Innovative refractory technology for coreless induction furnaces gulab patel, himanshu bhardwaj, raj mohan. Induction furnaces produce their heat cleanly, without combustion. Melting and refining technology for copper produced from. We are capable of providing complete production lines including smelting system, cooling system, dust removal system, and automatic feeding and pouring system. This work presents the first step concerning the design of a very high temperature inductive furnace dedicated to the characterization of molten metals in the 1 600 k 2 800 k temperature range. The design model drawings of the furnace were achieved using autocad. Temperature estimation of liquid steel in induction furnace. Magnetic fields and induced power in the induction heating. Induction furnace working through animation youtube. Design analysis of an electric induction furnace for melting aluminum scrap article pdf available october 2005 with 3,493 reads how we measure reads. Life of refractory lining is low as compared to eaf. Unless otherwise specified, the design duty shall be 110% of the furnace duty. This article focuses on computer software that functions as a furnace design and setup tool. These furnaces deliver clean, energyefficient melting capabilities through controlled processes.
Medium frequency furnace equipment for iron, steel and non ferrous metals. As the worlds largest manufacturer of induction melting systems, only inductotherm can offer proven, efficient, reliable and productive systems for all your melt shop needs. Attached to the steel shell and connected by a throat is an induction unit which forms the melting component of the furnace. Charged aluminum material is preheated by exhaust gas in the preheating tower, then the metal is. Specially designed for easier to use of operator, distinctly visible under. Compared to air melting processes such electric arc furnaces eaf with argon oxygen decarburization aod converters, vim of superalloys provides a considerable reduction in oxygen and nitrogen contents. Process design of furnaces project standards and specifications page 7 of 33 rev.
The main task of the present work is to design and construct a coreless induction furnace. A crucible is a metal container that you put inside of your furnace that holds the metal youre melting. Figure 1 iron melting coreless furnace with silica lining. The furnace design options can permit direct charge of sows or tbars on to the melt hearth. Induction furnaces induction furnace equipment solutions for your company power parts international will meet with you to discuss your induction melting plans, and then design and build an induction metal melting furnace that will fit all of your companys needs. Jan 07, 20 design and construction of an induction furnace cooling system. Not only sodalime glass, but also leadfree crystal, full lead crystal, opal and borosilicate. Development of an electric induction furnace for heat. Many analytical methods could be applied to induction heating and melting problems. Introduction the hightemperature vacuum distillation furnace is able to melt and consolidate the heavy metals, distill the volatile metals, be operable in argon containment box and heat reasonably fast while being capable of holding temperature. Numerical analysis of melting and holding furnaces in secondary. The quick melt qm top loading electric kiln the rapid fire front loading electric kiln utilize the rapid heat technology which is a 15 amps system that powers 1500 watts through our hand wired coils embedded within our ceramic insulation. Dm water circulation unit 5t induction melting furnace 2000 kg aluminum frame melting furnace large size induction furnace 600 kw to 5000 kw 750 kg to 3000 kg aluminum casted side frames steel frame structure.
The furnace is induction heated to ensure equipment. Metal is melted under the effect of alternating magnetic field induced by inductor. An optimum design of the lining of a medium frequency induction melting furnace. Design and fabrication of lowcost electrical resistance. The equivalent circuit method are general methods that can be applied to analysis and design of all induction heating applications, the coreless furnace is certainly one of them. Plasma furnace technology is now well proven in industry. Semiatin, electric power research institute, battelle memorial institute. For example, highcarbon ferrochromium is produced on an industrial scale, from transvaal chromite fines and fine, lowcostcarbonaceous reducing agents, in a dc transferredarc plasma furnace at palmiet ferrochrome in krugersdorp, south africa.
Inductotherm also builds heating systems for high temperature and ultrahigh temperature carbon. The equipment is of proven technical design, with high performance, versatile to install. Should you have a furnace need please feel us customers toll free 800 9663160 us customers toll free 800 9663160 click to free call. Basics of industrial glass melting furnaces iminfg. They can be used as holding furnace or casting furnace. Melting furnaces for steel, cast iron use electricity in induction and arc furnaces. A welldesigned inductor provides the proper heating pattern for your part and maximizes the efficiency of the induction heating power supply, while still allowing easy insertion and removal of the part. Figures 111 show the various views and sections of the electric heat treatment furnace developed. The furnace design mainly depends on the glass producta to be formed. The automatic melting furnace was designed to be a safe and easytouse electrical method for melting gold, silver and other nonferrous metals for casting and. Though induction furnaces are being used since a long time the production of mild steel by the induction furnace if is.
