Protective Atmosphere Hard Felt Graphite Carbonization Furnace: Energy-Saving Precision Heat Treatment Solution
The newly developed protective atmosphere hard felt graphite carbonization furnace of our company is a national standard energy-saving periodic operation furnace. Adopting an ultra-energy-saving structural design, it reduces power consumption by 20%～30% compared with traditional equipment. Specifically tailored for the heating and sintering process of graphite hard felt products, this furnace integrates advanced thermal insulation technology, intelligent control system and reliable atmosphere management function, making it an ideal choice for high-quality graphite felt processing in the industrial field.
I. Equipment Composition
This high-temperature protective atmosphere hard felt graphite carbonization furnace mainly consists of the following core components:
- Furnace body and full fiber furnace lining
- Heating elements and corrugated muffle tank
- Tank internal base and air intake/exhaust system
- Furnace cover and furnace cover lifting & rotating system
- Rapid cooling air supply & exhaust system
- Touchscreen instrument control system
- Environmental protection dust removal device (to be provided by the buyer)
- Furnace mouth sealing system
II. Process Design and Technical Advantages
1. Furnace Body
The furnace body structure is similar to that of a standard well-type electric furnace. The outer shell is welded from A3 steel plates and channel steel, and the furnace panel is made of 14mm-thick steel plate, which is fixedly connected to the furnace shell by bolts. The furnace shell adopts a combined design of head and steel plate, with movable spring supports installed at the bottom to adapt to the thermal expansion of the muffle tank under high-temperature working conditions and ensure the structural stability of the equipment during long-term operation.
2. Furnace Lining
The furnace lining adopts the company's proprietary full fiber manufacturing technology, and the fiber panels are assembled into an integral full fiber structure through a special process (with a compression ratio ≥35-40％). Using high-quality high-purity fiber needle-punched blankets as raw materials, it is processed into 300×300×300mm modules by special equipment. A certain compression amount is reserved during processing to ensure that each ceramic module expands in different directions after masonry, squeezing each other to form a gapless integral body, achieving excellent heat storage effect.
This furnace lining structure has significant advantages: low thermal conductivity, small heat capacity, excellent corrosion resistance, thermal stability and thermal shock stability, and good thermal insulation effect; the thickness of the insulation layer is ≥300mm, and the anchoring parts are arranged on the cold surface of the furnace body, effectively improving the high-temperature resistance strength of the fiber. Meanwhile, the lightweight design reduces the transportation difficulty of large-scale equipment and greatly shortens the on-site installation period. It can be directly fixed on the stainless steel anchor nails of the furnace shell steel plate, featuring convenient and efficient construction.
3. Heating Elements
The heating elements are made of high-temperature resistant resistance alloy strips (material: OCr25Al5A), which are wound into corrugated shapes and hung on insulating and heat-resistant ceramic hangers. It is recommended to regularly inspect the heating elements; if damage occurs, they should be replaced, repaired or reshaped in a timely manner to maintain uniform heating efficiency and extend the service life of the equipment.
4. Furnace Cover
The furnace cover adopts an integral water-cooled sealed flange structure, which is seated on the O-type rubber sealing ring of the upper flange of the muffle tank. The thermal insulation layer of the cover body is filled with ceramic refractory fibers, sealed and welded with 310S heat-resistant steel plates. The furnace cover is equipped with a bolt sealing and locking device to ensure uniform force between the furnace tank mouth and the furnace cover, and a heat-resistant rubber sealing ring is laid in the middle to realize the compression sealing between the furnace cover and the muffle tank.
The furnace cover is provided with a nitrogen inlet, a standby air inlet, a pressure measuring device, an exhaust port and a main temperature control thermocouple interface. A pressure maintaining valve is installed at the exhaust port to adjust the internal pressure; the water-cooled design can prevent the furnace cover from overheating and ensure stable sealing performance.
5. Heat-Resistant Steel Muffle Tank
The muffle tank adopts a bottomed head structure, which is hoisted inside the furnace chamber. The tank mouth is equipped with a water-cooled O-type silicone rubber sealing ring, forming an effective seal with the furnace cover to ensure the heat treatment atmosphere is in a stable working state. The muffle tank is a SUS310S heat-resistant steel welded part, with a thickness of 10mm at the upper part (tension zone) and 6-8mm at the lower part.
The cylinder body adopts a rolled corrugated design, which can significantly improve high-temperature strength, effectively prevent tank deformation, enhance deformation resistance, and greatly improve heat exchange efficiency, promoting uniform distribution of atmosphere and temperature inside the tank. A well-shaped heat-resistant steel support frame is added at the bottom of the tank to facilitate the stable placement of the material cylinder (the charging crucible is to be provided by the buyer).
6. Air Intake/Exhaust System
The air supply system is composed of nitrogen pipelines, equipped with solenoid valves, flow meters and other flow control components, and nitrogen is introduced from the bottom of the tank. In view of the large amount of volatile gas generated during the product heating process, the exhaust pipeline will be specially designed according to the volatile gas volume to ensure smooth emission.
