Complete Salt Bath Heat Treatment Plant

DESCRIPTION:

Complete salt bath heat treatment line for preheating, drying, carburizing, hardening, annealing, quenching, tempering (incl. bainite treatment) and washing of metallic parts. Usable batch size: Ø 800 x 1200 mm. Includes switchgear with Siemens S7 PLC, WinCC flexible visualization, batch data archiving and energy/load management, plus a dust extraction filter system. Positions refer to installation plan Rev. 4.

SCOPE OF SUPPLY:

1. Electric Shaft Furnace, type ESO-80/120 – 3 units (Pos. 3, 4, 16)

- Usable diameter: 800 mm

- Usable depth: 1,200 mm

- Nominal temperature: 500 °C

- Rated power: 50 kW

- Electrical connection: 400 V, 3/N/PE ~ 50 Hz

- Compressed air requirement: 6 bar

- Application: shaft furnace with air circulation for preheating and drying

- Housing: welded sheet steel construction reinforced with steel profiles

- Usable space: air guide cylinder with annular base, heated electrically by meandering resistance wire coils

- Air circulation: fan built into the furnace floor, indirectly driven by a flange motor; draws air from the usable space and blows it in a broad stream upwards outside the air guide cylinder through the heating coils

- Lid: raised mechanically by a pneumatic cylinder

2. Natural Gas-Fired Crucible Salt Bath Furnace, type GSOT-80/120 – 4 units (Pos. 5–8)

- Clear crucible diameter: 800 mm

- Clear crucible depth: 1,200 mm

- Crucible capacity: 540 l

- Nominal temperature: 750–950 °C

- Rated power: 200 kW

- Burners: 4 x Kromschröder BIC 65, ionization flame monitoring, direct ignition, IFD244 burner control, combustion air blower with distribution line incl. throttle valves

- Control mode: high / low / off

- Gas flow meter: DE25R25-40B with interface

- Fuel: natural gas H

- Gas flow pressure: approx. 70 mbar (operating range 65–75 mbar)

- Max. exhaust gas temperature at exhaust outlet: 600 °C

- Exhaust connection: Ø 250 mm

- Electrical connection: 400 V, 3/N/PE ~ 50 Hz

- Application: carburizing, hardening or annealing of metallic parts in a salt bath

- Housing: welded sheet steel construction reinforced with steel profiles, designed for all mechanical and thermal loads

- Usable space: special crucible, its raised edge resting on the top of the furnace casing

- Insulation: high-quality insulating bricks and lightweight firebricks

- Heating: 4 burners arranged around the crucible, heating the combustion chamber tangentially around the crucible

- Exhaust: routed from the combustion chamber through an exhaust pipe into an air preheater, which heats the combustion air (typically 15–20% energy saving compared to unheated air); draft interrupter after the air preheater, connected to the exhaust pipe to the chimney

- Ring extraction for removal of salt vapors

3. Electric Thermal Salt Bath (Tub Type), type ETOW-100/120/150 – 1 unit (Pos. 9)

- Clear tub length: 1,600 mm (usable length 800 mm)

- Clear tub width: 1,000 mm (usable width 800 mm)

- Clear tub depth: 1,500 mm (usable depth 1,200 mm)

- Usable salt capacity: approx. 2,240 l

- Max. nominal temperature: 450 °C

- Nominal heating output: 105 kW

- Cooling fan: volume flow 0.71 m³/s, pressure difference 1.86 kPa, motor power 2.2 kW

- Stirrer: three-phase motor with extended shaft, 2.2 kW, 1,420 rpm at 50 Hz, mixing blade D=148 / M16

- Electrical connection: 400 V, 3/N/PE ~ 50 Hz

- Application: quenching or tempering of metallic parts in a salt bath; bainite treatment of a batch also possible

- Housing: welded sheet steel construction reinforced with steel profiles, with built-in insulation

- Usable space: tub with its edge resting on the furnace housing

- Heating: meandering resistance wire coils arranged around the tub

- Stirrer mounted on a console at the end of the tub opposite the operator

- Continuous desludging for filtration of the molten salt, mainly carbonate removal; uses customer-provided equipment, operated with compressed air, must be emptied cyclically (at the edge of the tub)

- Enclosure with salt vapor extraction; pneumatic double swing doors at front and rear (in charging direction), opened and closed by the operator via a diverter valve

- Viewing window at eye level for precise positioning of the batch

- Slot in the enclosure ceiling for the hoist rope/chain

- Cooling fan cools the tub from the outside if adding warm parts heats the salt bath above the set temperature; warm air discharged through an exhaust vent

4. Electrically Heated 3-Stage Wash Tank, 3x100x125x150 – 1 unit (Pos. 11–14)

- Usable width: 3 x 800 mm

- Usable length: 3 x 800 mm

- Usable depth: 3 x approx. 1,200 mm

- Volume: 3 x approx. 1,900 l

- Nominal temperature: 70 °C (basins 2 and 3)

- Heating capacity: approx. 60 kW (2 x 30 kW, basins 2 and 3)

- Electrical connection: 400 V, 3/N/PE ~ 50 Hz

- Stirrers: 3 x hollow shaft motor with extended shaft, 1.1 kW, 1,500 rpm at 50 Hz, shaft material 1.4571, secured stirring element D=160 in material 1.4401

- Circulation capacity: approx. 324 m³/h

- Application: washing salt residue off metallic parts; batch can also be quenched in water in the first wash stage

