3. Energy and environment
(1) Energy ï¬ Develop economic methods for recovering low-grade heat, collection and utilization of waste heat, such as industrial heat and flue heat.
ï¬ Heating technology and equipment for efficient heat transfer, such as plasma heating that increases heat transfer rates.
ï¬ High temperature heat recovery technology.
ï¬ Further develop oxy-combustion technologies that increase thermal efficiency, such as fluid film technology.
ï¬ Collect bottom line data for energy utilization of heat treatment equipment to establish future energy efficiency standards.
ï¬ The method of recovering the atmosphere of the furnace.
ï¬ Accumulate advanced technologies that coordinate heat, electricity and heat treatment.
ï¬ Develop high temperature gas circulation systems to improve furnace efficiency, such as impact heating.
ï¬ New energy-saving process for local heating and surface hardening.
ï¬ Standardization of heat treatment equipment design to achieve versatility and reduce design costs.
(2) Environment ï¬ Reduce combustion and post-treatment technologies for CO, CO 2 and NOX.
ï¬ Elimination, reduction and recycling of cleaning fluids, management of waste oil and other quenching media, and recycling of waste.
ï¬ An inexpensive way to replace salt and oil quenching, such as water and inert gases.
ï¬ Low-cost air-cooling quenching technology for low- and medium-alloy steel parts, such as quenching technology that saves hydrogen.
ï¬ Proposed by-product fuels from non-liquid streams, such as gases emitted by combustion.
ï¬ Efficient cleaning technology that completely removes the workpiece traces.
4. Public welfare part
ï¬ Heat treatment hygiene safety regulations, such as safety management to avoid fire, personal injury, air quality inside the plant, ergonomics, barium salts and amine salts, and other hazardous substances.
ï¬ Personnel training on metallurgical foundation, furnace safety, curriculum setting, personnel requiring training.
ï¬ Develop heat treatment equipment to launch harmful bottom line to avoid future environmental pollution.
ï¬ Set the energy utilization bottom line of heat treatment equipment to set the limits for energy conservation standards in the future.
5. R&D projects worthy of attention
(1) Induction hardening using groundwater circulation induction quenching <500kW is closed by circulating cooling of groundwater. When used, the groundwater is pumped by deep well pump, and then purified and returned to the ground. This method is currently used in a 150kW Ajax Tocco induction hardening system from Roll Rite, Alger, Michigan. The daily fee is only in cents.
(2) Strong quenching process The steel parts developed by the Ukrainian Academy of Sciences Cobisco, the chilling quenching of water or brine, is a method for forming residual compressive stress on the surface and reducing distortion. It has been approved in the US to register IQ Technologies Inc with the Intensi Quench service mark. . Because of the substitution of water for oil, reducing oil consumption and significantly reducing production costs, it is valued and supported by the US Department of Energy.
(3) The development of high-temperature carburizing vacuum carburizing technology at temperatures above 1010 °C and the development of low-pressure carburizing technology have created conditions for high-temperature carburizing. This project has been included in the “Process and Materials Technology†grouping plan of the roadmap R&D program due to the significant reduction in the carburizing cycle and energy savings. WPI's CHTE promotes collaborative development between industrial companies and efficient collaboration, manufacturers and production users.
(4) Ni3Al intermetallic compound - New in-furnace anti-carburizing heat-resistant member material Ni3Al has been around for about 20 years, because it is very brittle and has not been used for a long time. The Oak Ridge National Laboratory team led by Chain T.Liu found that the addition of trace amounts of boron can significantly improve its plasticity. It can be used as a furnace basket and fixture. The Ni3Al material composition is 8% to 11% Al added with Cr, Zr, Mo, B. , 81% ~ 88% Ni. This material has excellent heat resistance, creep resistance and carburization resistance. Delphi-Saginaw Steering Systems has successfully conducted trials on the tray for several years through a collaborative research and development agreement with the Department of Energy.
