Large capacity gas atomization equipment

Large capacity GAS ATOMIZATION EQUIPMENT

Introduction

Gas atomization powder-manufacturing is characterized by small environmental pollution, high degree of ball-shape powder, low oxygen content and fast cooling rate and so on. Through many years’ constant innovation and improvement, our company has updated our gas atomization powder-manufacturing technique and technology several times in order to produce metal and alloy powders of high performance. Currently, the technology has become the leading factor to support and promote atomization powder-manufacturing equipment, new material research and new technology development. 

The operating principle of atomization powder-manufacturing equipment refers to the powder-manufacturing process that smelting metal or alloy under certain condition, with metal liquid poured obliquely to heat preservation crucible, flows out through liquid diversion mouth (downward), and takes advantage of the high pressure gases of nozzle to crush metal liquid into large amounts of fine and small liquid drop; The flying liquid drops solidify into ball-shape or sub ball-shape particles and thus complete the whole powder-manufacturing process.

I, Atomization powder-manufacturing features:

1.1   Meeting the requirements of manufacturing metals and its alloy that can not manufactured by water atomization.

1.2   Manufacturing ball-shape or sub ball-shape powder.

1.3   Manufacturing numerous special alloy powders for overcoming aliquation due to fast solidification.

1.4   Adopting suitable processing method to make the powder’s particle reach the required range.

II, Main Technical Parameters:

2.1 Capacity: 25kg, 50kg, 100kg, 200kg ,500kg(calculated by steel)

2.2 Smelting medium frequency power: 100kw, 160kw, 250kw

2.3 Medium frequency: 2500Hz

2.4 Vacuum pressure rising rate: 0.05Pa/min

2.5 Holding furnace power: 8Kw, 14Kw

2.6 Holding furnace temperature: 200-1200c(Resistance heating), 1700C(Induction heating)

2.7  Smelting furnace temperature: 1700C2.8  Cooling water pressure: 0.15-0.3Mpa

2.9  Cooling water flow rate: 8 m^3-12 m³/h

III, Structure and Composition of Gas Atomization Powder-manufacturing Equipment

The gas atomization manufacturing equipment mainly contains the following parts: Medium frequency smelting furnace(10kg, 25kg, 50kg, 100kg, 200kg), holding furnace, (10kg, 25kg), atomization system, atomization tank, powder and dust collecting system, gas supply system, water cooling system, control system, medium frequency power source, holding furnace power source system(10kg, 25kg level ones are not equipped with holding furnace) and so on.

3.1 Induction smelting furnace: It is a multi-functional induction smelting furnace in fact. It is composed of furnace body, furnace cover, elevation mechanism, temperature measuring mechanism, induction coil, tilting furnace mechanism. The induction coil is the core of the smelting and matches the intermediate power; the crucible is located in the induction coil and it can pour and cast with electricity; the tilting mechanism(10kg, 25kg level ones are equipped with manual casting) is connected with hydraulic-driven cylinder and the casting speed can be controlled by the hydraulic proportional valve.

3.2 Holding furnace:

The holding furnace is a metal liquid container located on the spray nozzle system and has the insulation function. It is smaller than the crucible of smelting system with thinner body to ensure the metal liquid’s pressure energy. The holding furnace has heating system and temperature measuring system. The heating system of holding furnace is divided into two types of resistance heating and induction heating. The resistance heating can reach 1200C, while the induction heating around 1900C. However, users have to choose the suitable crucible material. There are two choices of holding furnace’s power source. The resistance heating one is heavy current power regulator and the induction heating one SCR medium frequency power source.

3.3 Atomization system: It is made of spray nozzle, high pressure windpipe, valve and so on.

3.4 Tank(Atomization chamber): Actually it is a container that could connect all the devices according to the requirements. It is the space for condensation of metal liquid drops. The internal wall is stainless steel and the external wall is carbon steel and the size of the tank is related to the powder manufacturing requirements and capcity.

3.5 Powder and dust collection system: During the powder-manufacturing process, there are especially fine powders flying through the pipeline along the high speed air current. It has the secondary collection function when going through the equipment and achieves the effect of reduced environmental pollution and consumption of materials. At present the colleting is processed through cyclone separating device and water phase collection.

3.6 Hydraulic system: The system mainly provides hydraulic power to the tilting of the device and elevation of the furnace cover.

3.7 Gas supply system: It consists of intelligent valve, pressure control valve, pressure-reducing valve, pressure sensor, high pressure hose and pressure indicator. Adopting the intelligent system, the operating personnel can adjust the gas supply pressure of atomization nozzle online at any time during long distance operation and record with PC for later reference and research in order to acquire the precise powder-manufacturing operation technique. The system can also be optional abd is divided into manual control and automatic control.

3.8 Cooling system: Cooling system is indispensable and the whole set equipment is with water cooling. The temperature of cooling water will be reflected on secondary instrument with pressure alarming device to guarantee the safety of the equipment.

3.9 Control system: It is the operation control center of ZGW0.05 equipment. All the corresponding operating actions and relevant data of the equipment are concentrated on the control system, communications controlled by PC. Operating personnel can observe the internal condition of the equipment through PC displayer video image and carry out further operation on the related interface. The integrating operation process is completed here. If there is no need for long distance operation, the configuration is optional.

3.10 Medium frequency power source: It is the generator for providing medium frequency current, which is completed by the exchange process of AC—DC—AC. It generally selects KGPS-type thyristor medium frequency power source. Medium frequency transformer is installed inside the power source to solve the problems of interturn discharging and security. It realized the whole process of automatic constant temperature and temperature rising through communicating to the long distance PC in order to provide favorable and stable operating condition for test and production.