- Housing: welded stainless steel sheet construction reinforced with steel profiles

- Basin 1 (Pos. 11): unheated, with cooling plates to be connected by the customer to an existing cooling water circuit; removes heat from quenching the parts

- Basins 2 and 3 (Pos. 12, 13): washing stages for final cleaning, heated by replaceable heating cartridges

- Insulation: high-quality insulating panels

- Stirrers mix the water and speed up removal of salt particles from the batch

- Water flow: fresh water fed into basin 3, cascades over basin 2 into basin 1; salt concentration is highest in basin 1, which overflows into a pumping station (Pos. 14) leading to the wastewater tank

5. Switchgear and Control System – 1 unit (Pos. 20)

- Length: 6,000 mm (multi-section cabinet incl. main switchboard and control cabinet)

- Depth: 600 mm

- Height: 2,000 mm + 200 mm base (cable entry from below)

- Supply: 400 V AC, 3L/N/PE

- Current: approx. 650 A

- Power: approx. 420 kW

- Control voltage: 24 V DC

- Auxiliary voltage: 230 V AC

- Cabinet cooling: 2 roof-mounted cooling units

- Designed exclusively for operating the plant components in this offer

- Resistance heaters controlled according to their power by Eurotherm EPower thyristor controllers in a 2-phase energy-saving circuit, with upstream safety contactors

- EPower controllers with "load current management" option; transmit performance data to the central control system

- Safety temperature limiters on the GSOT gas-fired salt baths and the thermal salt bath

- Gas meter with M-Bus interface connected to the control unit; gas consumption data transmitted to the central control system

- PLC: Siemens Simatic S7-317 PN/DP, controls and regulates all plant components

- Audible and visual alarm at the end of the set heat treatment process

- Visualization: PC with Siemens WinCC flexible

- Order management and batch data archiving: PMQUALITI, prepared for batch analysis

- Processing of energy consumption and load management data

6. Air Cooling / Salt Draining Station – 1 unit (Pos. 10)

- Clear diameter: 800 mm

- Clear depth: 1,200 mm

- Application: cooling the batch and draining salt residues

- Construction: welded sheet steel reinforced with steel profiles

- Pull-out salt collection tray in the bottom, must be cleaned cyclically

7. Water Drip Station – 1 unit (Pos. 15)

- Clear diameter: 800 mm

- Clear depth: 1,200 mm

- Application: draining water from the batch after washing

- Construction: welded sheet steel reinforced with steel profiles

- Watertight drip tray at the bottom

8. Loading / Unloading Stations – 3 units (Pos. 1, 2, 17)

- Clear diameter: 800 mm

- Clear depth: 1,200 mm

- Application: preparing and setting down the batch before or after heat treatment

- Construction: welded sheet steel reinforced with steel profiles

9. Wastewater Tank 5 m³ – 1 unit (Pos. 18)

- Round tank (agitator tank) made of black polyethylene (PE-100)

- Usable capacity: approx. 5,000 l

- Diameter: approx. 1,600 mm

- Height: approx. 2,650 mm

- Design: double-walled round tank with lid, collects the saline wastewater from the 3-stage wash tank

- Plastic tank, no drain valve

- DN 500 manhole in the lid, complete with cover, seal and stainless steel quick-release fastener

- DN 50 loose flange nozzle for filling

- DN 50 loose flange nozzle with internal 90° suction bend, on the side of the tank cylinder, for extraction

- DN 100 vent designed as a 180° bend, incl. insect screen, permanently welded into the lid

- Galvanized steel agitator crossbeam on the lid, mounting point for an agitator (max. 100 kg), arranged off-centre (therefore no flow breakers)

- 2 lifting eyes

- 4 galvanized steel foot anchors for fixing the tank on a customer-provided foundation

- Operating conditions: max. density 1.1 kg/dm³, max. operating temperature 30 °C, pressureless

10. Dust Filter, VARIO 5.2 Multitube Surface Filter – 1 unit (Pos. 21)

Housing:

- Sturdy welded sheet steel construction

- Raw gas inlet with built-in deflector plate for downward flow and protection of the filter elements

- Inspection openings

- Support structure in sheet steel or steel profile design

Filter elements:

- Multitube surface filter

- Filter medium: high-quality polyester fine fiber needle felt

- High separation efficiency

- Very good regenerability, even with oily and moist dusts

- Robust and durable

- Temperature resistant up to 70 °C

- Clean gas emissions typically < 0.6 mg/m³ (depending on dust type)

- Environmentally friendly, recyclable

- Installed on the raw gas side

Filter cleaning:

- Continuous compressed air pulse cleaning during operation

- Constant airflow

Fan unit:

- Top-mounted fan with direct drive, 22 kW

- Sturdy design, very quiet

- Drive motor with built-in temperature monitoring

Disposal:

- Dust collection containers

Electrical control:

- Supplied loose with the unit

- For automatic operation of the entire system

- High-quality components

- Frequency converter with integrated PID controller for vacuum control

- Designed according to VDE guidelines

Technical data:

- Volume flow: 12,000 m³/h

- Temperature: 20 °C

- Number of filter elements: 28

- Filter area: 126 m²

- Compressed air requirement: 183 Nl/pulse

- Power: 22 kW

- Dimensions (L x W x H): 2,400 x 1,540 x 4,300 mm

- Dust collection containers: 3 x 40 l

- Weight: 2,075 kg

- Finish: RAL 7035

- Electrical connection: 400 V, 3/N/PE ~ 50 Hz

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