罩式退火炉是冷轧生产线的核心设备，主要执行热处理工艺。数十年来， 艾伯纳致力于热处理工艺研发与设备的制造，通过持续的技术创新推动行业变革升级。 艾伯纳于1972年创新性地将强对流技术 (HICON®)与纯氢工艺气氛相结合，率先开发出 (HICON/H2®)罩式退火炉技术。首座HICON/H2®罩式退火炉设计用于铜材的处理。经过不断的创新发展，该技术于1982年成功拓展至钢铁工业的应用领域。 这一技术迅速获得行业认可，为半成品热处理工艺带来革命性变革。
Bell annealer facilities are integral parts of cold rolling mills, where they are used to carry out heat treatment processes. EBNER has been involved in the development of heat treatment processes and the manufacture of heat treatment equipment for decades, constantly introducing innovations that have advanced the industry. For example, EBNER introduced bell annealer technology that combined high convection (HICON®) with straight hydrogen as a process atmosphere (HICON/H2®) all the way back in 1972. The first HICON/H2® bell annealers were designed to process copper base metals, but further development led to designs for the steel industry in 1982. The technology quickly established itself, revolutionizing the heat treatment of semi-finished products.
展开剩余95%HICON/H2®罩式退火炉成功运行数十年，在不断的发展中，性能获得提而成本也实现优化，推动整个行业在产品品质与经济效益两方面实现质的飞跃。
HICON/H2® bell annealers have been successfully operating for decades. Continuous development has increased their performance even as it has lowered costs, allowing the industry to take decisive steps forward in both quality and economy.
目前全球已有超过4900座HICON®炉台投入工业化运行，所生产的扁平材与线材处理总量逾8000万公吨。
Over 4900 HICON® workbases are in operation today, processing over 80 million metric tons of flat and wire products every year.
然而，无论是过往，还是当下，我们取得的成就，仅仅是一个新的起点。未来的发展要求正推动着整个行业在保持竞争力的同时，开发更具可持续性的工艺流程。面对这一行业挑战，我们历时数年专注研发，最终成功开发出新一代HICON®罩式退炉。在研发过程中，我们重点关注三大核心目标：最大化能源效率、减排以及简化操作流程。
Our past and current success is, however, only a starting point. The demands of the future are challenging the entire industry to design processes that are more sustainable, even as they remain competitive. With this challenge shaping our perspective, we invested several years of intensive effort in the development in what we intended to be the next generation of bell annealer furnaces. During development, an emphasis was placed on maximizing energy efficiency, eliminating emissions and simplifying operating sequences.
我们倾注的努力最终成就了真正新一代GREENBAFx®罩式退火炉。这些设备采用创新系统，既能将热能直接作用于工艺流程（直接加热），又能回收冷却过程中释放的能量（热交换）。在研发过程中，我们主要考虑了两大应用场景（图1）。
Our efforts have been rewarded with what is indeed the next generation of sustainable bell annealers, referred to as GREENBAFx® furnaces. These facilities feature innovative systems for inserting thermal energy into the process (direct heating) and for recycling energy released during cooling (heat exchange). During development, two main use cases were taken into account (see figure 1).
标准设计采用直接加热方式（即"基础方案"）。
A standard design with direct heating (the "basic case").
扩展设计采用热交换方式（即"升级方案"）。
An expanded design with heat exchange (the "advanced" case).
图1：研发过程中的重点关注问题及应用场景
Figure 1: Issues focused upon during development, use cases
采用直接加热方式的 GREENBAFx®设备 (基础方案)
GREENBAFx® FACILITY WITH DIRECT HEATING (the "basic" case)
在传统罩式退火设备中，加热过程通过加热罩实现——该加热罩扣放在内罩之上。内罩内部形成处理炉膛，炉料装填于此。热能来自于加热罩，通过热辐射方式传递至内罩。内罩将热能传导至炉膛，并通过气氛对流方式将能量传递至待处理炉料。
At traditional bell annealer facilities heating is carried out by a heating bell, which is placed over an inner cover. The interior of the inner cover forms the processing chamber, in which is the charge. Thermal (heating) energy is supplied from the heating bell, which radiates heat onto the inner cover. The inner cover then conveys the thermal energy into the processing chamber and atmosphere convection is used to transfer the energy to the charge.
