China Bright Annealing Furnace for Copper Coil

1. Technical Parameter
1.1 Furnace Type:
The periodical operated bright annealing furnace adopts roller hearth type. Throughout of the furnace is 1500Kg/h.
1.2 Purpose:
It is mainly supplied for bright annealing kinds of copper tube, wire, bar, and coil. Such as: copper, brass, bronze, cupronickel, and copper alloy. Maximum working temperature of the furnace is 950ºC.
1.3,:Product Data
1.3.1, Tube Coil

No.
Item
Data 1
Workpieces Type
Tube Coil 2
Material
Copper3
Max. Diameter of Coiled Pipe 1300mm(OD)x300mm(H)
4
Max. Weight200Kg

1.3.2, Straight Pipe

No.
Item
Specification1
Workpiece Type
Straight Pipe 2
Material ,,,
Copper, Brass, Bronze, Cupronickel 3
Out Diameter φ8-160mm4
Thickness 1.0-10mm5
Length 2.0-5.5m

1.3.3, Straight Bar

No.
Item
Specification1
Workpieces Type
Straight Bar 2
Material ,,,
Copper, Brass, Bronze, Cupronickel 3
Out Diameter of Straight bar 20-80mm4
Length 2-5.5m

1.3.4, Wire Coil

No.
Item
Specification1
Workpieces Type
Wire Coil 2
Material ,,,
Copper, Brass, Bronze, Cupronickel 3
Diameter of Wire 5-10mm4
Max. OD of Wire Coil1300mm(OD)x300mm(H)5
Max. Weight of wire Coil200Kg

1.3.5, Data of Standard Product

No.
Item
Specification1 (9010)
Copper Tube 76mmx2mmx5000mm
(160~8x3.5~1.0x5000~5500mm)

1.3.6, Work Tray

No.
Item
Specification1
Dimension 5800x1500x400mm3
Weight 260Kg

1.4,
Working Process of Each Zone

No.
Item
Function 1
Charge Purge Chamber
Expel air to a suitable level of oxygen during load. 2
Heating Chamber
Heat Product to required Temp. 3
Circulating Cooling Chamber60ºC
Cool down Product to 60ºC4
Discharge Purge Chamber
Expel air to a suitable level of oxygen during unload.

1.5,/ Temperature Range/ Temperature Uniformity

No.
Item
Function 1
Temperature Range400-800ºC2
Max. Working Temperature 900ºC3
Temperature Uniformity ±5ºC4
Heating Chamber 2
2 Zones

1.6,Furnace Dimension

No.
Item
Data 1
Working Width 1500mm2
Tunnel Height 400mm3
Working Height (Pass Line Height )1000mm4
Length of Charge Table 6100mm5
Length of Charge Purge Chamber 6150mm6
Length of Heating Chamber Inlet Plenum 1220mm7
Length of Heating Chamber 7800 mm8
Length of Heating Chamber Exit Plenum 1440mm9
Length of Radiation Cooling Chamber 6300 mm10
Length of Convection Cooling Chamber 6300 mm11
Length of Discharge Purge Chamber 6150mm12
Length of Discharge Table 6100mm13
Overall Length 48200mm14
Overall Width ~3000mm15
Overall Height ~3000mm

1.7, Electrical Requirements

No.
Item
Specification 1
Heating Power in Heating Zone 1# 160Kw2
Heating Power in Heating Zone 2#160Kw3(5)
Fast drives (5 Sets )8Kw4(4)
Heating Chamber Fans (4 sets )16Kw5(6)
Cooling Fans (6 Sets)45 Kw6
Control Equipments 3Kw

1.8, Power Source

No.
Item
Specification 1
Main Power 380V 50Hz 3 Phases2
Control Power 220V 50Hz Single Phase

1.9, Protecting Gas

No.
Item
Specification 1
Component 2~5%H2+95~98%N22
Flow Rate (normal) 45m3/h3
Gas Curtain 160m3/h4
Instant Max. Flow Rate 360m3/h

1.10,() Cooling Water Requirement(for Reference)

