煉(lian)爐區(qu)
煉爐師傅按照預定生(sheng)產(chan)目標,在廢銅材料中加入不等量的鋅塊(kuai)以制得不同規(gui)格的銅原料。
其(qi)中鋅材(cai)料(liao)市場價值為(wei)20000—25000元/噸(dun)。本廠(chang)車間目(mu)前煉銅(tong)(tong)爐(lu)(lu)容(rong)量(liang)大(da)約(yue)在(zai)2噸(dun)位左右,按每(mei)(mei)條(tiao)出爐(lu)(lu)銅(tong)(tong)條(tiao)130千克計(ji)算(suan),除(chu)去(qu)爐(lu)(lu)中必然產出的廢渣(zha)0.4噸(dun),一(yi)次(ci)開(kai)爐(lu)(lu)可(ke)制得(de)完整銅(tong)(tong)條(tiao)8-9塊左右。每(mei)(mei)隔大(da)約(yue)兩小時開(kai)一(yi)次(ci)煉銅(tong)(tong)爐(lu)(lu),取得(de)兩拇(mu)指大(da)小銅(tong)(tong)塊,送去(qu)化驗室(shi)做關于銅(tong)(tong)純(chun)度(du)的進一(yi)步分析,根據純(chun)度(du)分析結果和(he)預定銅(tong)(tong)條(tiao)純(chun)度(du)控制值, 煉爐(lu)(lu)師(shi)傅在(zai)銅(tong)(tong)爐(lu)(lu)中加(jia)入相應重量(liang)的銅(tong)(tong)料(liao)和(he)鋅料(liao)，這樣便可(ke)生產出所需(xu)的合格銅(tong)(tong)條(tiao)。
化驗室
為了保(bao)(bao)證生產出既合(he)格又保(bao)(bao)證經濟效(xiao)益的成(cheng)品(pin),化(hua)驗(yan)結果的準確(que)性就(jiu)顯(xian)得猶為重要。化(hua)驗(yan)室職責就(jiu)是根據送檢銅(tong)塊,快(kuai)速而準確(que)地將化(hua)驗(yan)結果告訴煉(lian)爐師傅。目(mu)前本廠銅(tong)料成(cheng)品(pin)純度控制在60.02—60.08之間,而根據本人(ren)的統計,每次(ci)送檢銅(tong)料純度均在 60.9—62.20左右，結果令人(ren)滿意(yi)。
但值得注意的(de)是在(zai)我了(le)解化(hua)(hua)(hua)驗室(shi)過程其間發(fa)生了(le)一(yi)(yi)段小插曲(qu),那天正好開爐,而值白班化(hua)(hua)(hua)驗師(shi)傅發(fa)現其中一(yi)(yi)淀(dian)粉試(shi)(shi)劑(ji)(ji)出現沉淀(dian)變質(zhi)現象(xiang),這將導致化(hua)(hua)(hua)驗工作無法繼續下去,而后果(guo)則是不(bu)能及時將銅條排出,造成(cheng)直接電力消費和時間無故流失。幸好化(hua)(hua)(hua)驗師(shi)傅反應夠快,在(zai)空調冷風作用(yong)下用(yong)了(le)四十(shi)分鐘左右趕(gan)在(zai)銅塊(kuai)送(song)檢之前，將淀(dian)粉試(shi)(shi)劑(ji)(ji)趕(gan)制出來(lai),后發(fa)現原來(lai)隔了(le)六(liu)天,淀(dian)粉試(shi)(shi)劑(ji)(ji)在(zai)較高室(shi)溫下變質(zhi),這期(qi)間化(hua)(hua)(hua)驗師(shi)傅沒提早檢查(cha)各種(zhong)試(shi)(shi)劑(ji)(ji),為生產(chan)做好準備負有不(bu)可(ke)推卸責任。此事給(gei)我們敲醒(xing)一(yi)(yi)個警(jing)鐘,本廠化(hua)(hua)(hua)驗師(shi)傅必須定(ding)期(qi)檢查(cha)和提前配足(zu)各種(zhong)試(shi)(shi)劑(ji)(ji),以免再次出現試(shi)(shi)劑(ji)(ji)變質(zhi)或者用(yong)量不(bu)足(zu), 造成(cheng)生產(chan)滯后的(de)問題。
割斷區
完(wan)整銅(tong)(tong)(tong)條經過吊繩牽(qian)引,在(zai)專用割斷臺上(shang)放置(zhi)平(ping)(ping)(ping)穩,再由割斷輪鋸切斷,制(zhi)得每塊(kuai)長高寬分別(bie)為(wei)(wei) 100cm×9.2cm×18.5cm的銅(tong)(tong)(tong)塊(kuai),重量約為(wei)(wei)130千克(ke)左右,再由銅(tong)(tong)(tong)條洗面(mian)(mian)(mian)機(ji)將銅(tong)(tong)(tong)條表(biao)(biao)面(mian)(mian)(mian)凹(ao)凸不(bu)平(ping)(ping)(ping)的表(biao)(biao)面(mian)(mian)(mian)打磨平(ping)(ping)(ping)滑,這樣(yang)有(you)利(li)于(yu)后期加工出(chu)來的銅(tong)(tong)(tong)帶表(biao)(biao)面(mian)(mian)(mian)的平(ping)(ping)(ping)整性和光滑度。目前由于(yu)產出(chu)的銅(tong)(tong)(tong)條表(biao)(biao)面(mian)(mian)(mian)不(bu)甚理(li)想(xiang),所以雙面(mian)(mian)(mian)各刨去(qu)2 mm的厚度,如洗面(mian)(mian)(mian)后的銅(tong)(tong)(tong)條仍有(you)凸出(chu)部,則(ze)用砂(sha)輪打磨去(qu)即可。