冷却过程采用的是类似的方式。行车用于将加热罩替换为冷却罩。冷却罩通过冷却空气和/或冷却水实现热能置换。通常，冷却过程中被置换的热能或直接废弃（直接耗散），或以低效方式回收（例如通过有机朗肯循环发电、用于加热水等）。
Cooling employs a similar method. A crane is used to replace the heating bell with a cooling bell, which uses cooling air and/or cooling water to subtract the thermal energy. Usually, energy subtracted during cooling either remains unused (is lost) or only recycled in an inefficient manner (e.g. converted to electricity in an ORC process, used to heat water, etc.).
GREENBAFx®系统采用了与众不同的创新方案，并成功获得专利。在该设计中，加热产生的热能直接作用于工艺气氛，全程无能量损耗。为此，高功率密度的电加热系统直接集成在炉台（扩散器）内部。
The new, patented GREENBAFx® system takes a different approach. In this design, the thermal energy from heating is fed directly, without detours, into the process atmosphere. To do so, an electric heating system with a high power density is integrated into the workbase itself (in the diffuser).
而炉台风机叶轮采用特殊设计，可实现工艺气氛向加热系统的无损流动。实际研究发现，该加热系统对气氛分布具有积极影响——其气氛流动性甚至优于传统罩式退火炉。
The workbase fan impeller is designed to ensure an ideal flow of atmosphere to the heating system, with no flow losses. In fact, it was discovered that the heating system has a positive effect on atmosphere distribution – that is, atmosphere flow is even better than that found at a typical bell annealer.
此外，为防止残余轧制润滑剂在电热元件表面沉积，我们专门开发了温度控制/气氛程序。该程序在每次退火前会对加热元件进行清洁。
Furthermore, to prevent residual rolling lubricants from collecting on the electric heating elements, a special temperature/atmosphere program was developed. This program cleans the heating elements before every anneal.
这些创新设计的综合应用，使得传统加热罩成为非必要组件：可采用简易隔热罩实现同等功能（图1选项"a"）。在此配置下，采用标准冷却罩进行冷却操作。
All of these features mean that the need for a heating bell is eliminated: it can be replaced with a simple insulated bell (figure 1, option "a"). In this case cooling is still carried out with a standard cooling bell.
另一种方案是采用一体化"工艺罩"（图1选项"b"）替代原有的加热罩、冷却罩及内罩组件。 该工艺罩可完全密封并隔离整个炉膛。整个热处理过程——从炉膛密封（夹紧）到解除密封——实现全自动运行。在此配置下，冷却过程通过安装于炉台的集成式冷却器（图1选项"b"）实现。
Alternatively, the heating bell, cooling bell and inner cover can be replaced by a single "process bell" (figure 1, option "b”). This bell encapsulates and isolates the processing chamber. It allows the entire heat treatment process, from the time the processing chamber is sealed (clamped) to the time it is released, to run fully automatically. In this case, cooling employs a cooling system installed in the workbase (an "integrated cooler" – see figure 1, option "b”).
采用工艺罩后，无需更换加热罩与冷却罩。如此一来，简化了操作与物流协调负担，因为所需的行车吊运作业和人工干预大幅减少。实际上，整个操作过程仅需两次（2次）行车吊运操作——第一次是工艺罩的安放到位，第二次是从炉台移除工艺罩。与传统罩式退火设备需六次（6次）行车作业相比，该工艺每次退火可减少四次（4次）吊运操作，降幅达66%。与此同时，该工艺还能小幅缩短整体的处理时间。
With a process bell, there is no need to exchange heating bells for cooling bells. This greatly simplifies operational and logistical burdens, as significantly fewer crane movements and operator interventions are required. In fact, only two (2) crane movements are needed - one when the process bell is placed, and one when it is lifted off the workbase. Compared to a typical bell annealer facility, where six (6) crane movement cycles are necessary, this represents four (4) or 66 % fewer crane movements per anneal. This also reduces processing times by a small margin.
