Dehydrating gas-oven bath PDPV 7635/10

The furnace is designed for dehydration of acidic sodium phosphate primary solution to transform it into a melt of hexametaphosphate. Production of this unique custom equipment meant new market penetration and required the introduction of new manufacturing processes including development of entirely new insulating materials.

High temperatures together with an extremely aggressive environment in the work area, especially at the melt outflow, represented challenging problem that was solved by using steel grade 17248 metal sheets and profiles. This material was used particularly for the manufacturing of jacketed melting bath to be cooled by water flow. The furnace lining is made by refractory shapes of our own production.

It was necessary to divide the furnace into several individual function units and assemblies already in the design phase in order to meet extremely short delivery date requirement. The segmentation was also maintained in the production process and the manufacturing of individual units was entrusted to the most experienced workers of required professions, including the outsourcing to external companies possessing the technologies that our company is not able to ensure in own operations.

This segmentation was also supported by the fact that assembly of the device is only possible directly in the customer’s factory in connection to the foregoing and subsequent technologies; it is not possible to start the trial operation without the technology integration. Therefore it was necessary to optimize and re-examine the assembly of single units into complete unit which provides reduction of time needed for final assembly on site.

All individual parts were inspected by representatives of the customer, the packing of all parts and dispatching started immediately after signing the letter of acceptance. Two of the three trucks needed for transportation are now on the way to the destination in Kazakhstan. Last truck carrying refractory shapes, having high demands on the quality of transportation, will be departed in the coming days.

Installation of the furnace in Kazakhstan will begin after the New Year as soon as the factory building including the technology for processing of input material and the technology for subsequent continuous processing of hexametaphosphate melt is ready. Reinforced assembly team together with engineers will participate on furnace installation as well as on tuning and operation of the control system.

The technical Parameters:

• Station outer dimensions (w x h x l): 3500x2800x9200

• Maximal chamber temperature: 1000 °C       

• Power of burner: 2000 kW

• Fuel: natural gas

• Weight of charge: approx. 5000 kgs

• Throughput(capacity): approx. 500kg/hour

• Operation system: PLC

• Furnace weight: 26 000 kgs

• Place of installation: Kazakhstan