users not, due to the use of people you plant pipeline configuration cost can share less, otherwise you will pay higher cost set another factory, piping engineering costs are less, and the pipeline configuration engineering staff is qualified and piping technology is careful, because it is related to the entire factory staff safety problem, and then in the purchase of natural gas on furnace and casting machine can use edge melting holding furnace, purchase additional aluminum Sheng Tonglai handling aluminum soup expense, according to the current aluminum die-casting plant generally take this kind of configuration, but often do not consider the consequences, such as the use of a furnace body Time concentration melting furnace must be repair, or order quantity suddenly reduced, this time to reduce the production cost to concentration melting furnace short stop action, then die casting machine side thermal insulation furnace can not be melted so unable to reach effective cost reduction plan will focus on melting furnace to stop furnace, if this time the electric furnace to no crucible type electric melting furnace, believe that your company will how to deploy without any menace from the “rear”, another proposal can use another way, so we suggest that if the plant more than 1200 tons of large-scale die-casting machine, or volume of production is not high, we propose can be single are respectively arranged small natural gas concentration furnace as side furnace use, when production is reduced or the furnace body can be respectively used in need of repair, the province to other furnace and equipment such as: electric furnace, crucible furnace and the aluminum soup handling equipment, as for other small and medium-sized die-casting machine, such as 1000 tons die-casting machine can be directly used without crucible type electric dissolving heat-insulated furnace as the machine side application of reducing production costs, every kilograms of melting cost only 0.25 – 0.35 yuan, using natural gas melting furnace melting aluminum environmental comparison Clean burning and melting loss rate is low, approximately every kilograms melting cost is 0.3 – 0.36 yuan. Melting loss rate of about 2% – 3%.
6 environmental protection and energy saving type crucible type electric melting furnace
Non crucible type electric dissolving heat-insulated furnace design is the use of SIC to radiation heating component to the aluminum directly heating and melting furnace lining, completely by using the Morgan high strength non-stick aluminum refractory material, to the factory on the casting refractory material cognitive and more than 20 years construction experience, perfect for the whole furnace lining construction essentials played thoroughly, the furnace lining structure even tougher in the use of more smooth and longer life, control system completely to take SCR with PLC and man-machine interface completely automatic control, aluminum soup temperature by PID automatic calculation system control temperature more stable operation, the purchase price is generally the main furnace body, environmental protection, energy saving, simple security staff, aluminum soup temperature control stability of aluminum soup without impurities, while reducing the casting defect rate, can greatly shorten the delivery time, and improve the workshop temperature polluted environment quality, melting aluminum ingots are easily added, aluminum melting loss rate is extremely low below about 0.05%, maintenance of equipment and maintenance simple. Approximately every kilograms of aluminum melting cost 0.25 yuan.
General casting manufacturers for the purchase of aluminum melting furnace body related information is limited, so the die casting machine side furnace selection methods generally adopted to measure the purchase price of furnace body criteria, the most common on the market to buy a furnace body mostly with low diesel type crucible furnace or low electric melting crucible furnace to use, or another kind of purchase way from that, he plants are used the furnace body to decide to buy, basically never to factory production castings quality demand, production cost and production workshop environment quality for choosing furnace body considered standard, and make detailed plans and analysis of various furnace application status, to plan the factory should choose the most economic the furnace body to use and with the factory casting production status, as deep into the discussion of each solution in Taiwan die casting machine for aluminum soup consumption per hour, and the entire plant all die casting machine for aluminum soup per hour maximum total amount of use, to determine the most economical most suitable machine side furnace purchase, with the price only to measure order reference the furnace body, or listen to the unscrupulous sales deliberately deceived easily decided to buy die casting machine side furnace, or to his factory decided not suitable for factory use standard purchase adopt centralized fusion Furnace with electric furnace to use, so in the furnace has very many problems. For example:
( 1) the overall cause melting aluminum soup consumption insufficient supply;
( 2) the die casting machine arrangement caused by excessive aluminum soup supply side;
( 3) provides a low temperature aluminum soup caused by electric furnace can rapidly warming lining of serious slagging,
( 4) melting furnace repair electric furnace to melt during the whole plant production line shutdown;
( 5) diesel price escalation caused production cost rise;
(6 ) the use of cast iron pot cast iron caused by excessive;
( 7) diesel type crucible furnace direct burning aluminum melt, causing massive damage of aluminum and workshop air dirty dirty;
( 8) the temperature increase caused by unstable casting defect rate production man-hour waste.
So we suggest that manufacturers in the purchase of furnace body so as to collect relevant information about furnace body to make the choice and evaluation, believe that the above problem will not happen in your factory. So we suggest the hypothesis can be used Aluminum Casting as the main fuel of die casting machine, electric oven side ideal, do not put high cost spent on LPG or natural gas piping construction costs, so we sincerely suggest manufacturers as close as possible to the expenses spent on electric power company for electric capacity to costs are relatively low, and the production cost is also reduced after casting while improving the high temperature working environment and maintenance workshop or factory safety would be more practical.