这一设计的另一个优势在于，占地面积较传统罩式退火炉大幅减少。具体而言，由于"被动式"工艺罩的直径显著小于加热罩，且无需外部配套设备（如管道等），各炉台间的纵向间距可进一步缩减。此外，由于每个炉台都配备独立的集成式加热系统，彻底消除了传统加热罩调度所需的等待时间，从而完全避免了产能损失。
Another advantage of this design is that less space is required than at traditional bell annealer facilities. That is, as the "passive" process bell has a significantly smaller diameter than a heating bell and no external equipment (ducting, etc.) is required, the longitudinal distance between workbases can be reduced. Furthermore, as each workbase now has its own integrated heating system, there are no waiting times for a heating bell to become available and no throughput is lost.
热损耗降至最低，设备能够实现高效运行。与此同时实现二氧化碳与氮氧化物零排放。能效表现突出，较传统罩式退火炉节能量可达5%。
Heat losses are reduced to a minimum, meaning that the facility can operate extremely efficiently. Zero emissions are created, with both CO2 and NOx emissions eliminated. Finally, energy consumption is up to 5 % lower than that at a typical bell annealer facility.
在基础配置方案中，可选择采用混合加热系统对设备进行升级。若选用该方案，设备将配备加热罩。可采用两种方式进行处理：或选择炉台集成电加热系统，亦可选用燃气（天然气/氢气）加热罩系统(图2)。
In the "basic" design, an optional possibility is to equip the facility with hybrid heating. If this option is selected, the facility is equipped with a heating bell. Charges can then be processed using either the integrated electric heating system of the workbase or with the gas-fired (natural gas, hydrogen) heating bell (see figure 2).
这一配置方案的优势在于用户可灵活选择加热方式，例如根据当前能源供应情况或公辅费用择优而选。
The advantage of this option is that the user can select the heating method flexibly, for example based on the current availability or price of utilities.
混合加热系统通常亦可对现有设备进行改造升级。
This hybrid heating option can generally be retrofit into existing facilities.
图2：基础方案采用GREENBAFx®直接加热系统；图示为额外配置的混合式加热罩（可采用电加热或燃气加热方式）。
Figure 2: "Basic case” with GREENBAFx® direct heating system; the figure shows an additional heating bell (gas-fired) for hybrid heating (electric/gas)
配备热交换系统的 GREENBAFx®(升级方案)
GREENBAFx® FACILITY WITH HEAT EXCHANGE (the "advanced case")
热交换系统的核心目标在于回收冷却余热并重新导入工艺流程，通过预热相邻炉台上的冷料卷实现能量再利用。
The goal of heat exchange is to return the energy released during cooling to the process. This is done by using the energy to preheat a cold coil stack on a neighboring workbase.
HICON®工艺罩通过高速气流强制通过密封的炉膛（集成式内罩）外部的环形间隙，实现空气冷却功能。空气受热后携带热能，随即被输送至隔热的热交换回路。随后，自动挡板将热空气导入另一个HICON®工艺罩，热空气可对工艺罩内的炉料进行预热（图3）。
A HICON® process bell allows air to be forced through the annular gap around the exterior of the encapsulated processing chamber (the integrated inner cover) at high speed, enabling the air to be used for cooling. This air becomes heated and, as it is now transporting thermal energy, it is fed into an insulated heat exchange circuit. Automatic dampers then lead it to another HICON® process bell, under which another charge is ready for heat treatment, and the air preheats the charge (see figure 3).
图3：GREENBAFx®热交换系统的升级方案
Figure 3: "Advanced case” with GREENBAFx® heat exchange
这一设计的核心在于热交换过程发生在集成内罩外表面，保证了安全性（内罩下的工艺气氛成分）不受影响。
A crucial element in this design is that heat exchange takes place across the exterior of the integrated inner cover, ensuring that safety (the composition of the atmosphere beneath the inner cover) is not influenced.
HICON®工艺罩将冷却阶段收集的热能输送至热交换系统，同时也实现了物料本体蓄热的传导。为满足特定工艺要求需实施缓冷处理时，该工艺阶段释放的热能可同步回收利用。
As a HICON® process bell transfers the thermal energy collected during cooling to the heat exchange system, heat stored in the mass of the furnace components (taramass) is also transported. If a slow cooling process is needed to fulfill technological requirements, the energy released during that process is also used.
