Energy-Saving Regenerative Roaster for Global Use

1. Diagram

2. Structural Explanation

The shell of the regenerative gas combustion furnace is made of high-quality steel and is welded together. Inside and on the top and bottom of the furnace body, there are support and reinforcement structures to ensure that the furnace body has a stable and non-deformable characteristic. The furnace lining is made of high-quality aluminous bricks, and between the furnace shell and the furnace lining, there are high-quality insulation bricks and alumina insulation blankets as insulation materials; the furnace top uses high-alumina rock wool and perlite as insulation layers. These materials are lightweight and have excellent insulation performance, preventing the loss of high-temperature heat and ensuring the energy-saving effect of the equipment.

The furnace top bricks are designed in an arched shape to make the structure more sturdy and durable. The interior of the furnace door is filled with high-quality fiber materials, and the furnace door itself is made of heat-resistant materials, which is not prone to high-temperature deformation; the fire hole is cast with heat-resistant materials and is set inside the furnace chamber; the air supply and exhaust pipes are welded with galvanized steel pipes, which have a beautiful appearance and good corrosion resistance.

The cylinder conversion mechanism is equipped with a magnetic switch indicator light, which can directly display the operating status of each component; the temperature sensor is inserted downward from the furnace top and installed, not only detecting more accurately and reasonably, but also avoiding damage to the sensor caused by collisions when the shell and mold enter and exit. The control unit selects electrical components from well-known brands at home and abroad, which have the advantages of stable operation, reliable performance and precise control.

3. Introduction of Regenerative Burner

The regenerative gas combustion furnace adopts advanced regenerative burner technology. During the conventional combustion process, the fuel combustion will produce exhaust gas, which carries a large amount of heat and is discharged; as the furnace temperature rises, the heat loss gradually increases, resulting in the inability to fully utilize the heat of the exhaust gas.

To solve this problem, relevant institutions and technicians drew on the experience of steel plant emission treatment and energy-saving technology advantages, and developed and designed the regenerative burner. This new type of regenerative burner can heat the ambient air to high temperature in a very short time. When the hot air enters the furnace chamber, it will draw the exhaust gas around the furnace chamber, forming a high-temperature and thin air with an oxygen content lower than 21%; the fuel is sprayed near this high-temperature thin air, and it achieves complete combustion in an oxygen-rich environment with an oxygen content of 2% to 20%.

At the same time, the high-temperature exhaust gas produced by the combustion in the furnace chamber is discharged through another set of burners, and the heat carried by it is absorbed and stored by the heat storage mechanism of this burner. Using a working temperature-lower reversing valve, it is switched at a specific frequency (the conventional switching cycle is 50-50 seconds or 60-60 seconds), so that the two sets of burners are in alternating heat storage and release working states.

At present, the exhaust temperature of the box-type furnaces used by most factories is usually over 700℃, while the exhaust temperature of this regenerative combustion furnace can be controlled within 150℃, truly achieving the dual emission effect of energy saving and environmental protection.

4. Overall Control Structure of Point Fire Burner

Inlet valve of point fire burner: When the temperature is lower than 900℃, this valve remains open.

Pneumatic electromagnetic valve: It is mainly used to control the opening and closing of the inlet valve; press the red button on the valve body to achieve manual switch control.

Observation hole of point fire burner: It is mainly used to observe whether the ignition is successful or the flame is extinguished.

Gas valve of point fire burner: By controlling the gas intake volume, the flame size is adjusted.

5. Ignition Control Box

Ignition indicator light: After pressing the ignition button, the indicator light turns on, indicating that the equipment is in the ignition process.

Ignition button: Before opening the ignition gas valve, the ignition button must be pressed; when the flame is stable and burning, release the button (Note: If the ignition fails after a single attempt for more than 5 seconds, the ignition operation must be re-executed).

Foot switch: Its function is the same as the furnace door lifting button, and this switch is added to facilitate the collaborative operation of the operator with both hands.

6. Main Burner Gas Cut-off Valve

Main burner gas valve: Both sides A and B are equipped with gas cut-off valves, which can adjust the flame size by controlling the gas flow.

7. Inlet and Exhaust Direction Switcher Intake and exhaust cylinder: During the operation of the equipment, the cylinder controls the opening and closing of the valves according to the preset program at regular intervals.

Smoke exhaust temperature sensor: This device collects temperature data from the smoke exhaust pipes on both sides A and B and transmits the data to the instrument in the control box.

8. Blower

During operation, it is necessary to ensure that the intake port of the blower remains unobstructed and that there are no obstructions at the outlet.

(Note: The blower must operate in a horizontal position. It is strictly prohibited to place it tilted to prevent the equipment from being damaged due to vibration; after fully opening the damper, the locking screws must be tightened for fixation.)

9. Main burner cooling valve

During equipment operation, the main burner cooling valve must remain open at all times to ensure continuous intake for cooling; regardless of whether the equipment is in operation or in shutdown, this valve can remain in the fully open position (Note: There are a total of 4 cooling valves on both sides A and B. If the cooling valves are not opened, it may cause damage to the burner mechanism due to high temperature and other faults.)

10. Heat storage ball feeding device

When adding heat storage balls, first unscrew the flange installation screws, then simultaneously lift the flange and the sealing plug.

(Note: Do not remove the center screws of the flange to prevent the sealing plug from falling into the heat storage chamber.)

11. Heat storage ball discharging and cleaning

When cleaning, first unscrew the blind plate screws of the flange, and then the heat storage balls can be discharged; after all the internal heat storage balls have been removed, reinstall the sealing components (Note: During installation, ensure that there is no air leakage between the sealing surface of the flange and the blind plate.)

After each cleaning of the heat storage balls, the ash chamber must be opened for cleaning operations.

(Note: After cleaning and readding the heat storage balls, clean the ash storage chamber simultaneously.)

12. Transportation and packaging

The equipment is packaged using a combination of steel structure and medium-density fiberboard (MDF) to ensure its safety during transportation.