Objective
To achieve maximum energy savings of 0.055 TEP/t of treated steel in the manufacture of drop-forged components by replacing the conventional hardening and tempering treatment with a more simple method to directly lower the temperature of the drop-forged components from +- 1,000 deg C to ambient temperature.
The efficiency of process can be illustrated as follows:
- The qualitative efficiency:
the products derived from this process are provided with mechanical and technological characteristics which are equal and better than the present ones and above all they grant a constant life quality.
The optimized data for each type of links are put into the memory of the processor which, at each reply of the same lot, makes the auto-adjustment of all parameters of the furnace on the base of these data.
- The economic result:
this plant uses the residual heat existing inside the links after the forging, thus eliminating one heating phase.
The heat recovery and the particular cares taken for the manufacturing process, result in energy savings equal to 61% compared to a standard manufacturing process.
SAVINGS OBTAINED
Specific consumption of energy using a traditional quenching and tempering process on continuous 1,200 kg/h capacity furnace: 80 Nm3/Ton CH4.
Specific consumption of energy using the above described process: 31 Nm3/Ton CH4.
Saving: 49 Nm3/Ton - Energy Saving: 61%.
PROFIT AND LOSS ACCOUNT
The above plant can produce 13,000 Tons/tear with a total cost of 259 mlit/yr all included.
Cost of external source for quenching and tempering plus sand blasting operations: 170 Lit/kg.
Saving per year on costs of external source:2,053 mlit - Investment Cost 2,200 mlit - Payback/year 1 - IRR % 58% - depreciation: 3 year
N.B. Evaluation ex taxes
The project relates to tractor track links and digger components.
Projections for the scheme are based on 2 drop forging lines equipped with 40,000 and 25,000 N presses with an overall annual production rate of 17,000 tons of forged steel components. The process involves the following stages: 7 minutes to conform component temperature as it leaves the press at 850 deg C. Quenching (in 20 ') to 300-500 deg C and maintenance of this temperature for 15-20' (time necessary for thermal treatment) and lastly cooling of components to environmental temperature.
With conventional hardening and tempering treatment methane consumption is 80 Nm3/t of treated steel (to maintain fluidized bed temperature) in contrast to the anticipated 15 Nm3/t of treated steel for the treatment proposed. Energy saving would therefore have to be 0.055 TOE/t of treated steel.
The work programme was organised in four phases:
. tests on components conventionally hardened;
. laboratory and performance tests on components produced in 1980-81;
. construction of two plants to operate the new process in 1982;
. tests in 1983 of components produced by the new plants.
Programme(s)
Topic(s)
Call for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
41014 Castel Vetro Potenza
Italy