(5) APM and APMT (higher strength APM alloy) alloy long-life radiant tube Sadvik Company of Kanthal AB, Sweden, developed APM and APMT alloys following Kanthal Al heating wire. This material is still based on A-1 powder material, by hot isostatic pressing (Hot Isostatic Pressing) and deep drawing. Electrothermal and gas radiant tubes made of APM alloy can withstand double heat flow compared to conventional heat resistant alloy radiant tubes, and can withstand heat flows of 9 to 10 kJ/m2 at 925 °C.
(6) A flat radiant panel that can be built into the furnace wall developed by the Gas Technology Institute for furnaces can increase the radiation surface, lower the surface temperature, extend the life of the furnace, and increase the furnace temperature. Uniformity, reducing the lining, reducing the size of the furnace by 50%, speeding up the furnace heating and cooling rate, and producing less NOx.
(7) Reverse annulus single-ended radiant tube Developed jointly by North American Manufacturing Company (North American Mfg. Co.) and Gas Research Institute (GTI). The heat radiation rate is high, and the tube made of the same material can withstand higher temperatures, improve combustion efficiency by 10%, reduce NOx by 50%, and has a long service life.
(8) Low NOx gas intense internal circulation (Forced Interval Recirculation) radiant tube GTI developed U-shaped radiant tube extension tube temperature is uniform. When the furnace temperature is 1010 ° C and the air heat temperature is increased from 455 ° C to 480 ° C, the NOx generated is <0.008% (vol). Generally, the NOx generated by the preheated air radiant tube is 0.02% to 0.25% (vol).
(9) Direct Flame Impingement Technology The high-speed burner with multi-nozzle flat embedded in the furnace wall, the injection speed reaches 1 Mach (~330 m/s), and can work under the condition of excess air coefficient α=1. Improve energy efficiency by 35%, reduce NOX by 70%, increase productivity by 25%, reduce oxidation loss by 50%, and save potential of US$150 million to US$150 million.
(10) Closed-loop control technology The neural grid system control principle is used to comprehensively control material selection, phase change, heating process and infiltration layer. The software provided has the function of optimizing the strength/weight ratio of the part and has a main and passive electromagnetic sensor that monitors the depth of diathermy throughout the heating process.
(11) Software for predicting the state of residual stress during carburizing and quenching of steel parts.
(12) DANTE software to extend the residual stress state of machine parts.
(13) Software that accurately predicts the quantitative data of steel heat treatment phase transformation.
(14) Process Heat Assessment and Survey Tool (PHAST) This software is a project planned by the US Department of Energy for users to convert thermal energy according to different combustion modes and heat recovery parameters. It can compare the furnace in working condition. Under the performance, calculate the energy saving potential under various working conditions.
(15) Furnace Energy Analysis Tool Calculates fuel and electricity consumption cost data by hour, year or per pound of parts.
(16) Energy efficient analysis software.
Sixth, organize implementation measures
1. Establish two heat treatment technology R&D centers to organize enterprises in the whole industry to participate in R&D to achieve the roadmap goals and complete the proposed R&D projects.
2. Encourage and organize heat treatment companies to participate in R&D to achieve the roadmap goals and complete the proposed R&D projects.
Seven, the conclusion
1. In the critical moment of China's industrial structural adjustment and unprecedented attention to energy and environment, the US heat treatment technology roadmap has given us great inspiration and has a high reference value for the development of China's heat treatment industry development strategy and planning. It is worth learning. And draw on.
2. Learning from the experience of the American Heat Treatment Society, the new council of the 2008 Council decided to establish a branch heat treatment technology development strategy research committee. Its purpose and task is to track the development of foreign heat treatment technology, carry out domestic status research and develop the development strategy of China's heat treatment industry, and provide consulting for enterprises and the government to provide heat treatment development strategies.
3. Due to limited knowledge and insufficient language and other skills, our understanding of the roadmap is not deep enough, accurate and even wrong. We also hope that leaders and colleagues will criticize and correct.
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