Foundry. Furnaces and Systems for metal melting, holding and transfer, and for heat treatment.

Transcription

1 Foundry Furnaces and Systems for metal melting, holding and transfer, and for heat treatment

2 More than heat... Made in Germany For more than 50 years, Nabertherm with its 300 employees has been developing and producing crucible furnaces and heat treatment systems for foundry applications and metal processing. 150,000 customers in 100 countries are proof of the success of our company. Short delivery times are ensured thanks to our diverse range of products and wide variety of standard furnaces. Setting standards in quality and reliability Decades of experience in industrial furnace building result in the generally acclaimed high "Nabertherm quality". State-of-the-art engineering, use of high-quality materials, modern regulating and control technology, are competitive edges from which you can benefit. Innovation and technology With its wide range of melting and holding furnaces, Nabertherm supplies customized solutions for demanding foundry applications, whether electrically heated or fuel-fired bale-out furnaces or tilting crucible furnaces for temperatures up to 1400 C. User-oriented solutions from one source industrial furnaces from Nabertherm as standard or special semiautomatic or fully-automatic concepts permit high optimization potential for melting and holding non-ferrous metals. After-sales service Global delivery of standard spare parts, within 24 hours ex-works. This service is also available for older models. Modification, refurbishment, transfer or extension can be carried out promptly, even for older equipment. Continued high level of support. Training sessions arranged on request, either in our plant or on site. 2

3 Content Page Competitive edges... 5 Resistance-heated crucible furnaces Bale-out crucible furnaces, brick lined Bale-out crucible furnaces, fibre lined Tilting crucible furnaces, brick lined Tilting crucible furnaces, fibre lined SiC rod heated tilting furnaces Laboratory tilting crucible furnaces Resistance-heated bath-type furnaces Fuel-fired tilting furnaces Tilting crucible furnaces Tilting melting furnaces Burner technology Exhaust gas discharge Liquid metal transport equipment Transport ladle TRP 240/S Transportable crucible furnaces Automatic carousel systems Dewaxing furnaces Annealing, hardening, tempering, solution treating and ageing Switchgear and controllers Nabertherm Homepage

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5 Competitive edges Customized solutions through Wide product range Innovative technology Practical R&D department Productive furnace operation through Reduced downtimes Pneumatic lid operation (optional) Integral working platform (optional) Heated pouring spout (optional) Precise switchgear and controllers Small heat loss through High-quality lightweight refractory bricks or energy-saving fibre insulation Insulated swivel lid Long service life through Freely radiating heater coils Rugged furnace construction Collar plate made of insulating concrete Long service life of crucibles through Optimized furnace construction Cast-iron collar protection ring Furnace protection in case of crucible failure through Generously dimensioned emergency outlet Crucible failure alarm (optional) Quick crucible change through Easily removable collar plate Cost effectiveness through Low purchase costs Low energy consumption Low ageing of heater coils Production security through Global service network Fast spare part supply Tele-service and monitoring Instant fault diagnosis via Internet C Melting range of selected metals and their alloys Tin Lead Zinc Aluminium Bronze Silver Brass Gold Copper 5

6 Resistance-heated crucible furnaces: Bale-out crucible furnaces, brick-lined Furnace chamber temperatures up to 1000 or 1300 C Durable lightweight hot-face insulating bricks Optimized efficiency and extended service life due to freely radiating heating elements mounted on horizontal support tubes Heating on all 4 sides Protection against contamination by insulation and sealing of the crucible Protection of the rim of the bale-out opening by heat-resistant cast iron ring T 80/11 Model Tmax Crucible Capacity Outer dimensions Power Weight Melting Holding in mm performance 1 lid C Kg Al Kg Cu A B C kw kg kg/h Al kg/h Cu open/ closed (kw) T 80/ BU /9* T 110/ BU for holding 5/10* T 150/ BU only 5/10* T 180/ BU /15* T 240/ BU /15* T 10/ A * - 35* T 20/ A * - 3/6* T 40/ A * - 3/7* T 80/ BU * - 4/9* T 110/ BU * - 5/10* T 150/ BU * - 5/10* T 180/ BU * - 7/15* T 240/ BU * - 7/15* T 10/ A * 47** 5/8** T 20/ A * 63** 5/10** T 40/ A * 84** 5/12** T 80/ BU * 190** 5/15** T 10/ A * 47** 5/8** T 20/ A * 63** 5/10** T 40/ A * 84** 5/12** T 80/ BU * 190** 5/15** 1 The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C 6