No.
Item
Specification 1
Fans in heating Zone 50L/M
2
Cooling Zone100L/M3
Convection Cooling Zone 150L/M

1.11, Throughput of the Electrical Furnace

No.
Item
Standard Workpiece 1
Material (9010)
Copper Tube 2
Product
Tube 3
Loading Capacity of Each Tray 80(5)
80Pieces (5 layers)4
Length of Products 55
Net Weight of Each Tray 800Kg6
Tray Weight 260Kg7+
Tray+ Product 1060Kg8()
Throughput Rate (Net)1500Kg/h9
Max. Roller Load 400Kg/m10
Heating Temperature 800ºC11
Loading Cycle 30 min/
30min/tray

,
2. Brief Introduction of Equipment
2.1, Charge Table
,./.,,.
At the charge end of the furnace a driven roller topped table allows coils or straight tube/bar to be loaded onto trays, which are designed to carry the load through the process. Each roller on the table is mounted on bearings supported by the main structure and is driven by chains connected to a fast drive system which transports the loaded tray into the charge purge chamber.
2.2, Charge Purge Chamber (CPC)
...
Doors are fitted at each end of the Charge Purge Chamber to seal in the atmosphere. These doors are opened and closed by an external pneumatic cylinder and are fitted with pneumatically operated clamps.. At this stage, products are remaining in standstill.
,,.,..
The CPC entry door opens for the product batches to be transferred from the charge table into the charge purge chamber and then closes.
After purging the charge purge chamber discharge door and furnace chamber doors are opened simultaneously and the loads (in the charge purge chamber, furnace and radiation cooling chamber) are indexed forward. The charge purge chamber's discharge door and furnace chamber doors are then closed before the charge purge chamber's inlet door can be opened again to accept the next load from the charge table..
,.,.,,.
The Charge Purge Chamber is a gas tight steel case construction with rollers and external roller drive systems. The rollers are mounted in sealed bearings to maintain atmosphere integrity.
2.3, Heating Chamber Entry Plenum
,.,..
In order to ensure adequate thermal separation between the charge purge chamber (CPC) and the furnace, an entry plenum and furnace door is provided.
The entry plenum is a gas tight steel structure insulated on the inside and fitted with an insulated fiber.
,..,...
To minimise the loss of atmosphere integrity during loading and minimise re-purge time, two filament curtains are fitted behind the doors; and ceramic fiber isolating wall which driven by pneumatic cylinder is mounted in this section. An insulated membrane explosion relief port is designed at top of the furnace.
2.4, Furnace Heating Chamber
2.4.1, Casing
,,,.
The main heating chamber is a gas tight steel structure reinforced with structural steel members that are arranged to be suitable for installation on a level foundation.
,,..
All heating elements, and thermocouples have sealing glands, and rollers are mounted in sealed bearings with gaskets to ensure gas tightness.
,..
Gas expel canopy which connected with hydraulic pressure tank is designed at side wall to control furnace pressure. Beside, protective gas inlet is also fitted on side wall.
2.4.2, Insulation
,..330mm.,.
The furnace is lined with a composite construction of refractory brickwork (thickness: 330mm) and low thermal mass ceramic fibre to give good insulating properties, together with good resistance to mechanical damage and gas erosion. Removable refractory pieces are provided to facilitate removal and replacement of rollers.
.,..
The partial roof sections are lined with ceramic fibre modules arranged to give resistance to high velocity gas recirculation.
The modules are fixed to the casing by special anchors which are set back from the hot face to minimise heat conduction through the lining via the fixing arrangement.
2.4.3, Heating Arrangement
0Cr25AL5,..
,160Kw.320Kw.
Heat is provided from 0Cr25AL5 alloy tape resistance elements fitted in the roof and hearth.
Power of each heating zone is 160Kw. Overall power is 320Kw.
2.4.5, Drive Mechanism
,.
Drive mechanism for roller conveyor of heating chamber consists of electrical speed reducer and manual speed reducer. Roller rotating method has three type:
(1):..
Fast Speed Rotating: for discharge products rapidly out of heating chamber.
(2):..
Slow Speed Rotating: as product are transferred into heating chamber, to reduce movement of inertia, it shall change to slow speed rotating.
(3):.,,.
Forward and Backward Rotating: to avoid deformation, rollers will forward and backward moving during heating process.
,PLC,.
Speed reducer of heating chamber is controlled by frequency transducer. All mechanical movements are controlled by PLC.
2.4.6, Atmosphere Gas Recirculation System
4Kw.,.,."V"...
Each zone is equipped with two powerful plug in type atmosphere recirculation fans. These fans are roof mounted and supported in a water cooled bearing housing. The fan shafts are fitted with a gas tight sealing arrangement.
The protective atmosphere gas is discharged radially outwards from each fan. These protective atmosphere gases move vigourously over, through and around the charge promoting high convection heat transfer coefficients with rapid and uniform heating.
Each fan is driven by an electric motor via a vee belt drive, and fitted with a rotation sensor. When cooling water run out, it will set out alarm signal and power supply will cut off.
2.5, Furnace Chamber Exit Plenum
..
It has same structure with furnace chamber inlet plenum. Isolating door in this section is opened at same time with the insolating door in inlet plenum section.
2.6, Radiation Water Cooling Section
,....
This is a double cased water jacket steel tunnel to provide radiation cooling to the tray and charge immediately following exit from the furnace. This accommodates a full tray length and allows for all tubes to be cooled by the radiation cooler before being index driven into the jet cooler. Heat is taken away through water recirculation.
,,.,.
,.
Radiation water cooling section is divided independent four parts. Each part has integrated pipework. The radiation cooler section is a gas tight fabricated steel construction, mounted on a structural steel stand and containing a number of driven rollers.
2.7, Primary Convection Cooling Chamber
130ºC.
The primary convection cooler (PCC) will cool the work after it leaves the radiation cooler to approximately 130oC.
..,..
..
The primary convection cooler (PCC) is a double cased water jacket split into 3 atmosphere gas recirculating zones to ensure uniform cooling of the load. A plug-type fan and muffle is fitted to each zone to ensure that atmosphere is recirculated and continually cooled over the chamber walls, which are a double cased water jacket. The cooled atmosphere gases then pass into a plenum chamber and up though slots over the charge and tray to achieve the required charge output temperature.
The water jacket likes a heat exchanger.
2.8, Discharge Purge and Cooling Chamber (DPCC)
60ºC,,.
To cool the load to 60ºC or below and to ensure that the furnace atmosphere is not contaminated a discharge purge and convection cool chamber (DPCC) is included.
,....,.,.
In addition to cooling circulating fan in this section, the DPCC has entry and exit doors which driven and clasped by pneumatic cylinder, of the same construction as the Charge Purge Chamber and a rapid purge system such that the chamber can have the necessary full atmosphere purge in a reduced time.
These doors are opened and closed by an external pneumatic cylinder and are fitted with pneumatically operated clamps.
2.9, Discharge Table
..
At the discharge end of the installation a driven roller topped table is provided to fast drive the charge from the discharge purge and cooling chamber. This table is of a similar design to that of the charge table.