Thus, the heat stored in an 8tonne furnace is 800 kwh, i. Oil fired furnace furnace oil is the major fuel used in oil fired furnaces, especially for reheating and heat treatment of materials. Rugged bushing type hinge box instead of bearing type. Basic design considerations the inductor is similar to a transformer primary, and the workpiece is equivalent to the transformer secondary fig. By changing the geometry of the induction coil, induction melting furnaces can hold charges that range in size from the volume of a coffee mug to hundreds of tons of molten metal. Induction heating, coreless furnace, equivalent circuit method. Deposits and condensation from flue gases in glass furnaces. During melting the offgases are emitted into the plant by the eaf through openings for the electric power supply and the oxygen lance. Refining in induction furnace is not as intensive or effective as in electric arc furnace eaf. Vacuum induction melting is indispensable in the manufacture of superalloys. An advanced highpower induction melting system as shown in fig. Exhaust gas discharge over the crucible edge is the standard design for our gas and oilfired cruicible furnaces. Furthermore, we are one of the leading global suppliers for the pro.
Ldo is used in furnaces where presence of sulphur is undesirable. Power supplies can be in ranges from 10 kw to 42 mw, with melt sizes of 20 kg to 65 tonnes of metal respectively. This section introduces furnaces and refractories and explains the various design and operation aspects. Induction furnace supplier melting furnace designing and. In figure 3 is reported electrical energy consumption for induction furnace process reference plant ifa versus electric energy consumption for two different scrap melting processes via electric arc furnace. Edward allen colby patented an induction furnace for melting metals in the year 1890 and produced the first steel the united states in 1907 5. Theory solutions of the electromagnetic field equations induction melting furnaces operate at frequencies for which the wavelength is large compared to the di. When the induction coil is placed next to or around a workpiece, the lines of force concentrate in the air gap between the coil and the workpiece.
Induction melting offers the modern foundry a clean, efficient, costeffective melting facility with all the advantages of stateoftheart technology and environmental protection. Electrical energy consumption for scrap melting process via induction furnace is higher compared with eaf process. Aluminum largecapacity melting, holding, and heating. Melting and refining technology for copper produced from scrap charge air products and chemicals, inc. Of the several operating cases, the one in which the heater duty is the highest, shall be regarded as the normal case. We supply new melting furnaces with our power supplies and offer general repair services for furnace reconditioning. Design and construction of an induction furnace cooling system. Induction furnace capacities range from less than one kilogram to one hundred tonnes, and are used to melt iron and steel, copper, aluminium, and precious metals the advantage of the induction furnace is a clean, energyefficient and wellcontrollable melting process compared to most.
Theory of heating by induction 7 tromagnetic, or flux around it. We have observed that the major problems in oilfired furnace are nonuniform flame distribution, oxidation of metal. Backed by the long experience and expertise in the induction furnace technology, the design section provides the vital ingredients, information and data which go into the manufacture of the most reliable and energy efficient furnaces. For many processes melting is the first step in producing a useful product. Nov 28, 2014 foundries use this type of furnace and now also more iron foundries are replacing cupolas with induction furnaces to melt cast iron as the former emit lots of dust and other pollutants. Different melting techniques are in practice with different energy sources. This video explains induction furnace introduction, advantages, parameters, eddy current, electromagnetic induction, working principle through animation. An induction furnace is an electrical furnace in which the heat is applied by induction heating of metal. Induction melting furnace manufacturer, induction furnace. Induction furnaces use electromagnetic induction to heat and melt metal such as silver, gold, platinum, iron, steel, zinc, platinum, bronze, aluminum, copper, brass, and silicon for a variety of industrial purposes.
Design and implementation of an induction furnace diyala journal of engineering sciences, vol. Design analysis of an electric induction furnace for melting. Banyard the banyard brand has specialised for over 50 years in ferrous and nonferrous metal induction heating. Design analysis of an electric induction furnace for. Furnace manufacturers can use the furnxpert program to accurately and efficiently size furnaces for their customers, while heat treaters, process engineers, and plant operators can use the design and analysis software to determine the best setup for any. Coreless induction furnaces medium frequency furnace equipment is used for iron, steel and non ferrous metals. Magnetic fields and induced power in the induction heating of.
We have designed a special graphite crucible for this furnace. Improving energy efficiency in aluminum melting defc07. Induction furnaces basics of foundry melting furnaces. This paper deals principally with the mechanical and electrical requirements for induction furnace. Exhibit 1 compares the efficiency and metal loss for different types of furnaces. It took about 95 minutes to melt the first charge of 2kg resulting in a melting rate of 21. There are many different design for the electric induction furnace but they are center around basic idea. Induction skull melting furnaces ism vacuum induction melting furnaces vim electromagnetic cold crucible furnaces emcc electroslag remelting furnaces esr alpha. For the 110kg capacity, we recommended our integrated type small gold melting furnace, this model is special designed for the beginner or jewlery shop who want to start the gold refinery business, this mini gold melting furnace with a power range from 5kw15kw adjustable, the power supply adopt the igbt technology from germany, it is the. As a professional china induction furnace manufacturer, we are equipped with a famous factory and plant and engineers with decades experience, as well as providing with electric arc furnace, induction heating furnace, melting furnace, ccm machine, tmt rebar mill, wire rod mill, finishing mill, reversible rolling mill, cold rolling mill, section rolling mill, etc.
