Frequently Asked Questions
1) How can we conduct a gas/energy consumption analysis and optimize the gas/energy usage for a muffle furnace?
To protect the muffle, a muffle furnace usually stays powered on at all times.
Gas consumption depends on the furnace sides, as well as the oxygen content requirement. When the furnace is not working with a load (during night shift, for example) the gas flow can usually be turned down to 30% - 40% of the working rate.
With an optimized structure and superior insulation design, our furnace is energy efficient. After reaching the required profile, the heating elements will work at about 50% or less of the maximum power output. This extends the lifespan of heating elements, and saves power. When the furnace is not working with a load, the insulation power of empty furnace is usually 20% - 35% of the max power output.
2) What are common spare parts that a customer should stock to guarantee uninterrupted operation of a belt furnace? How often are these parts replaced?
Typical spare parts include a belt, a brush, a Solid State Relay, a cooling fan, a thermal couple, heating elements, et cetera. Under normal working condition, our furnaces can run 3-4 years without needing any major parts replaced.
3) What does a customer need to do to prepare for a belt furnace installation?
The following elements must be ready before the belt furnace can be installed:
- Power Supply
- Gas Supply
- Exhaust System
- Water Cooling System
Our engineers will issue clear instructions on this preparation beforehand.
4) Is there a device that can be installed in a belt furnace to prevent parts from falling off of the belt?
Yes. A hearth plate with walls can be incorporated within the furnace. The belt would travel through the furnace on a metal hearth plate with side walls, which would prevent products from falling off the belt.
5) What types of control systems will work with the belt furnace¡¯s operation system?
- Direct controllers on the furnace will offer basic control of parameters, such as zone temperature, belt speed, et cetera.
- A Windows-based industrial computer control system allows for easy profile setting, storage of multiple profiles, an straightforward working status monitor, and easy access to all operating data history.
- Beckhoff embedded control systems are suitable for customers that require a Beckhoff embedded control system.
6) What is the most common type of gas used to form a gas curtain in the furnace?
Nitrogen is most commonly used for a gas curtain. It is inert, safe, and effective in keeping air out of the furnace. Additionally, the cost is relatively low.
7) What is a FEC heater?
FEC stands for Fully Enclosed Coil, which means that the heating wires are embedded within the ceramic fiber boards. This design protects the heating wires, and also provides power distribution evenly in order to maintain the temperature uniformity.
8) What is a commonly used insulation material in a furnace?
Alumina silicate fiber is a high performance insulation material commonly used in our furnaces. It has small density, as well as good energy saving performance.
9) What are the requirements for a cooling water system?
Usually, the cooling water needs to meet requirements for pressure. Also, a proper corrosion inhibitor must be added.
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