,Other Parts
3.1, Exhaust Canopies
...
The inlet end of the Charge Purge Chamber and the exit end of the Discharge Purge Chamber and Cooling Chamber are provided with exhaust Canopy for the purpose of removing the atmosphere discharging from these chambers. The canopy terminates at a point local to the furnace structure. The atmosphere gases discharge should be ducted by the buyer to the exterior of the building.
3.2, Protective Atmosphere
,,,.,.,,.
A protective atmosphere gas flow distribution system is provided, together with flowmeters and valves to each section of the installation with the main header terminating in a flanged connection to accept the buyers supply from their atmosphere storage. All pipeworks are located at bottom of furnace chamber which provide a uniform atmosphere. Double pipework of atmosphere gas supply is included in each set, one is electrical controlled, and the other is manually controlled.
A multi point atmosphere gas analysis system is incorporated.
3.3, Cooling Water Pipework
,.
..
The cooling water system includes connections, valves and drain points arranged to discharge into tundishes for connection to the recirculating water cooling system. The proper arrangement is easy installation and replacement.
3.4, Roller Conveyor Arrangement
.,.....
The charge is conveyed through the equipment on a series of rotating rolls. These rollers are plain or fitted with collars as appropriate to retain the work centrally throughout the equipment. All the rollers are fitted with stub shafts. These stub shafts are mounted in flange mounting, gas tight, bearings attached to the furnace casing, cooling sections, etc., each bearing being provided with a lubricating point. At one side of the conveyor roller, the stub shafts are fitted with sprocket wheels for driving purposes. All roller drives are guarded.
,..
The conveyer rollers are manufactured from a suitable heat resisting nickel chrome alloy or mild steel, according to the temperature conditions applicable generally as follows:

