New Electric Heating Upgrade Process for Microwave Roller Kiln

Microwave High-Temperature Roller Hearth Kiln, New Electric Heating Upgrade Equipment

For inquiries about Microwave Roller Hearth Kiln, contact Mr. Xu: 156 7439 3491

I. Heating Characteristics of Microwave Roller Hearth Kiln:

The microwave high-temperature roller hearth kiln is a versatile microwave high-temperature industrial equipment, upgraded and transformed based on traditional electric heating roller hearth kilns. It fully utilizes the characteristics of microwave heat sources, employing proprietary microwave roller rods for transmission. Under microwave radiation, the molecular particles of the material medium rapidly rub and move to generate heat, with the material's center heating first. This results in stronger thermal power, faster heat generation, and more balanced temperature rise. Therefore, the microwave roller hearth kiln offers high heat utilization, short firing cycles, large production capacity, uniform heating of products, excellent quality, flexible process adjustments, strong operability, high automation, high intelligence, ease of use, safety and reliability, small footprint, no environmental pollution, significant energy savings, strong environmental friendliness, and reduced labor requirements. This series of equipment is suitable for sintering, synthesis, decomposition, and calcination of non-metallic materials under air atmosphere or oxygen-rich conditions. The microwave high-temperature roller hearth kiln helps improve production capacity and facilitates easy maintenance of the equipment structure.

The microwave roller hearth kiln is a continuous firing kiln, a tunnel kiln that uses rotating rollers as carriers for the green body. Green bodies and workpieces are placed on many closely spaced horizontal microwave roller rods, and the rotation of the rollers transports the material from the kiln entrance to the kiln exit. The heating method employs microwave rapid heating, hence the name microwave roller hearth kiln.

1. Energy saving: Saves over 40% energy compared to traditional heating kilns;

2. Excellent product quality: Based on the overall microwave heating mechanism, products are heated uniformly, resulting in high quality;

3. High production efficiency: Based on the overall microwave heating mechanism, the heating speed is 5-15 times faster than traditional electric heating kilns, and due to the low thermal capacity of the insulation system, the cooling speed is also fast.

4. Process flexibility: Depending on the material, pure microwave heating or a combination of microwave and electric heating can be selected.

5. Reliability: Equipped with an industrial-grade water-cooled microwave source system, capable of 24-hour uninterrupted use. The microwave leakage value of the equipment system is far below the standard, equivalent only to the radiation level of using a mobile phone. It comes with a microwave anti-leakage alarm device and safety lock, automatically or manually cutting off the microwave source when microwave levels exceed standards;

6. Small equipment footprint: Simple equipment structure;

7. Environmental friendliness: Microwave kilns produce no waste gas or wastewater emissions;

8. Strong operability: Easy to use, with PLC + touch screen control, built-in USB interface for automatic data recording, storage, and editing/printing functions. Multiple temperature curves can be set, with both automatic and manual sintering functions.

The green body can be placed directly on the rollers or first on a垫板 (pallet), which is then placed on the rollers. As the rollers continuously rotate, the green body advances sequentially. Each roller end has a small sprocket, driven by chains to rotate independently. For smooth and safe transmission, the chains are often divided into several groups for driving. Rollers in low-temperature areas are made of heat-resistant nickel-chromium alloy steel, while those in high-temperature areas use high-temperature-resistant high-alumina ceramics such as corundum ceramics. Above and below the heating chamber of the microwave roller hearth kiln, microwaves are fed in to heat, dry, fire, and sinter the green bodies inside. Between the microwave feed port and the roller track, refractory materials isolate and prevent direct contact with the products being fired.

II. Advantages of Microwave Industrial Equipment:

The microwave high-temperature roller hearth kiln heats materials by absorbing microwave thermal energy themselves. Because microwaves are a frequency of electromagnetic waves, objects in a microwave field cause polarization of polar and non-polar molecules, turning them into dipole molecules. These align with the electric field direction, and since the electric field is alternating, the dipoles rotate and vibrate with the field changes. For example, at a frequency of 2450 MHz, they rotate and vibrate 2.45 billion times per second, producing an effect similar to molecular friction, thus absorbing the electric field's energy and generating heat, with the object itself becoming the heat source. Therefore, microwave heating involves the material heating itself uniformly. In contrast, conventional heating methods use thermal radiation, convection, and conduction, heating the object from the outside in, resulting in high heat loss, low energy efficiency, long heating times, uneven heating, tendency for coking, large exhaust gas treatment requirements, extensive kiln foundation engineering, rough production environments, and the need for regular kiln cleaning, shutdowns for maintenance and replacement, with maintenance being time-consuming and labor-intensive.

Microwave technology offers energy savings (converting to thermal energy, saving over 30% compared to traditional heating methods), environmental friendliness (no external emissions, effectively reducing harmful substance generation), cleanliness (materials heat themselves by absorbing microwaves, no contact, improving product quality and yield), high thermal efficiency (fast heating speed, high energy utilization), and ZhongSheng microwave industrial equipment can reach temperatures up to 1600°C, with a temperature difference within the kiln chamber of ±10°C and temperature stability of ±5°C, easily integrating with automated and intelligent operations, significantly improving the production environment.

III. Quality of ZhongSheng Microwave Equipment:

A. Possesses independent intellectual property rights. All company products have their own patents; currently, the company holds 12 invention patents and 57 utility model patents.

B. The company's technology and products rank among the top in the industry. Through product appraisal meetings organized by the Hunan Economic and Information Commission and the Hunan Resource Comprehensive Utilization Association, it was unanimously agreed that these three product technologies have reached advanced domestic levels. The company's microwave heating kiln technology has been selected for the National Development and Reform Commission's Energy-saving Technology Promotion Catalog (Fifth Batch). Purchasing our company's industrial products may qualify for certain national subsidies.

C. High configuration, high standards, and new technology ensure product quality. ZhongSheng Company uses 1.5KW industrial-grade microwave sources with continuously adjustable power (0.1~1.49kw), ensuring uniform, adjustable, and controllable microwave cavity temperature to meet different technical process requirements and guarantee 24-hour uninterrupted use. Other manufacturers typically use 1.2KW or 1.0kw household-grade microwave source systems (incapable of 24-hour continuous operation) with non-continuously adjustable power, unable to ensure uniform, controllable, and adjustable cavity material temperature, nor meet different process requirements. In microwave heating equipment, ZhongSheng Company uses裂缝天线 (slot antenna) for energy feeding, ensuring uniform microwave fields and preventing microwave reflection from damaging the magnetron, enabling 24-hour uninterrupted use and long service life (magnetron lifespan is generally affected by reflected microwave power and cooling methods). Additionally,易损件 (wear parts) like magnetrons can be replaced without shutdown and without microwave leakage. General manufacturers use direct microwave feeding methods, making it difficult to achieve uniform cavity material temperature and unable to perform online magnetron replacement without shutdown. 

IV. Services: Technical exchange / Small sample testing / Visit / Equipment ordering

For inquiries about Microwave Roller Hearth Kiln, contact Mr. Xu: 156 7439 3491

Factory address: No. 18 Xinyuan Road, Economic Development Zone, Yueyang City, Hunan Province, Linkzone U Valley Phase II