Forever Electromechanical Launches Eco-Friendly Low-Carbon Steel Ball Production Line, Empowers Green Manufacturing for Bearing Industry

 In response to the global industrial low-carbon transformation trend and stricter energy-saving emission reduction standards for metal forging and hot rolling sectors, Forever Electromechanical has officially released a new generation of green low-carbon steel ball production line after two years of R&D and repeated field testing. The integrated production line covers billet heating, hot rolling, shaping, quenching and tempering processes, achieving breakthroughs in energy consumption reduction, heat recovery and pollutant control. It has been put into trial operation at multiple bearing steel ball manufacturers, delivering remarkable carbon reduction benefits and stable production performance.

Traditional steel ball manufacturing lines mainly adopt open-type intermediate frequency heating furnaces with low heat utilization efficiency. Mass heat escapes during billet transmission, and outdated power supply leads to high power consumption per ton of finished steel balls. In addition, traditional quenching cooling water cannot be recycled completely, resulting in large water waste and scattered oil mist emissions in the workshop, which fails to meet the environmental protection requirements of modern industrial parks. Many steel ball enterprises face high energy bills and frequent environmental supervision pressure, restricting their long-term development.

The new low-carbon steel ball production line optimizes core heating and thermal circulation modules as the key breakthrough. The heating furnace adopts fully enclosed multi-layer nano thermal insulation lining and integral sealed furnace body design, which greatly reduces heat radiation loss. Matching upgraded IGBT intermediate frequency power supply, the equipment’s electrothermal conversion efficiency is increased by 18%, cutting power consumption per ton of steel balls by nearly 22%. The waste heat recovery system is newly installed at the furnace outlet to collect high-temperature residual heat generated after billet heating. Recycled heat can be used for preheating raw steel blanks and heating workshop cleaning water, turning waste heat into reusable energy and effectively lowering overall factory fossil energy demand.

fully automatic forging rolling steel ball production line

In terms of water and waste gas treatment, the line equips a full closed circulating cooling water system. Quenching cooling water passes through filter, oil separation and cooling tower cyclic processing, with a water recycling rate over 95%, drastically cutting tap water consumption. A centralized oil mist collection and purification device is arranged above the quenching area to absorb volatile quenching liquid mist, and purified gas is discharged up to standard without polluting the surrounding environment. The whole production process realizes zero sewage discharge and low volatile organic compound emissions, perfectly matching international green factory assessment standards.

Structurally, the automatic steel ball production line adopts intelligent modular layout, with PLC linkage control for each working section. The system automatically adjusts heating power, rolling speed and quenching flow according to steel ball specifications, avoiding invalid energy waste caused by manual misoperation. Field operation data shows that the finished product qualification rate of bearing steel balls reaches 99.2%, and the annual carbon emission of a single production line can be reduced by more than 160 tons compared with old-fashioned equipment. It can produce carbon steel, alloy bearing steel balls of various sizes, widely applicable to automotive bearings, mechanical equipment and mining bearing supporting fields.

The person in charge of Forever Electromechanical stated that green low-carbon manufacturing is the core development direction of metal processing equipment. The newly upgraded steel ball production line balances high production efficiency and environmental protection performance. The company will also provide reconstruction and upgrading services for customers’ old steel ball lines, helping bearing manufacturers complete energy-saving transformation at low cost. In the future, the enterprise will continue to research waste heat reuse and intelligent energy-saving control technology, launch more low-carbon heat treatment and rolling equipment, and assist the global bearing industry to realize energy conservation, emission reduction and sustainable development.