这样的热交换量意味着热处理周期总能量的30%可被回收至生产流程，显著提升经济效益。
This amount of heat exchange means that it is possible to return up to 30 % of the total energy of a heat treatment cycle back to the process, providing an excellent financial advantage.
在热处理工艺结束时，可采用两种方式对炉料进行最终冷却： HICON®工艺罩提供的风冷系统，或安装于炉台的换热装置（即"集成冷却器"）。风冷过程产生的热能可输送至中央系统，并接入其他热交换装置（如气/水或气/油换热器）。采用外部工艺循环，可进一步提升能量回收效率。
At the end of a heat treatment process, final cooling of the charge can employ either air cooling provided by a HICON® process bell or a heat exchanger ("integrated cooler") installed in the workbase. The thermal energy from air cooling can be supplied to a central pipe end and tied in to another unit, such as an air/water or air/ oil heat exchanger. This makes it possible to recycle still more energy by employing it in an external process.
图4所示为710℃/62吨退火工艺（配备热交换系统）温度/时间曲线。
Figure 4 shows the typical time/temperature profile of a 710 °C / 62 t anneal with heat exchange.
在此退火工艺中，热能通过强对流氢气从料卷外表面（带材边缘区域）导出，输送至工艺罩内壁（集成式内罩），最终传递至空气循环气流（高温气体）。上图展示了强对流氢气从工艺罩内壁（集成式内罩）收集热能并传递至料卷外缘的完整过程。热空气流温度在热交换过程中从约500℃（气体离开1号工艺罩时）降至约250℃（离开2号工艺罩时）。
In this anneal, thermal energy is drawn out of the exterior of the coils (from the strip edges) by high-convection hydrogen, transported to the interior wall of the process bell (integrated inner cover) and then transferred to the circulating stream of air (high-temperature gas). On the bottom side of thefigure below, it can clearly be seen how the high-convection hydrogen takes thermal energy from the interior wall of the process bell (the integrated inner cover) and transfers it to the exterior of the coil. The temperature of the hot stream of air falls from around 500 °C at the start of heat exchange (when the gas exits process bell 1) to about 250 °C (when it leaves process bell 2).
释放的热能直接用于预热低温炉料，此时可清晰观察到：待冷却炉料芯部温度下降，以及待预热炉料芯部温度上升。因此，料卷平均温度直接反映出传导至低温料卷的热能总量。值得注意的是，热空气流在不同工艺罩间持续流动数小时仍能保持相对稳定——即使回流空气温度逐渐升高且传热量持续下降。
The energy that is released is that which is used to heat the cold charge, and the drop in the core temperature of the charge that is being cooled and the rise in the core temperature of the charge that is being preheated can be clearly seen. The average coil temperature thus represents the amount of energy that has been transferred to the cold coils. Of particular interest is the fact that the hot stream of air flowing from one process bell to the other remains fairly constant for several hours, even as the temperature of the air being returned gradually increases and the amount of energy that is being transferred falls.
必须寻求经济性与工艺参数的最优平衡——延长热交换时间虽可提升能量回收率，但却会降低设备产能。
An economical and optimal balance of factors must be found, as while more energy can indeed be collected by extending the duration of heat exchange this reduces the throughput of the facility at the same time.
如图所示的案例中，热处理工艺/热交换系统的能耗约为124千瓦时/吨（kWh/t）。相较于能耗约178千瓦时/吨的常规退火工艺，经过8小时热交换后，能耗可降低54千瓦时/吨，或节能率达30.3%。
In the example shown here, the energy consumption of the heat treatment process with heat exchange is abt. 124 kWh/t. When compared to a typical annealing process, which has an energy consumption of around 178 kWh/t, this means that an energy saving of 54 kWh/t or 30.3 % can be achieved after 8h of heat exchange.
假如在高温条件下（如850~900℃）进行退火处理，则可回收利用的能量将进一步提升。
If anneals are carried out at high temperatures (e.g. 850- 900 °C), even more energy can be recovered.