Item (mm)
Diameter (mm)
Pitch
Material 1,
Charge/discharge Table 11465020#
Steel 2
Charge Purge Chamber
11465020#
Steel 3
Inlet Plenum 114250-(20/25)
Ni-Cr4
Primary Heating Chamber114250-(20/25)
Ni-Cr5
Exit Plenum 114250-(20/25)
Ni-Cr6
Radiation Cooling Chamber 11465020#
Steel 7
Primary Convection Cooling Chamber 11465020#
Steel 8
Discharge Purge Chamber 11465020#
Steel

3.5, Roller Drive Mechanism
,.:
All the rollers through the line are index driven at set intervals by means of inverter controlled variable speed AC motors driving through reduction gear units. Working process of the line as following:
→→()→→→→()→→→()→→
Product load on charge table --- door of charge purge chamber open --- roller conveyor of charge table and charge purge chamber fast speed rotate --- door of charge purge chamber close --- inner door of charge purge chamber open --- isolating door of heating chamber open --- roller conveyor of charge purge chamber and heating chamber fast rotate --- product in heating chamber (first limit position) --- roller conveyor of charge purge chamber stop rotating --- roller conveyor of heating chamber rotating (slow speed) --- product in heat chamber (second limit position) --- rollers of heating chamber forward/backward moving
→,→()→→→()→→
Product secondly load on charge table (prepare to charge into charge purge chamber) --- set time out , isolating door open --- roller conveyor of heating chamber and radiation cooling chamber fast rotate --- product conveyed to radiation cooling chamber --- product in first limit position ---- isolating door of heating chamber close --- roller conveyor of radiation cooling chamber slow speed rotate --- product in second limit position --- rollers forward/backward moving
→→→()→→()→→
Product secondly load in heating chamber --- product thirdly load on charge table and convey to charge purge chamber --- time out (in radiation cooling chamber) --- roller conveyor of radiation cooling chamber and primary convection cooling chamber fast rotate --- product in first limit position of primary convection cooling chamber --- rollers of primary cooling chamber rotate (slow speed) --- product in second limit position in primary convection cooling chamber --- roller of primary convection cooling chamber forward/backward moving
→→→→→()→→→
Product secondly loaded in radiation cooling chamber --- product thirdly loaded in primary heating chamber --- products fourthly loaded on charge table and transferred into charge purge chamber --- time out (in primary convection cooling chamber) --- door of discharge purge chamber open --- roller conveyor of primary convection cooling chamber and discharge purge chamber fast rotate --- products conveyed to discharge purge chamber --- rollers of discharge purge chamber stop --- door of discharge purge chamber close.
→→→→→→()→→→.
Product secondly loaded in primary convection cooling chamber --- product thirdly loaded in radiation cooling chamber --- product fourthly transferred to heating chamber --- product fifthly loaded on charge table and conveyed to charge purge chamber --- time out ( in discharge purge chamber) --- product in limit position of discharge table --- door of discharge purge chamber close.
,....S7-300PLC..
One circle of above working process is completed. Each section can be automatically/manually operated. Control system adopts S7-300PLC.
3.6,()Emergency Dive (manual)
,....
In the event of power failure, it is essential that rotation of the hot conveyor rolls is maintained, therefore a manually operated handle is provided for emergency manual rotation of the furnace heating chamber drive.
3.7,/ Electrical/Temperature Control System
Temperature Controller:
SR53,4-20mA,,.±1ºC.
The temperature in each zone is controlled by a microprocessor based temperature controller, working in conjunction with a 'K' type thermocouple.
The 4-20mA output control signal from the temperature controller is fed to the drive boards of the thyristor stacks which supply the heating elements in a burst fire switching mode. Temperature control uniformity is ±1ºC.
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Each of the main heating circuit is fitted with an independent over temperature safety instrument that will measure the temperature. If the temperature of either zone rises above the pre-set safe value then the safety instrument will automatically shutdown the heaters in that zone.
SH,.180mm.
A multi-point temperature recorder (SH model) is provided to give a permanent record of the temperature in each heating zone. Screen of the recorder is 180mm.
,,,,,,,,,,,3VU13,MY,,,. (3),2400x600x2000mm.
Electrical control equipments are housed in a floor standing sheet steel instrument cubicle approximately 2400x600x2000mm (3 sets). This is built into areas for incoming supplies, furnace heater controls, motor controls and indication, temperature control and finally PLC processor, input / output racks.
This cubicle contains, mains supply isolator handle, power consumption meter, voltmeter, ammeters, selector switches, thyristors, push buttons, indicator lights, motor starters and inverters, temperature control and record instruments, PLC processor, associated I/O racks and panel mounted operator interface together with audible and visual alarm to indicate plant status. All internal circuits and wiring are protected by miniature circuit breakers. The thyristor outputs are protected by fast acting fuses. All those instruments are supplied by famous suppliers.