The air supply system is interlocked with the pressure measuring system: when the pressure inside the tank reaches the preset value, the solenoid valve is automatically closed; when the pressure exceeds the preset maximum value, the automatic pressure regulating system starts to relieve pressure; when the pressure drops to the preset lower limit value, the solenoid valve is reopened to supply air, maintaining a slight positive pressure environment inside the furnace. Compressed air continuously provides pressure for the furnace cover compression cylinder to ensure the sealing ring is locked and sealed. The equipment is also equipped with a safety explosion-proof valve to improve operational safety.
7. Rapid Cooling Air Supply & Exhaust System
Workpieces are prone to oxidation if directly taken out of the furnace after heating. To achieve rapid cooling, the equipment is equipped with an external rapid cooling device: cooling fans, pipelines, valves and other components are installed at the bottom of the furnace body, which can quickly cool the furnace tank according to process requirements. A large amount of replacement gas is introduced outside the tank, and multiple exhaust holes are set at the upper part of the furnace body to ensure gas circulation.
8. Furnace Cover Lifting & Rotating Structure
The lifting and rotation of the furnace cover are driven by a dedicated control system, including a steel structure cantilever bracket connected to the lifting shaft and a lifting electric cylinder. The bracket is connected to the furnace body through an integral sliding bearing seat. The furnace cover and the lifting shaft bracket are connected by a connecting pair with reserved thermal expansion length to adapt to thermal deformation under high-temperature working conditions.
Both the lifting and rotating actions of the furnace cover are equipped with travel control switches, and the lifting action is additionally equipped with an overtravel protection switch. All water pipes, air pipes and wire pipes are routed through the pit, erected in the bridge frame of the steel structure bracket, and can be freely dragged with the lifting and rotation of the furnace cover without affecting the operation of the equipment.
9. Product Extraction Device (to be provided by the buyer)
To facilitate the extraction of workpieces after processing, it is recommended to configure a tooling disc with lifting lugs (length of lifting lugs is about 1.5 meters) to realize safe and efficient transfer of workpieces.
10. Environmental Protection Dust Removal Device (to be provided by the buyer)
This device consists of a waste gas centralized combustion chamber and an alkaline spray tower. The waste gas generated during the processing of graphite hard felt is collected through pipelines and introduced into the centralized combustion chamber for incineration. The incineration flue gas is then treated in the alkaline spray tower to ensure emissions meet international environmental protection standards.
11. Temperature Control System
11.1 Temperature Control Method
The equipment is equipped with 2 main temperature control thermocouples, which form a closed-loop control system with imported intelligent digital display temperature control instruments, high-power thyristor modules, phase-shift triggering systems and heating elements. The furnace chamber is divided into 2 temperature control zones to automatically adjust the temperature inside the furnace and ensure uniform temperature in the entire furnace chamber.
11.2 Temperature Control System Configuration
A new type of automatic furnace temperature control system is constructed using imported program temperature control instruments from Shimaden (Japan) and Maxwell power module phase-shift control technology. It can separately set the heating rate, holding temperature and holding accuracy according to the preset process curve, automatically adjust the heating slope and holding time, and display the theoretical value and measured value in real time, improving the control level and temperature control accuracy. This design enables precise matching between heat supply and workpiece heat absorption, resulting in more reasonable energy consumption, and is also equipped with an over-temperature light alarm function.
11.3 Temperature Recording
A paperless recorder is used to record the process curve in real time. The thermocouple is made of nickel-chromium-nickel-silicon material (grade K), and the furnace temperature measurement compensation wire is connected from the instrument cabinet to the furnace body thermocouple to ensure measurement accuracy.
11.4 Furnace Cover Lifting Interlock Protection Design
- The heating program can only be started when the furnace cover is closed to the specified position;
- Limit protection switches are set for both lifting and rotating actions of the furnace cover;
- An acousto-optic alarm method is adopted to accurately indicate the over-temperature area, facilitating maintenance personnel to quickly diagnose and eliminate faults;
- The control circuit is designed separately from the high-power heating circuit. The control circuit can be debugged without connecting the heating circuit, and the heating circuit can be powered in zones;
- A dedicated power distribution cabinet is configured to supply power to the entire system. The cabinet is equipped with overvoltage and overcurrent protection automatic switches to ensure the reliable operation of the system, and an inspection light is installed inside the cabinet;
- Power supply voltage indication and heating power indication for each zone and each phase are provided to facilitate real-time monitoring of heating status and quick location of fault causes when heating efficiency decreases.
III. Core Competitive Advantages
- Super Energy-Saving Performance: Proprietary full fiber furnace lining and optimized structural design, with a power saving rate of 20%～30%, complying with national energy-saving standards;
- Stable Protective Atmosphere: Interlocking between air intake/exhaust and pressure control systems maintains a constant slight positive pressure environment, eliminating workpiece oxidation and ensuring product quality stability;
- Precise Temperature Control Capability: Dual-zone temperature control combined with imported components, featuring high temperature control accuracy to meet the requirements of high-precision sintering processes;
- Robust and Durable Structure: Corrugated SUS310S muffle tank and high-temperature resistant components can adapt to harsh working conditions and extend the service life of the equipment;
- Easy Operation and Maintenance: Touchscreen control, modular design and lightweight furnace lining simplify installation, operation and maintenance processes.
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