In quenching oil, solid particle impurities, sludge decomposition produced by thermal shock, etc. are the main sources of pollution, and the size of these pollutant particles is very small, usually between a few tenths of a micron to a few microns. However, when the pollutant content exceeds a certain amount, it will cause the performance and surface finish of the quenching oil to decrease, resulting in a decrease or instability in the quality of the product after heat treatment; moreover, the pollutant will increase the consumption of the quenching oil.
In order to solve the above problems, we recommend a purification mode of quenching oil, which has been improved on the traditional purification mode.
Quenching oil traditional purification mode
(Filter type)
——The traditional purification effect is not ideal
Figure 1 Principle of filter element interception filtration (traditional filter mode)
As can be seen from the schematic, the general filtration uses filter element layer filtration, which cannot purify the particles in the oil. And it is necessary to replace the filter element regularly, so that the cost increases, and the maintenance is more troublesome, the maintenance cost is higher, and the cycle is longer.
Quenching oil in-line purification mode
(Centrifugal)
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FM600 quenching oil online purification system is mainly composed of centrifugal filter, oil transmission system, control system three parts (British import centrifugal host)
Fig. 2 Sludge carbon black centrifugal filtration effect
Figure 3 Principle of quenching oil centrifugal purification system
(Whether nitrogen needs to be selected according to the furnace type)
Figure 4 Schematic diagram of centrifuge structure and working principle
(FM600, MANN+HUMMEL, UK)
The key component of the centrifugal filter (Fig. 5) - the double-jet center rotor, through which the pressure generated by the oil is converted into the driving force of the rotor, driving the rotor to rotate at high speed, the speed can reach more than 6000 rpm, and the centrifugal force generated is about 2000 times more than gravity. Centrifugal filtration relies on the action of centrifugal force to analyze impurities. Because the proportion of oil and pollutants is different, the amount of centrifugal force received is also different, and when the particle size is certain, the larger the density of the particles, the greater the centrifugal force. As a result, centrifuges can quickly and efficiently separate metal abrasives as well as contaminants that wear parts or spoil oil.
Indicators and system configuration
The specific configuration is subject to the actual situation on site.
Advantages of in-line purification systems
FM600 quenching oil online purification system is independently installed on the oil tank or separately installed bracket, using online bypass continuous purification mode, real-time separation of particulate matter in quenching oil, does not affect the normal operation of quenching furnace equipment and heat treatment production. Since the centrifugal purification oil system removes pollutants from the oil by centrifugal force, it is a pure physical process, and there will be no change in the composition characteristics of the quenching oil, and the performance indicators of the quenching oil are not reduced. Moreover, compared with other purification equipment, centrifugal oil purification systems also have the following advantages:
1: The use of foreign advanced technology, the host for pure British imports, excellent performance.
2: No filter element, no consumables, service life of more than 10 years.
3: Compact size, save installation space, easy to install.
4: Simple structure, unique hydraulic drive principle, no wearing parts design, high operational reliability, low failure rate.
5: High purification accuracy, can separate 0.26 micron size of particle impurities (Figure 5).
6: High purification rate, can remove other oil purifier can not remove the tiny particles of impurities, gum, sludge, etc.
7: The whole machine has small power and low energy consumption.
8: Installation, disassembly is simple and convenient, the cleaning time is short, it only takes 5 minutes.
9: Dry sewage, sludge into lumps or cakes, or thick paste. No oil loss.
Fig. 5 Analysis results of separation of dirt from 1g quenching oil purification system
(Source M+H, Germany)
Figure 6 Number of particles per 10 ml of oil at different stages of purification
l Applicable oils: cutting oil, hydraulic oil, lubricating oil, engine oil, hot kerosene, quenching oil, forging oil, drawing oil, anti-rust oil, gear oil, hydraulic transmission oil, cylinder oil, rolling oil, circulating oil, locomotive special oil, turbine oil, cooling oil, heavy oil, compressor oil, cleaning oil, heat conduction oil, EDM oil, etc.
l Typical applications: metallurgy, mining, coal, petrochemical, electric power, shipbuilding, engineering machinery, automobile manufacturing, railway, locomotive, machining, aircraft manufacturing, papermaking, cement, building materials, food, plastics and rubber, military and other industries.
