Professional Documents
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in
Induction furnace
Programme on
Energy Conservation in Foundry Industry
E Nand Gopal
The Energy and Resources Institute
11th August2014
Contents
Melting furnaces
Melting
furnace
Arc furnace
Secondary
refining
furnace
Electric
furnace
Melting
furnace
Medium
frequency
furnace
Induction
furnace
Mains
frequency
furnace
Coke
Channel type
furnace
Cupola
Natural gas
Reverberatry
furnace
Heavy oil
Coreless
Channel
Medium
frequency
coreless
type
Frequency:
500 2000 Hz
Crucible size:
50 kg 20MT
Switching device: SCR or IGBT
Laws
governing
induction
heating
Electromagnetic induction
The joule effect
4
Best
operating
practices
Crucible
size
Panel
capacity
and type
Technology:
SCR or IGBT
Panel capacity: Power density (kW / kg)
Cooling
water
circuit
Pump specification
Type of piping and size of piping
Pump
specification
Piping
10
SEC (kWh/tonne)
650
624
603
600
550
571
539
511
507
500
Average
Best
450
400
Kolhapur
Belgaum
Europe
Kolhapur 63 units
Belgaum 15 units
Europe WB report 2012
11
500
Power, kW
400
300
Delay in
spectro
analysis
200
100
0
12
250
200
1:05:00 PM
1:07:00 PM
1:09:00 PM
1:11:00 PM
1:13:00 PM
1:15:00 PM
1:17:00 PM
1:19:00 PM
1:21:00 PM
1:23:00 PM
1:25:00 PM
1:27:00 PM
1:29:00 PM
1:31:00 PM
1:33:00 PM
1:35:00 PM
1:37:00 PM
1:39:00 PM
1:41:00 PM
1:43:00 PM
1:45:00 PM
1:47:00 PM
1:49:00 PM
1:51:00 PM
1:53:00 PM
1:55:00 PM
1:57:00 PM
1:59:00 PM
2:01:00 PM
2:03:00 PM
2:05:00 PM
2:07:00 PM
Power, kW
Analysis - Discussion
500
450
400
Temperature
drop
350
300
Delay in
spectro
analysis
150
100
50
13
150
100
50
10:38 AM
10:40 AM
10:42 AM
10:44 AM
10:46 AM
10:48 AM
10:50 AM
10:52 AM
10:54 AM
10:56 AM
10:58 AM
11:00 AM
11:02 AM
11:04 AM
11:06 AM
11:08 AM
11:10 AM
11:12 AM
11:14 AM
11:16 AM
11:18 AM
11:20 AM
11:22 AM
11:24 AM
11:26 AM
11:28 AM
11:30 AM
11:32 AM
11:34 AM
11:36 AM
11:38 AM
11:40 AM
11:42 AM
Power, kW
Analysis - Discussion
Induction furnace power curve
450
All moulds
not ready
400
350
300
250
200
Small ladle
pouring, power
loss during
pouring
14
250
4:10 PM
4:12 PM
4:14 PM
4:16 PM
4:18 PM
4:20 PM
4:22 PM
4:24 PM
4:26 PM
4:28 PM
4:30 PM
4:32 PM
4:34 PM
4:36 PM
4:38 PM
4:40 PM
4:42 PM
4:44 PM
4:46 PM
4:48 PM
4:50 PM
4:52 PM
4:54 PM
4:56 PM
4:58 PM
5:00 PM
5:02 PM
5:04 PM
5:06 PM
5:08 PM
5:10 PM
5:12 PM
5:14 PM
5:16 PM
Power, kW
Analysis - Discussion
Induction furnace power curve
450
400
350
300
???
200
150
100
50
15
400
10:02:00 AM
10:08:00 AM
10:14:00 AM
10:20:00 AM
10:26:00 AM
10:32:00 AM
10:38:00 AM
10:44:00 AM
10:50:00 AM
10:56:00 AM
11:02:00 AM
11:08:00 AM
11:14:00 AM
11:20:00 AM
11:26:00 AM
11:32:00 AM
11:38:00 AM
11:44:00 AM
11:50:00 AM
11:56:00 AM
12:02:00 PM
12:08:00 PM
12:14:00 PM
12:20:00 PM
12:26:00 PM
12:32:00 PM
12:38:00 PM
12:44:00 PM
12:50:00 PM
12:56:00 PM
1:02:00 PM
1:08:00 PM
1:14:00 PM
Power, kW
Analysis - Discussion
2000
1800
1600
Dual-trak
furnace,
poorly utilized
1400
1200
1000
800
600
???
200
16
Analysis - Discussion
Induction furnace power curve
700
600
Power, kW
500
400
300
Almost Ideal
200
100
0
17
Charge preparation
and charging
Furnace lining
Emptying the
furnace
Energy monitoring
and data analysis
18
21
22
24
26
Furnace lining
Select the correct lining material
Do not increase lining thickness at bottom or sidewalls. Increase in
lining means reducing capacity of furnace
Do not allow furnace to cool very slow. Forced air cooling helps in
developing cracks of lower depth, this helps in faster cold start cycle
Cold start cycle time should be ideally not more than 120% of normal
cycle time
Coil cement should be smooth, in straight line and having thickness of
3 to 5 mm
While performing lining ensure that each layer is not more than 50mm.
Compaction is better with smaller layer
Monitor lining performance
27
E Nand Gopal
+91 99715 17752
e.nandgopal@yahoo.com
enand.gopal@teri.res.in