需要特别指出的是：热交换时间并非简单的产能损耗因素。部分热交换时间常与工艺缓冷阶段重叠，且集成加热系统所需加热时间缩短（因炉料并非从环境温度开始加热，而是已预升温至约310℃）。
Note that the heat exchange time is not a pure "loss" that reduces the throughput. Part of the time often runs during a technological slow cooling phase, and the heating time required by the integrated heating system is shorter (as the charge does not start at ambient temperature, having been preheated to around 310 °C).
此外，从工艺角度而言，略微延长热交换时间对料卷质量具有积极影响。缓慢的加热速率促进轧制润滑剂的挥发，而缓慢的冷却速率则能防止卷材间的粘结。
Furthermore, from a technological point of view a minor extension of the time has a positive effect on coil quality. The slow heating-up rate aids the evaporation of rolling lubricants, while a slow cooling rate helps prevent stickers between wraps.
图4：GREENBAFx® 热交换退火的时间/温度曲线图
Figure 4: Time/temperature plot of a GREENBAFx® heat exchange anneal
GREENBAFx®系统的热能回收，协同其他高效设计特性，在降低排放的同时实现显著节能效益。
Thermal recovery, alongside other high-efficiency features of the GREENBAFx® design, is an approach that reduces emissions even as it provides significant financial savings.
相较于传统燃气式设备， GREENBAFx®退火炉可实现二氧化碳和氮氧化物排放量的大幅降低。以年产量25万吨的生产线为例，采用这一技术每年可减少二氧化碳排放量约9055吨，减少氮氧化物排放量约11.8吨。与传统电加热罩式退火炉（年产能25万吨）相比， GREENBAFx®系统可实现年节电量约13,500兆瓦时。按照0.12欧元/千瓦时的电价进行计算，采用此项技术每年可节约电费160万欧元。
That is, in comparison to a classic gas-fired facility, a GREENBAFx® annealer allows an enormous reduction in the amounts of CO2 and NOx that are expelled. For example, at a facility with a throughput of 250,000 t/y, annual emissions would be reduced by around 9055 t of CO2 and around 11.8 t of NOx. The savings in electrical power, when compared to a classic bell annealer with an electric heating system and a throughput of 250,000 t/y, would reach abt. 13,500 MWh/y. Assuming a price for electricity of 0.12 €/kWh, this represents a savings of 1.6 million euros per year.
图5和图6显示了二氧化碳和氮氧化物排放的削减潜力和节电量，以及这些都与年产量的函数关系。
Figure 5 and Figure 6 show the potential reductions in CO2 and NOx emissions, as well as savings in electricity, as a function of the annual throughput.
图5：二氧化碳（CO2）和氮氧化物（NOx）的潜在减排量
Figure 5: Potential savings in CO2 and NOx
图6：潜在节电量
Figure 6: Potential savings in electrical power
选择 GREENBAFx®的原因。
WHY CHOOSE GREENBAFx® ?
零排放工艺：无CO2、无NOx Emission-free process with zero CO2 and zero NOx emissions🔸GREENBAFx® 设备年产能可达25万吨，每年可减少二氧化碳排放量约9055吨，减少氮氧化物排放量约11.8吨。
🔸A GREENBAFx® facility with a throughput of 250,000 t/y reduces emissions by ~ 9055 t of CO2 and ~ 11.8 t of NOx per year
显著节能——源自高效能源利用率 Significant energy savings due to high energy efficiency🔸采用直接加热（基础方案）
可实现高达5%的节能效果
🔸Energy savings of up to 5 % due to direct heating ("basic" case)
🔸采用热交换技术（升级方案）
可实现高达30%的节能效果
🔸Energy savings of up to 30 % due to heat exchange ("advanced" case)
🔸与标准电加热罩式炉相比，功率损耗减少约5％
🔸Reduced power draw (abt. - 5 %) compared to standard bell annealer facilities with electric heating
可提供多种余热回收系统方案，例如： A variety of systems can be provided to recover waste heat, such as🔸热交换回路中的气氛烧嘴
🔸Atmosphere outburner in heat exchanger circuit
🔸空气/水或空气/油热交换器
🔸Air/water or air/oil heat exchanger
🔸直接空气加热系统
（热风可用于车间、料卷存储区等区域的加热）
🔸Direct air heating (hot air is then used to heat the workshop, coil storage area, etc.)