Benefit analysis
——Ai Xielin ordinary push plate furnace as an example
(For reference only)
Before the centrifugal oil purification system, each quenching furnace uses 60 barrels of oil, the average price of oil per barrel is 5000 yuan, normal loss, and the annual need to supplement the quenching oil accounts for about 5% (2-3 barrels) of the total use. The traditional filter is replaced every 6 months, and the cost of each replacement is about 1000 yuan. The heat exchanger is replaced every 5 years, and the cost of each replacement is about 50,000 yuan. The quenching tank needs to be stopped every 2 years to clean up, the cleaning cost includes labor costs, the management fee is about 10,000 yuan, and the loss of 4% (2 barrels) of quenching oil is lost at the same time.
It can be calculated as follows: 5000 x 2 + (50000÷ 4) + (10000 ÷ 2) + 5000 x 2 ÷ 2 + 1000 x 2 = 34500 yuan.
After the centrifugal oil purification system is adopted, the service life of each heat exchanger can reach 16 years, without the need to specifically clean the quenching tank, and the cutting and replacement filter cycle is extended by at least 4 times.
This shows that the average direct savings of 34,500 –15,500 = 19,000 yuan per year can be seen
Each unit is calculated according to an average of 2 heat treatment equipment: 2 x 19000 = 38000 yuan, here has not yet calculated the stability of the quenching oil performance after purification to improve the quality of the workpiece, as well as reduce the indirect economic benefits brought by the quenching furnace equipment failure for the enterprise, and the benefit is far greater than the above-mentioned cost savings.
Case 1
1.1 Time: Installed in March 2018
1.2 Application location: NGC, Wanliyang, Zhejiang, DPCA
1.3 Application equipment: 4 sets of Aixilin multi-purpose furnaces, 3 sets of Aichelin converters, and ECM push plate furnaces in France
1.4 Site Conditions:
Equipment oil consumption: 8000-20000 L
Oil working temperature: 80 °C
Oil viscosity: 26cSt@40°C
Figure 7 On-site installation
Figure 8 shows centrifugal purification of carbon black debris
1.5 Feedback on the application of online purification oil system
* Ten hours to purify the full tank of oil peat black, the effect is remarkable
Case 2
1.1 Time: May 2016 installation
1.2 Application location: Tangshan Aisin Gear Factory, Zhejiang Jinhua Jifu (Wanliyang Transmission)
1.3 Application equipment: 2 sets of Japanese push plate furnaces, 2 sets of Aichelin push plate furnaces, 2 sets of multi-purpose furnaces
Equipment oil consumption: 18000-20000 L
Oil model: Japan Izumitsu isothermal quenching oil
Operating temperature: 130°C
Oil viscosity: 36cSt@40 °C
Figure 9 On-site installation
Figure 10 shows dry, bulky carbon black debris
Seven days after the installation of the centrifugal filtration purification system, the viscosity of the oil decreases and the cooling effect becomes better.
* Purified a lot of sludge, the oil is much cleaner
* The appearance of the workpiece is brightened
Case 3
FM600 quenching oil online purification system is currently one of the most advanced quenching oil online purification equipment at home and abroad. The system has been applied in many enterprises at home and abroad, and has achieved good application results, and has been highly recognized by customers.
