How Much is the Energy Consumption For Stainless Steel Oil Cooler Vacuum Brazing?

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Taking the energy consumption of 25.4Hn brazing of a stainless steel oil cooler as an example, the weight of the product loaded in the vacuum brazing furnace is 800~900kg at a time. The product heating curve is shown in Figure 1.

Figure 1 25.4 Hn welding curve

Transformer rated power P1=180kw, mechanical pump rated power P2=7.5kw/set, Roots pump P3=7.5kw/set, fan motor P4=37kw.

The heating power of the first heating stage is 90%-100%P1, and the heating time is 100min; the heating power of the second and third heating stages, the heating time are respectively; the power of the three heating stages is 30%-40%P1, and the heating time is 20min. , 35min, 40-45min. After brazing and heat preservation, the heating element of the vacuum furnace stops supplying power (the transformer stops supplying power). The mechanical pump and Roots pump start to run to the starting point of air cooling (900℃) about ten minutes before heating, and the running time is 340-345min; when the fan motor is started to stop before the furnace is released, the running time is close to 100 minutes.

Based on the above data, it can be roughly calculated as follows:

(1) Electricity for heating and heat preservation (electricity for transformer):

W1=(90%~100%) P1×100min＋60%P1×(15min＋20min)＋(30%~40%) P1×(20min＋35min＋40~45min)=(16200+3780+5130)~(18000+3780+7200) kw •Min =25110 ~28980 kw•min =418.5~483 kw•h

(2) Electricity for vacuum pump:

W2=(P2+P3)×(340~345)min=5100~5175 kw•min =85 ~86.25 kw•h

(3) Electricity for fan motor:

W3=P4×100min=3700kw•min=61.7 kw•h

The total power consumption of a complete vacuum brazing process:

W =W1+ W2+ W3=(418.5~483) kw•h +(85 ~86.25) kw•h +61.7 kw•h=(565 ~631)kw•h

According to the brazing furnace producing 3 batches of products every day and working 350 days a year, each vacuum furnace consumes electricity in one year:

W year=(565 ~631) kw•h×3×350 =593250~662550 kw•h

Calculated on the basis of the electricity supply price of 0.82 yuan per kilowatt-hour, this company’s annual electricity consumption for each vacuum furnace is W years×0.82=486465~543291 yuan.

It can be seen that each vacuum brazing furnace consumes a huge amount of energy in one year. Moreover, according to actual measurements, this company’s vacuum furnace has a serious problem of uneven furnace temperature. The temperature difference between the upper and lower furnace chambers can even reach tens of degrees. In this way, the heating and holding time of brazing is increased, and this phenomenon causes serious unnecessary waste. In addition, when brazing some larger products, under the condition of severely uneven furnace temperature distribution, in order to make the whole furnace product quickly reach the brazing temperature, the brazing temperature is even increased from the normal brazing temperature of the product 1120℃ to 1150℃ This approach not only increases energy consumption, but such a high temperature may cause the grains of the base material to grow seriously and reduce the strength of the product.

Assuming that the vacuum can be heated uniformly, if only the brazing and holding time is shortened by 10 minutes, each vacuum furnace can save electricity every year

W province=(40%P1＋P2＋P3)×10min×3×350=913500 kw•min=15225 kw•h

Can save: 15225×0.82=12484.5 yuan

If the furnace temperature is uniform and the brazing time is reduced by ten minutes, it can save RMB 1,2484.5 per year. If the furnace can be heated evenly, the heating and holding time of brazing can be shortened. There are only dozens of vacuum furnaces in the company. Electricity can save a lot of cost.

Shanghai Geheng Vacuum Technology Co., Ltd. is a vacuum heat treatment furnace manufacturer with many years of experience in design, manufacturing and production. Mainly produce vacuum heat treatment furnace, vacuum sintering furnace, vacuum brazing furnace, New Energy And Environmental Protection Equipment and other vacuum equipments.Provide customized services, equipment work area can be based on customer output.