7 Bale-out crucible furnaces, fibre-lined Furnace chamber temperatures up to 1000 or 1300 C Energy-saving fibre insulation For further technical specifications see bale-out crucible furnaces, brick-lined TF 110/10 Model Tmax Crucible Capacity Outer dimensions Power Weight Melting Holding in mm performance 1 lid C Kg Al Kg Cu A B C kw kg kg/h Al kg/h Cu open/ closed (kw) TF 80/ BU /9* TF 110/ BU nur zum 5/10* TF 150/ BU Warmhalten 5/10* TF 180/ BU /15* TF 240/ BU /15* TF 10/ A * - 35* TF 20/ A * - 3/6* TF 40/ A * - 3/7* TF 80/ BU * - 4/9* TF 110/ BU * - 5/10* TF 150/ BU * - 5/10* TF 180/ BU * - 7/15* TF 240/ BU * - 7/15* TF 10/ A * 49** 5/8** TF 20/ A * 66** 5/10** TF 40/ A * 88** 5/12** TF 80/ BU * 200** 5/15** TF 10/ A * 49** 5/8** TF 20/ A * 66** 5/10** TF 40/ A * 88** 5/12** TF 80/ BU * 200** 5/15** 1 The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C 7

8 Resistance-heated crucible furnaces: Tilting melting furnaces, brick-lined Furnace chamber temperatures up to 1200 or 1300 C Durable lightweight hot-face insulating bricks High melting performances, optimum efficiency and long service life due to freely radiating heating elements mounted on horizontal support tubes Low energy consumption for melting (0.4 kwh/kg Al) Optimum temperature uniformity by heating on 2 sides and rear wall Trouble-free operation with 2 cushioned hydraulic cylinders Low heat loss and protection of the furnace chamber against contamination by insulation and sealing of the crucible Exact and uniform pouring at different tilting angles Rugged steel construction K 40/12 Model Tmax Crucible Capacity Outer dimensions Power Weight Melting Holding in mm performance 1 lid C Kg Al Kg Cu A B C kw kg kg/h Al kg/h Cu open/ closed (kw) K 10/ A * 45** 3/7* K 20/ A * 60** 3/7* K 40/ A * 80** 3/7* K 80/ TP * 180** 4/10* K 150/ TP * 210** 5/12* K 240/ TP * - 8/17* K 360/ BUK * - 11/20* K 400/ TBN * - 12/22* K 10/ A * 45** 5/8** K 20/ A * 60** 5/8** K 40/ A * 80** 5/8** K 80/ TP * 180** 6/11** 1 The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C 2 Crucible with long spout 8

9 Tilting melting furnaces, fibre-lined KF 80/12 Furnace chamber temperatures up to 1200 or 1300 C Energy-saving fibre insulation For further technical details see tilting melting furnaces, brick-insulated Model Tmax Crucible Capacity Outer dimensions Power Weight Melting Holding in mm performance 1 lid C Kg Al Kg Cu A B C kw kg kg/h Al kg/h Cu open/ closed (kw) KF 10/ A * 47** 3/7* KF 20/ A * 63** 3/7* KF 40/ A * 84** 3/7* KF 80/ TP * 190** 4/10* KF 150/ TP * 220** 5/12* KF 240/ TP * - 8/17* KF 360/ BUK * - 11/20* KF 400/ TBN * - 12/22* KF 10/ A * 47** 5/8** KF 20/ A * 63** 5/8** KF 40/ A * 84** 5/8** KF 80/ TP * 190** 6/11** 1 The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C 2 Crucible with long spout 9

10 Resistance-heated crucible furnaces: SiC rod heated bale-out & tilting furnaces TC 80/14 Furnace chamber temperature up to 1400 C High melting performance in the range above 1200 C Protection of the SiC heating elements by special anti-vibration mounting Protection of the furnace chamber against contamination by special insulation and sealing Heat-resistant cast iron ring for protecting the rim of the bale-out opening Optimized performance Service-friendly furnace operation (heating elements can be replaced at temperature) Model Tmax Crucible Capacity Outer dimensions in mm Power Weight Melting performance 1 C Kg Al Kg Cu A B C kw kg kg/h Al kg/h Cu TC 20/ A * 120** TC 40/ A * 120** TC 80/ BU * 180** TC 150/ BU * 220** KC 20/ A * 120** KC 40/ A * 120** KC 80/ BU * 180** KC 150/ BU * 220** 1 The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C 10