The equivalent circuit method is regarded as general method because this method doesnt determine the dimensions, frequency or the power requirements of the specific. Coreless type induction furnace design and construction. A furnace is an equipment used to melt metals for casting or to heat materials to change their shape e. Induction melting furnaces inductotherm group australia. This heats the surface of the charge material, causing it to melt. Ultimately, the furnace was constructed and the final aim, which is melting the metal, was achieved. Medium frequency induction furnaces melting solutions. Tilting furnaces kbr with recuperative burner, gasfired, for melting and. The stack melters energy sav ings, greater production and reduced. For induction melting and mass heating, the early induction heating coils were manufactured from copper tubing wrapped in multiple turns around a mandrel. Inductor design is therefore one of the most important aspects of the overall induction heating machine. During the course of the project two experimental furnaces were designed and fabricated at the albany research center. The inherent advantages and disadvantages of gas fired furnaces are provided in the next column. The practical development of various channel furnaces for steel making quickly followed through the late 19th and early 20th centuries 46.
Induction furnace electrical circuit circuit diagram images. Unlike the melting and mass heating coils, the heat treating induction. The furnace would weigh six hundred pounds empty, and sevenhundred and fiftypounds with a fullcharge of glass, depending upon the chemical composition of the glass used. Bhatia abstract heat treatment is the linked process for treatment of machined and forging components. Energy saving potential of melting in mediumfrequency. The burning fuel brings the interior temperature of the furnace above the melting point of the charge material placed inside. Design and fabrication of inductors for induction heat treating. Design the radiant section of the furnace having a radiation section average flux of 12,000 btuhrft2. Innovative refractory technology for coreless induction.
Put the metal you want to melt inside the crucible and use a pair of fire tongs to set it in the middle of your furnace. Melting the metals to test the performance of the furnace. Keywords induction furnace, resonant tanks, impedance matching network, work coil, power controller. To study the useful factors when selecting a pump for cooling system of induction furnace. Design and construction of the coreless induction furnace dr. The induction coil actually functions as a transformer primary, with the workpiece to be heated becoming the transformer secondary. Special furnace design 1500kw 2x3000kg melting furnace at the time of casting norway 5m design coreless induction melting furnace with all accessories safety back and side barriers back tilting, capture hood and easy lining removal system hydraulic furnace lid gas vacuuming system demountable top cassette design high insulated shielding system. Melting furnace there are two type of the furnace structure. The extent of the losses depends on the furnace design, the fuel used, and. The average tube temperature in the radiant section is estimated to be 800 deg f.
Design and construction of the coreless induction furnace. Design and fabrication of inductors for induction heat. Figure 2 furnace pictorial view with detailed dimensions. Design and prototype development of a minielectric arc. Induction furnace for metals melting furnaces for melting type fimnt manual extraction absolute alloy homogeneity guaranteed by the medium frequency converter reduction of melting losses due to uniform temperature distribution on the melting material. Allow the furnace to heat the crucible and melt the metal before taking it out with tongs for casting. How induction furnaces work induction definition the act of inducing bringing about or causing. Lets introduce the small top loading kiln and front loading metal melting kiln we have for sale. Andritz metals delivers furnace systems for reheating and heat treatment, as well as melting and refining furnaces. Lessons learned roger hillson km4lhz a presentation for the virginia wireless society. Pdf design analysis of an electric induction furnace for. The workflow in the design and fabrication of the proposed metal melting furnace is shown in the figure 1. The cleanliness and availability of electrical energy sources in nigeria is of paramount importance to its use in foundries, hence the need for this design. Fundamental aspects of alloy smelting in a dc arc furnace.
The basic frame for the system was acquired from a glass. The products are widely used for smelting or heating metals such as steel, copper, and aluminum and are mainly used for metal casting and steel smelting. The extent of the losses depends on the furnace design, the fuel used, and the method of imparting heat to the metals. Induction furnace lining and industrial vibrator design. Continuous aluminum melting and holding crucible furnace. The following subsections present the components of the furnace and their design aspect. A transformer efficiency of about 83% was also achieved. Furnace framework inconsidering the superstructure of the furnace, my main concern lieinthedurabilityand strengthrequired to support a tiltingfurnace. Publishers pdf, also known as version of record includes final page, issue and volume.
Pdf design and construction of the coreless induction furnace. Then, a design, meeting certain specification was prepared, taking into consideration the available facilities. Gb operating instruction melting furnace beco technic. Induction furnace design, induction furnace technology. The channel induction furnace consists of a refractory lined steel shell which contains the molten metal. It combines the feature of a tower type melting furnace and a stationary type crucible furnace. Induction melting furnace 1 induced in the metal is a current which heats the latter. Studies on direct re duced iron melting in induction furnace.
51 1304 593 545 1184 356 1205 1477 1208 1439 450 1332 361 1185 140 766 337 536 53 1104 262 366 1166 519 1089 768 1100 320 520 258 549 430 1149 1 543 148 1453 277