[China Aluminum Industry Network] On December 3, the 2015 (2nd) China International Aluminum Fusion Summit was held in Harbin with the theme of “focusing on casting technology, leading the future of processing, focusing on technological exploration, and achieving mutual benefitsâ€. The conference was organized by Shanghai Cosmos Business Development Co., Ltd., China Nonferrous Metals Processing Industry Association, and Harbin Dongsheng Metal Materials Co., Ltd. As the industry's melting and casting industry exchange platform, the conference gathered experts and scholars in the industry and production technology elites. Explore the production technology and jointly promote the technological upgrading of the casting industry and promote the development of the industry.
Wang Guojun, director of the technical center of Aluminum Corporation of China Northeast Light Alloy Co., Ltd., delivered a keynote speech at the meeting entitled "The Program and Measures for Saving Energy and Reducing Consumption of Aluminum Processing Products." He pointed out that China's aluminum processing industry has developed rapidly and has become a major producer of aluminum processing materials. The aluminum processing industry consumes a lot of energy, and the smelting process, as a large energy consumption process for aluminum processing, is a key area for the country to implement energy conservation and emission reduction, and gradually eliminates serious pollution, excessive energy consumption, obsolete equipment, and development of a reasonable industrial layout. The performance and configuration of equipment and the improvement of the technological level have become the mainstream trend in energy saving and environmental protection development of the aluminum alloy industry.
At present, the development of aluminum alloy casting industry in China is far behind that of foreign countries. Currently, it is in the stage of crazy introduction and large adjustment of product structure. The traditional energy consumption of the smelting process is determined by the casting process. The smelting process is to form a liquid metal by heating the solid metal and hold it for a certain period of time, and then to form a solid state process. Therefore, the metal in the casting process is This transition between states is the root cause of large energy consumption in the casting process. Advanced aluminum alloy casting equipment is a concrete embodiment of the modernization of aluminum processing industry, and it is an effective means to increase the efficiency of equipment utilization, energy conservation and consumption reduction. Therefore, the company needs to reasonably select various equipments for the melting process and continuously upgrade the tooling to create the basic conditions for the energy saving and consumption reduction of the aluminum alloy casting process. Including the improvement of smelting methods, upgrading of degassing purification methods and equipment, automation and intelligentization of casting equipment, and reasonable equipment matching.
In terms of technology, process improvement, optimization and innovation can provide inexhaustible power for energy saving and consumption reduction of aluminum alloy casting process. The improvement of the process yield is an important means to reduce the production cost and energy consumption of the aluminum alloy casting process. Enterprises should pay attention to the following points in this process:
1. Reasonably select the proportion of feed, reduce smelting loss, and achieve energy saving;
According to the author's statistics on the production practice of a 36-ton smelting furnace, it is concluded that: When more than 2 tons of remelted aluminum ingots are injected, the amount of slag is less than 1.5% when it is not cast into tertiary waste, and less than one ton of remelted aluminum is used. Ingots, do not cast three levels of waste, slag volume reached 2.0%; using a corresponding first-level waste, almost no heavy melting aluminum ingots, slag volume of 2.5%; when the input reactivation of ingots and three grades of slag, the slag volume is higher, About 15%. Illustrates the effect of different charge quality on energy consumption.
Different metal elements and different shapes can affect the melting process. Under normal circumstances, the addition of alloying elements to aluminum alloys can be done in blocks, or in the form of pie-shaped master alloys, or in the form of powders or cakes. From the viewpoint of energy conservation, the latter is better than the former.
2, choose the appropriate casting method and the exact casting parameters, improve product yield, achieve energy saving;
The surface of a conventional ordinary die cast ingot is susceptible to cold septa, cracks, non-metallic inclusions, metal leaching, and internal crystalline defects. In order to meet the requirements of pressure processing, ingots have to be milled or increased in the amount of milling, which increases the metal loss caused by geometric wastes, affecting the increase of the yield and thus causing unnecessary energy consumption.
Hot-top casting technology and low-level casting technology are widely used casting technologies for modern aluminum alloy production companies, which greatly reduces energy and cost. Energy conservation and consumption reduction have achieved remarkable results.
3. Develop a new type of smelting process technology, and achieve short-term energy saving and consumption reduction. Aluminum alloys can be used to cast aluminum alloys; the continuous casting and rolling technology is developed, and the ingot heating and integration process is developed.
4, the development of recycled aluminum recycling, energy saving.
Aluminum is highly recyclable and can be recycled many times. For each ton of primary aluminum produced, power generation, transmission losses, and the total energy consumption required for transporting fuel is about 45,000 kWh, and about 12 tons of carbon dioxide is emitted, and one ton of recycled aluminum can be produced. The consumption is only about 2800 kWh, and the emitted carbon dioxide is only about 600 kg, which can save about 95%.
China's aluminum alloy casting process has great potential for energy saving and consumption reduction, and there is huge room for improvement in product quality. It is necessary to catch up with the control level of aluminum alloy casting energy in developed countries, and there is still a long way to go for product quality. All employees in the aluminum processing industry need to continuously explore and Work hard.
(China Aluminum Network reporter Shao Qiping)
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