1.1 Time: November 2009
1.2 Location: Bodycote, Germany
1.3 Application equipment: German IPSON-10 multi-purpose furnace
Equipment oil consumption: 4000L
Oil model: Houghton 470
Quenching oil temperature: 70-90 °C (temperature can reach 160 °C after quenching)
Oil change cycle: 1-2 years
Figure 11 Post-installation scene (Bodycote)
Figure 12 Purification effect of centrifugal oil purifier after 5 hours of operation
Figure 13 After 4 days of operation, the centrifugal oil purifier cleared out 30kg of carbon black and other dirt
1.6 Centrifugal oil purifier usage
* Clean the centrifuge rotor 3 times a day for the first five days
* Clean up once a day for the second week
* Clean up once every three days on the third Wednesday
* After one month, clean up every two weeks
* After that, clean up once every 3 months
Case 4
1.1 Time: October 2018, March 2019
1.2 Application location: Ningbo Geely Automobile Phase 1, Phase 2, NGC, DPCA
1.3 Application equipment: Aixilin push plate furnace, multi-purpose furnace
Equipment oil consumption: 40T
Oil model: rapid quenching oil
Oil viscosity: 13-22cSt@40 °C
Quenching oil temperature:
The oil replacement cycle is not replaced, and the oil is replenished regularly
Figure 14 Live installation on site
Figure 15 Status after 1 month of operation and 3 months
1.5 Centrifugal oil purifier usage
* On the fifth day of operation, the rotor is still full of carbon black
* After one month, as shown
* Condition at 3 months
Case 5
1.1 Time: October 2015, October 2019
1.2 Application location: Chengdu Tianma Railway Bearing Co., Ltd., Northeast Special Steel Eagle Wheel Machinery
1.3 Application equipment: Aichelin multi-purpose furnace 3 sets, continuous furnace 4 sets, converter 3 sets
Equipment oil consumption: 4000L-12000 L
Oil model: Derunbao
Quenching oil temperature: 80 °C
In order to reduce the cost of use, the user has not changed the oil.
Figure 16 Mobile centrifugal purification system
Figure 17 Use a 2-hour effect
* Customer feedback is good
* The oil quality is ideal
* Eliminates the need to clean the oil tank
Case Six
1.1 Time: February 2010
1.2 Location: Getrag (Jiangxi) Driveline Nanchang Plant
1.3 Application equipment: Aichelin (Aichelin) multi-purpose furnace 5 sets, continuous furnace 1 set
Oil replacement cycle: 2-4 years, in order to reduce the cost of use, the user has not changed the oil, only in the case of poor oil quality (about 1 year), after precipitation, replace one-third.
Figure 18 Getrag (Jiangxi) Driveline Company Nanchang plant heat treatment site, five multi-purpose furnaces after the installation of centrifugal filter purification oil system on the scene
Figure 19 Illustration of side mounting
Figure 20 Overview of the specific location after installation
* All five multi-purpose furnaces are equipped with centrifugal filtration purification oil system
Fig. 21 Centrifugal filter purification oil system installed in a continuous furnace
Figure 22 Status of purification of oil and carbon black debris after one week of installation
1.6 Comparison before and after the use of centrifugal filter oil purifier
1.7 The use of centrifugal oil filter purifier enables customers to greatly reduce the comprehensive cost of maintenance equipment. Improved comprehensive economic benefits.
Case Seven
1.1 Time: May 2010
1.2 Application location: Getrag (Jiangxi) Driveline Company (Yudu) factory
1.3 Application equipment: 6 sets of IPSON multi-purpose furnaces, 1 set of Aichelin continuous furnaces
Fig. 23 The quenching oil centrifugal filtration purification oil system is applied at the Getrag Yudu plant
Due to the continuous use of oil products for many years, the dirt in the oil products increases, and the cooling quality of the oil products decreases, resulting in a decrease in the surface hardness of the workpiece, and even unqualified waste products. In addition, the surface brightness of the workpiece is poor, the appearance is ugly, after cleaning, there is still a large amount of carbon black and other dirt on the surface of the workpiece.