11 Laboratory tilting crucible furnaces K 1/10 Furnace chamber temperatures up to 1000 or 1300 C Crucible with spout included as standard delivery Compact bench-top design, crucible can be emptied easily due to tilting mechanism with pneumatic assist Crucible insulated by hinged lid Model Tmax Crucible Capacity Outer dimensions in mm Power Weight Melting performance 1 C Kg Al Kg Cu A B C kw kg kg/h Al kg/h Cu K 1/ A * - K 2/ A * - K 4/ A , * - K 1/ A * 10** K 2/ A * 10** K 4/ A , * 14** 1 The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C 2 Outer dimensions plus transformer in separate housing 11

12 Resistance-heated bath-type furnaces B 250 Furnace heating chamber temperature up to 1000 C Long service life and small connected loads due to walls with special bricks and insulation High energy efficiency through heating located in top cover of furnace (free heat radiation onto bath surface) Bath can be cleaned easily due to swivelling cover Small heat loss from filling and ladling openings with insulated lids Optional: Adaption to suit dosing pump, modifiable ladling opening Model Tmax Capacity Outer dimensions Weight Ladling well Power Holding in mm C Kg Al A B C D kg mm kw kw B x B x B x

13 Fuel-fired crucible bale-out furnaces Furnace chamber temperatures up to 1200 C or 1400 C Gas- or oil-fired High melting performance with high energy efficiency High-quality lightweight refractory brick insulation High combustion efficiency due to positive pressure operation (avoids air ingress) Low energy consumption (approx. 1.3 kwh/kg Al) Optimum furnace chamber geometry through use of high crucible stands, correctly sized exhaust flues and optimized combustion space Low noise level Generously dimensioned emergency outlet to protect the furnace in case of crucible failure Optional working platform Side exhaust (models TB 80/12 TB 240/12) Exhaust discharge over rim of crucible (for models TB 10/14 TB 80/14, side exhaust available as extra) TB 240/14 Furnace Tmax Crucible Capacity Max. melting Consumption Consumption Burner Outer dimensions Weight type performance 1 holding melting rating in mm C Kg Al Kg Cu Kg Al/h Kg Cu/h Lid closed KWh/kg kw A B C D kg KWh/h Al TB 80/ BU * ,3-1, TB 100/ BU * ,3-1, TB 110/ BU * ,3-1, TB 150/ BU * ,3-1, TB 180/ BU * ,3-1, TB 240/ BU * ,3-1, Cu TB 10/ A ** 22 1,0-1, TB 20/ A ** 22 1,0-1, TB 40/ A ** 25 1,0-1, TB 60/ A ** 25 1,0-1, TB 80/ A ** 25 1,0-1, The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C A B C D 13

14 Fuel-fired tilting melting furnaces KB 240/12 Furnace chamber temperatures up to 1200 C or 1400 C Gas- or oil-fired Tilting system with two powerful and precise hydraulic cylinders For further technical details see fuel-fired bale-out crucible furnaces Exhaust discharge over rim of crucible Side exhaust discharge available as extra Furnace Tmax Crucible Capacity Max. melting Consumption Consumption Burner Outer dimensions Weight type performance 1 heat retention melting rating in mm C Kg Al Kg Cu Kg Al/h Kg Cu/h KWh/h KWh/kg kw A B C D kg KB 80/ TP * ,3-1, KB 150/ TP * ,3-1, KB 180/ TP 412 H * ,3-1, KB 240/ TP * ,3-1, KB 360/ TBN * ,3-1, KB 400/ TBN * ,3-1, KB 40/ R400/TP ** 22 1,0-1, KB 60/ R ** 25 1,0-1, KB 80/ R ** 25 1,0-1, The specified melting performances are maximum values. In practice, approx. 80% is achieved. * at 700 C ** at 1000 C A B C D 14