🔸能源平衡系统
🔸Tie-in to energy storage system
炉料堆垛内无超温 No temperature peaks in the charge stack🔸导热气体温度适中
🔸As the gas transferring heat is not at an excessive
temperature
可选择多种冷却方案 Optional cooling variants🔸高性能的空气冷却
High-performance air cooling
🔸集成冷却器
🔸Integrated cooler
🔸快速冷却系统：集成式冷却装置搭配高性能空气冷却装置
🔸Fast cooling system: integrated cooler paired with a high-performance air cooler
🔸无需开放冷却水供应，杜绝料卷水渍导致的质量问题
🔸There is no need for a supply of open cooling water, eliminating potential quality issues caused by water droplets on coils
单一HICON® 工艺罩替代加热罩、冷却罩和内罩的三重功能 A single HICON® process bell replaces the heating bell, cooling bell and inner cover🔸无公辅接头
🔸No utility couplings
🔸无需更换不同功能的罩子
🔸No bell exchange
🔸操作大幅简化
🔸Operations are massively simplified
🔸热处理工艺实现完全自动化
🔸Heat treatment cycles can be fully automated
行车吊运周期数降低 Reduced number of crane cycles🔸仅需两次（2次）行车吊运（放置罩子、吊起罩子），而非通常情况下的六次（6次）
🔸Only two (2) crane movements are required (place bell, lift bell) instead of the usual six (6)
每个炉台均配备独立的加热系统 Each workbase is equipped with an independent heating system🔸无需等待“使用中”的加热罩，避免产能下降
🔸No waiting times for "busy" heating bells that may reduce throughput
加热罩可采用混合加热系统（燃气/电加热) Hybrid-Heating Option with heating bell🔸加热类型（电、天然气、氢气）可根据能源供应情况及价格自由选择（部分加热类型可能对罩子操作方式或热交换有要求）。
🔸The heating type (electric, natural gas, hydrogen) can be freely selected in response to the availability and price of utilities (restrictions in bell handling and heat exchange may apply)
控制热电偶安装于受保护位置 Control thermocouple installed in a protected position🔸装料过程中不会损坏
🔸Cannot be damaged during charging
延长组件的使用寿命(例如集成式内罩) Extended service life of components (e.g.integrated inner covers)🔸由于热应力降低
🔸Due to reduced thermal stresses
运行时噪音极低 Extremely low amounts of noise generated🔸即使是风冷阶段
🔸Even during the air cooling phase
空间需求低 Low space requirements🔸炉台间的间距要求低
Reduced longitudinal distance between workbases
🔸无需再配置阀站隔热罩
Heat shields for valve stands are no longer required
🔸换热管道所需空间与排烟管道大致相同
🔸The heat exchange ducting requires roughly the same amount of space as exhaust gas ducting
升级改造 Retrofits🔸现有多种设备均可加装集成式电加热系统和/或热交换系统
🔸Many types of existing facilities can be upgraded with an integrated electric heating system and a heat exchange system
总结与结论
SUMMARY AND CONCLUSIONS
随着新一代罩式退火炉的创新研发——该研发过程明确以能效最大化、零排放和流程简化为核心目标——金属行业在建立可持续生产方法方面迈出了重要一步。
With the innovative development of a new generation of bell annealer facilities, during which a clear emphasis was placed on maximizing energy efficiency, eliminat- ing emissions and simplifying operational processes, a significant step has been made towards creating a sustainable production method for the metals industry.
如上述所言，我们面临的挑战始终是：在为客户提供可持续生产方案的同时，确保其保持国际市场竞争力和行业领先地位。
As stated above, the challenge has been to provide our customers with sustainable production methods, while still allowing them to remain competitive and maintain their positions in the international market.
GREENBAFx®系列罩式退火炉提供多种可选配置方案：既可作为经济高效的全新设备（具备吸引力的投资回收期），也可作为现有设备的升级改造方案。
The different variants in the GREENBAFx® line of bell annealers are available as financially appealing new facilities with attractive amortization periods配资信息与市场分析平台, as well as upgrade packages for existing facilities.
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