Figure 24 A large amount of solid oil impurities was removed
Fig. 25 Impurities separated by centrifuge after 36 h
Practice has proved that after the installation of the oil purification system, the oil quality improves significantly, and the appearance of the workpiece changes greatly. The hardened layer soft spot is gone. So far, there is basically no need to change the oil, only to replenish the normal oil loss. In addition, the manual management cost of cleaning mailbox fouling is greatly reduced, the surface quality of the workpiece is improved, and the long-term comprehensive economic benefits are very considerable.
Case 8
1.1 Time: July 2019
1.2 Application location: Hunan Zhuya Hande factory
1.3 Application equipment: Aichelin (Aichelin) push plate furnace 8 sets, converter 2 sets, a total of 16 sets of centrifugal purification system installed
Equipment oil consumption: 18000 L
Oil model: Houghton quenching oil
Oil viscosity: 23-26cSt@40 °C
Quenching oil temperature: 70-90 °C (temperature can reach 100 °C after quenching)
Fig. 26 Continuous push plate furnace installation of online purification oil system
Figure 27 Centrifugally filtered out bulk carbon black debris
The installation of the online purification oil system saves a lot of harsh physical labor for Fast employees, without regularly stopping the furnace and drilling into the quenching tank to clean up the deeper sludge and debris, but also saves a lot of costs, more importantly, improves product quality, and increases comprehensive benefits.
Case Nine
1.1 Time: Installed in August 2019
1.2 Application location: Zhejiang Nuojin Electric Appliance, Yantai Northeast Special Steel
1.3 Application equipment: Taiwan Sanyong network belt furnace, AiXilin double push plate furnace
Equipment oil consumption: more than 12 tons
Due to cost considerations, customers do not change oil, but only replenish oil regularly.
Figure 28 Installation of a purification oil system at the site
Fig. 29 Filter out the debris into dry blocks
Online centrifugal filter purification oil system is suitable for gear processing, shaft processing, chain production, casting annealing, tool manufacturing, automotive, petrochemical, aerospace and other occasions that require quenching oil as a heat treatment medium.
High viscosity oil professional centrifugal oil purifier
l Suitable for oils
All kinds of cold pier molding machine lubricating oil (molding oil), drawing oil, and other high viscosity oils.
l Applicable fields
Mechanical processing field, gear and bearing processing field, powder metallurgy industry filtration, fastener manufacturing field
Fig. 30 High temperature resistant stationary centrifuge
Fig. 31 High temperature resistant mobile centrifuge
(Above) Use the Filter effect
Automatic slag removal centrifuge
l Automatic slag removal centrifuge application field
Food manufacturing industry, glasses and glass industry, powder metallurgy, semiconductor industry, sewage treatment, chemical industry, petrochemical field, concrete processing and manufacturing industry, mine development, pipe processing industry and other large factories and mine purification fields.
About Tianhang Zhiyuan
Products & Services
In-line oil purification and industrial non-destructive testing
Beijing Tianhang Zhiyuan Technology Co., Ltd. aims to promote the world's advanced technology to the mainland's industrial modernization construction, and provide relevant supporting equipment and technical support for the mainland's aerospace, railway, transportation, petrochemical, nuclear industry, automobile and other fields. At present, there are two main sectors involved in the business: in-line oil purification technology and industrial non-destructive testing technology.
Online centrifugal oil filter purification system adopts British proprietary technology, compared with other equipment, compared with the general similar filtration technology has a unique superiority, equipment power is small, simple structure, installation, disassembly, cleaning are more convenient. Without replacing the filter element, the oil loss is minimized, and the quality and characteristics of the oil are effectively guaranteed, which greatly improves and improves the quality and equipment life of the workpiece. Directly and indirectly reduce production costs and increase comprehensive economic benefits.
Industrial CT non-destructive flaw detection technology is a relatively sophisticated technology, which is derived from foreign computer tomography analysis technology. At present, this technology is widely used in the continent's aerospace, aviation, military, nuclear industry and other fields, and gradually expanded to the automotive, petroleum, railway, transportation and other civilian fields, providing effective technical solutions and related equipment for the independent research and development and process improvement of the mainland's core equipment.