熱軋區(qu)
割斷后的(de)銅(tong)(tong)條(tiao)在經過1000℃高溫中加熱,再過熱軋(ya),壓軋(ya)成厚度在2.3cm左右的(de)銅(tong)(tong)帶。期間本人用秒表測(ce)試過銅(tong)(tong)條(tiao)壓軋(ya)成毛坯銅(tong)(tong)帶用時(shi)(shi)(shi)(shi),分別為(wei)第(di)一次(ci)(ci)用時(shi)(shi)(shi)(shi)01:47, 第(di)二(er)次(ci)(ci)用時(shi)(shi)(shi)(shi)01:53, 第(di)三次(ci)(ci)用時(shi)(shi)(shi)(shi)01:59, 第(di)四次(ci)(ci)用時(shi)(shi)(shi)(shi)01:44, 第(di)五次(ci)(ci)用時(shi)(shi)(shi)(shi)01:52。以上每帶平均用時(shi)(shi)(shi)(shi)為(wei)01:51，此步驟平均每小時(shi)(shi)(shi)(shi)處理37個銅(tong)(tong)帶。
水洗區
每塊(kuai)銅(tong)塊(kuai)經(jing)(jing)初軋步(bu)驟下(xia)來,由于表面(mian)雜質(zhi)存在(zai),為了避免(mian)影(ying)響成品(pin)(pin)品(pin)(pin)質(zhi),必須再(zai)次經(jing)(jing)過封火爐再(zai)過水(shui)洗(xi)程序。水(shui)洗(xi)區按照酸(suan)性(xing)的(de)(de)(de)不同分(fen)為兩種(zhong)水(shui)池(chi)。濃(nong)(nong)度(du)(du)高的(de)(de)(de)為6—8度(du)(du),濃(nong)(nong)度(du)(du)低(di)(di)的(de)(de)(de)則(ze)為3—5度(du)(du)。其中(zhong)銅(tong)帶(dai)表面(mian)產生中(zhong)紅(hong)色(se)(se)斑(ban)塊(kuai)可以(yi)(yi)由水(shui)洗(xi)池(chi)的(de)(de)(de)酸(suan)液洗(xi)去,而暗紅(hong)色(se)(se)斑(ban)塊(kuai)則(ze)由水(shui)洗(xi)期(qi)間(jian)的(de)(de)(de)鐵(tie)制細(xi)毛(mao)刷除,經(jing)(jing)過這一系列(lie)處理方式(shi)下(xia)來的(de)(de)(de)銅(tong)帶(dai)，明顯地閃耀出銅(tong)自(zi)身固(gu)有的(de)(de)(de)光(guang)澤。同樣軋板期(qi)間(jian)仍然存在(zai)紅(hong)色(se)(se)斑(ban)塊(kuai)和紅(hong)色(se)(se)斑(ban)塊(kuai),則(ze)仍需(xu)重來一次水(shui)洗(xi)步(bu)驟。水(shui)洗(xi)期(qi)間(jian)要定期(qi)地檢查水(shui)池(chi)中(zhong)的(de)(de)(de)酸(suan)度(du)(du),及時(shi)加酸(suan)以(yi)(yi)免(mian)酸(suan)含量過低(di)(di)導致水(shui)洗(xi)不充分(fen).
水(shui)洗用(yong)(yong)時：分別為第一次(ci)用(yong)(yong)時04:53, 第二(er)次(ci)用(yong)(yong)時04:43, 第三(san)次(ci)用(yong)(yong)時04:58, 第四次(ci)用(yong)(yong)時04:30, 第五次(ci)用(yong)(yong)時04:37。以上每(mei)帶(dai)平均用(yong)(yong)時為04:40，此步驟平均每(mei)小(xiao)時處理13個銅帶(dai)。
軋(ya)板區(qu)
軋板(ban)區(qu)按輪輥(gun)區(qu)分為180的(de)初軋,110的(de)中軋。按照各(ge)(ge)種輪輥(gun)大小不(bu)同將熱軋下來經封火爐鍛(duan)燒過的(de)銅帶(dai)經由(you)以上(shang)兩個(ge)步驟,由(you)粗糙到精細(xi)加(jia)工(gong)出來。同樣，本人(ren)也記錄了(le)各(ge)(ge)步驟的(de)用時：
初軋用(yong)時(shi)(shi)：分別(bie)為(wei)第(di)一次(ci)用(yong)時(shi)(shi)05:37, 第(di)二次(ci)用(yong)時(shi)(shi)05:53, 第(di)三次(ci)用(yong)時(shi)(shi)05:59, 第(di)四次(ci)用(yong)時(shi)(shi)05:14, 第(di)五次(ci)用(yong)時(shi)(shi)05:22。以(yi)上(shang)每(mei)帶平(ping)均用(yong)時(shi)(shi)為(wei)05:37，此(ci)步驟平(ping)均每(mei)小時(shi)(shi)處理12個銅帶。
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