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Production process of converter equipment

Release time：2026-01-06

Based on high-strength structural materials and wear- and high-temperature-resistant materials, the converter body—designed to meet the demands of high-temperature smelting and heavy-load operation—is manufactured through a continuous process encompassing raw material refining, structural shaping, weld reinforcement, stress relief, precision machining, assembly integration, liner protection, and inspection and acceptance. Throughout the entire process, development is driven by three core objectives: structural strength, sealing reliability, and temperature- and wear-resistance.

I. Raw Material Preparation and Preprocessing

Raw Material Selection: The core structural components are made from high-strength, low-alloy materials and forged parts. Wear-prone complementary parts are made from heat-resistant and wear-resistant alloy materials, ensuring material compatibility with high-temperature and heavy-load operating conditions.

Raw Material Inspection: Using methods such as material analysis and mechanical property testing, verify that all raw material specifications meet the design requirements and reject any nonconforming materials.

Preprocessing: Surface rust removal and cleaning are performed on the selected materials to eliminate oxide scales and impurities. For critical structural materials, preheating treatment is carried out in advance to relieve internal stresses within the materials and prevent deformation during subsequent processing.

II. Material Cutting and Structural Forming

Precision material cutting: Based on the design dimensions, raw materials are cut and processed using CNC cutting technology to obtain rough blanks for core components such as furnace shells and supporting frames, with strict control over dimensional tolerances during cutting.

Main body forming: The furnace shell blank is processed into a cylindrical shape through a rolling process. When joining multiple cylindrical sections, positioning fixtures are used to ensure coaxial alignment. Irregular-shaped parts such as the furnace mouth and steel tapping spout are formed using stamping or splicing processes, thereby reinforcing the structural integrity of the edges.

Forming the load-bearing structure: The load-bearing frame is fabricated in segments using a combination of thick-plate welding and cast-welding processes, followed by overall assembly. This ensures that the structure achieves the required roundness and load-bearing strength after forming.

3. Core Structure Welding and Stress Relief

Welding Operations: The core structural joints are constructed using a combination of high-strength welding processes. During the welding process, welding parameters are precisely controlled to ensure uniform and robust weld bead formation.

Weld Seam Inspection: After welding is completed, non-destructive testing methods are used to identify internal defects in the weld seam, such as cracks, porosity, and incomplete penetration. Any weld seams that fail inspection must be reworked, re-welded, and re-inspected to ensure welding quality.

Stress Relief Through Heat Treatment: After welding, large structural components undergo either complete annealing or normalizing treatment to thoroughly eliminate residual welding stresses, stabilize the dimensions of the structure, and prevent deformation or cracking caused by stress release during subsequent use.

IV. Precision Machining and Component Assembly

Precision Machining: Precision machining is performed on critical components such as connecting shafts, bearing mating surfaces, and flange interfaces to ensure dimensional accuracy, geometric tolerances, and surface smoothness of these parts, thereby guaranteeing that the assembly clearance meets design requirements.

Component Integration and Assembly: First, precisely align and secure the connecting shaft to the supporting frame. Then, assemble and integrate the supporting frame with the furnace shell using connecting components, leveraging positioning fixtures to ensure the precise relative positioning of all components. Next, complete the assembly of complementary parts such as transmission components and slag-blocking structures, and adjust the flexibility and coordination of all moving parts.

V. Construction of Fire-Resistant Lining

Inner lining pretreatment: Perform secondary cleaning and rust removal on the inner wall of the furnace shell, then apply a bonding primer to enhance the adhesion between the furnace shell and the refractory material.

Layered Construction: Inside the furnace shell, the permanent protective layer and the working-layer refractory materials are laid in sequence. For areas prone to erosion, such as the furnace mouth and the steel tapping spout, high-strength, wear-resistant refractory materials or unshaped refractory materials are compacted and formed. During construction, ensure that brick joints are uniform and mortar fills them completely, avoiding gaps that could allow high-temperature molten steel to seep through.

Lining curing: After masonry is completed, perform natural curing or low-temperature curing to ensure that the strength of the refractory lining steadily increases and to prevent spalling and cracking caused by rapid temperature changes—both heating and cooling—once the lining is put into service.

6. Overall Inspection and Finished-Product Acceptance

Appearance and Dimension Verification: Conduct a comprehensive inspection of the equipment’s overall appearance, precisely measure key parameters such as furnace body dimensions, roundness of the supporting frame, and coaxiality of connecting shafts, and confirm that they meet the design specifications.

No-load trial run: Conduct no-load adjustments on the transmission and mating parts, check the operating speed and smoothness, and confirm that there are no abnormal phenomena such as jamming or unusual noises. Verify the operational reliability of components such as the slag-blocking structure and the steel tapping spout.

Finished Product Acceptance: Compile the inspection data and process records from all preceding stages, conduct final acceptance of the finished product, and complete the production process upon successful acceptance.

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