3.8, operator Interface Panel
GP.
A GP operator interface panel comprising a colour display and an integral alphanumeric membrane type keypad is provided and located on the main control panel.
,:
The operator interface panel provides a man-machine interface and has the following features:-
1, .
Operator prompting for information input
2, .
Selection of pre-defined process/recipe information
3, .
Adjustment of process/recipe information
4, .
Indication of sequence faults
5, .
Indication of failure alarm.
6, .
7, Provide over-temperature alarm.
3.9, Alarm Mimic
:
An alarm system is provided and indicates the following alarm conditions:-

Alarm No.
Description 11
Zone 1# over temperature 22
Zone 2# Over Temperature 311#
Zone 1# Recirculation Fan 1# Stopped 412#
Zone 1# Recirculation Fan 2# Stopped 521#
Zone 2# Recirculation Fan 1# Stopped 622#
Zone 2# Recirculation Fan 2# Stopped 71#
Cooling Fan 1# Stopped in Primary Convection Cooling Chamber 82#
Cooling Fan 2# Stopped in Primary Convection Cooling Chamber 93#
Cooling Fan 3# Stopped in Primary Convection Cooling Chamber 10
Cooling Fan Stopped in Discharge Purge Chamber and Cooling Chamber 11
Protecting Gas Supply Stopped12
Cooling Water Supply Stopped 13
Charge Table Prepare loading Failure 14
Discharge Table Ready to Unloading Failure 15
Drive failure 16
Forward/backward Moving Failure 17
Furnace door Open Failure

3.10, Atmosphere Oxygen Monitoring
,ZOA-300.:
For clean annealed brass and bright annealed copper, the plant is therefore supplied with an oxygen analyser to monitor the low oxygen ppm level in all the plant chambers on a timed cycle basis or can manually be locked onto one chamber for example the primary convection cooling chamber as an aid to achieve best process quality.
1,,,.
The ZOA-300 Model oxygen analyzer has stable capability with long-life service.
2,,,.
It adopts air convection method which reduced maintenance frequency.
3,,,,.
Directly plug structure provide a rapid and correct analyzing data.
4,,,.
With operator interface, it is easy operating.
5,,.
Limit alarm data can be freely set.
6,,.
Timing automatically storage, it is easy for check data. .