15 Burner technology Burner Burner technology for furnace chamber temp. of 1200 C or 1400 C Gas-, oil-, or dual-fuel burners with state-of-the-art technology Two-step control Automatic operation Flame head can be removed easily when burner is swung out On dual-fuel burners, fuel changeover by manual or automatic switch-over, no conversion work required Delivered complete with gas train consisting of pressure regulator, gas filter, pressure gauge, solenoid valves and all other necessary devices Built to meet DIN 746, Part 2 Standards High operational and functional safety Low NOx emission Safe flame monitoring Easy to install Service-friendly construction Easy to maintain Express delivery of spare parts KB 360/12 with operating platform Exhaust gas discharges Over the crucible rim: Applies to models: TB 10/14 - TB 80/14, KB 80/12 - KB 400/12, KB 40/14 - KB 80/14 Optional extra: Side exhaust High melting performance Low energy consumption Extraction hood Exhaust gas Crucible Burner Side exhaust gas discharge: applies to models: TB 80/12 - TB 240/12 Low dross loss Reduced hydrogen pick-up Reduced emission of pollutants With swivelling or hinged lid for energy saving Exhaust gas To chimney Crucible Burner 15

16 Transport systems Transport ladle Furnace chamber temperature up to 900 C Electrically heated Transfer of molten charges to casting stations Optimized centre of gravity Smooth-running Rotostop gears Easy to operate Precise pouring Long crucible life through ideal arrangement of heating modules Avoidance of long service downtimes due to individually replaceable heating modules TRP 240/S Model Crucible Max. temperature Melting performance Outer dimensions in mm Power C Kg Al/h W D H kw TRP 240/S TP 587/TP 587 SF Transportable crucible furnaces Standard crucible furnaces with fork-truck slots and shock absorbers for safe transport Transport arrangement to suit all resistance-heated crucible furnaces, models T... - TF... (see pages 6 and 7) Automatic carousel systems Automatic rotation to casting and/or ladling stations Fully-automatic control High positioning accuracy Revolving tables up to 8 m diameter Up to 6 holding furnaces Time for 60 movement < 30 seconds Emergency duct below the turn-table High efficiency and productivity 16

17 Dewaxing furnaces S 240/S N 200/GS For melting wax patterns out of moulds and subsequent firing of ceramic investments Furnace chamber temperature up to 850 C Fume discharge through integral outlet Reception and draining of residue through special hearth trough and heated bottom outlet Model Tmax Inner dimensions in mm Volume Outer dimensions in mm Power C W D H Litres W D H kw Top-loading furnace S 240/S Box-type furnaces N 100/GS N 150/GS N 200/GS N 300/GS N 450/GS N 650/GS N 1000/GS N 1500/GS N 2200/GS

18 Annealing, hardening, tempering, solution treating and ageing Box-type, bogie-hearth and top-loading furnaces Electrically heated Temperatures up to 1800 C Volumes up to 20,000 litres Temperature accuracy down to ± 2 K Normal and protective-gas atmosphere Manual, semi- or fully-automatic operation Process documentation capability Air circulation Reasonably priced customized technology due to wide range of furnace types and ancillaries High optimization potential since complete systems are provided from one source Rapid investment pay-back through highly efficient processes Uniform mechanical properties of cast products through high temperature accuracy and precise control of heat treatment High productivity and implementation of automated concepts Ask for our separate leaflet on heat-treatment furnaces and systems Furnace 600 Handling device Charge 18 Quench tank

19 Switchgear and controllers Controllers from our own R&D department Optimized process control through individual adaptation of switchgear and controllers to suit furnaces and installation Long service life and prevention of downtime through high-quality electrical and electronic components Operation at reduced capacity possible through multi-step circuitry Control of energy costs with kwh-meter and operating hours counter Highest electrical safety for personnel and environment through residual current circuit-breaker System control options: Melt temperature control designed as: cascade on/off-regulation Thyristor heating regulation: phase switching phase angle control or solid-state relay, (zero-point switching) Visual/audible signals for all functions Over-temperature policeman Temperature recorder kwh-meter and operating hours counter Crucible failure alarm Adjustable timer Special voltages possible Power management for optimum utilization of available energy capacities Ask for our separate leaflet on switchgear and controllers. 19

20 The whole world of Nabertherm Apart from the solutions presented here for foundry applications, Nabertherm provides a wide variety of alternative solutions for heat treatment. Thanks to our close collaboration with many world-renowned customers, we are able to provide a solution for your kind of problem. If you need support in the fields of glass, ceramics, heat treatment of metals, foundry or other applications, we are at your disposal. References: Headquarters: Nabertherm GmbH Lilienthal/Bremen, Germany Phone +49 (04298) 922-0, Fax -129 info@nabertherm.de Reg.-Nr. C 3.5/09.02 (englisch) Angaben ohne Gewähr, Technische Änderungen vorbehalten.