Single-furnace induction melting systems built in the 1950s and 1960s required about 5,000 connected kilowatts and 750 kWh/t to produce 6 to 7 tons of metal per hour. Two-furnace systems from that period needed about 4,000 connected kilowatts and 800 kWh/t to produce the same amount of metal.
Are induction furnaces efficient?
In a typical induction furnace the energy loss in equipment is between 100 to 130 kWh per tonne. The furnace efficiency is around 65 to 75% .
What is the cost of induction furnace?
| Power Source Min Price Max Price | Electric Rs 50000/Piece Rs 2000000/Piece |
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What is melt rate of induction furnace?
| KW CAPACITY SIZE FREQ HZ MELT RATE (KG /HOUR) | 175 3000/1000 260 | 250 1000/500 430 | 350 1000/500 620 | 450 1000/500 815 |
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How does an induction melting furnace work?
In the induction furnace, a coil carrying alternating electric current surrounds the container or chamber of metal. Eddy currents are induced in the metal (charge) , the circulation of these currents producing extremely high temperatures for melting the metals and for making alloys of exact composition.
Which is the main drawback of induction furnace in refining of steel?
The one major drawback to induction furnace usage in a foundry is the lack of refining capacity : charge materials must be free of oxides and be of a known composition, and some alloying elements may be lost due to oxidation, so they must be re-added to the melt.
What can be the advantages of induction furnace over conventional furnaces?
The induction metal furnaces are cleaner with greater control over emissions and their release to the environment . You can focus more on the foundry process with less waste generated. Additionally, the forges are less noisy compared to their open-hearth counterparts.
What are the two types of induction furnace?
There are two main types of induction furnace: coreless and channel .
What is the difference between electric arc furnace and induction furnace?
Electric arc furnace uses electric arc generated by electrified electrode to melt metal and ore, while induction furnace uses electrified induction coil to heat and melt metal .
What are the types of induction furnace?
- Core type induction furnace.
- Vertical core type induction furnace.
- Indirect core type induction furnace.
- Core less induction furnace.
How do you calculate the melt rate of an induction furnace?
( A ) For Steel Ingot
2 tons 1 hr divided by 0.8. is 2.0 ÷ 0.8 = 2.5 Tons / Hour should be the required furnace melt rate at 1600oC . 5th Now refer the furnace specification table. You will find the nearest melt rate can be achieved by 1500 kW 1 3 Tons Furnace i.e. 2.6 Tons 1 Hour Melt rate.
What are the advantages of using induction furnace rather than cupola?
Besides, cupolas emit many pollutants, specifically dust, making induction a cleaner and safer way to melt cast iron . Another thing is that induction furnaces do not require an arc or combustion, making the temperature safer to work with.
How can I reduce the power consumption of my induction furnace?
Another way to reduce energy consumption in the furnace is to pour at the coolest temperature that is practical and avoid temperature overshooting . For example, if metal that could have been poured at 2,750°F is allowed to rise less than 10% to 3,000°F, heat losses are boosted by 33%, using significantly more energy.
Which current is induced in the induction furnace?
An induction heater consists of an electromagnet and an electronic oscillator that passes a high-frequency alternating current (AC) through the electromagnet. The rapidly alternating magnetic field penetrates the object, generating electric currents inside the conductor, called eddy currents.
What causes heating in induction furnace?
In an induction furnace, the metal charge material is melted or heated by current generated by an electromagnetic field . When the metal becomes molten, this field also causes the bath to move. This is called inductive stirring.
Can you melt steel with electricity?
About one-quarter of the world’s steel is produced by the electric-arc method , which uses high-current electric arcs to melt steel scrap and convert it into liquid steel of a specified chemical composition and temperature.
What is medium frequency induction furnace?
medium frequency induction furnaces are mainly used for metal smelting , roughing of mechanical parts and part-heating treatment processes.
Where induction furnace is used?
These furnaces are used in steel and iron mills , but can also be used for nonferrous metals. Medium-frequency graphite crucible induction furnaces are typically used to cast precious metals. The crucible and the inductor can also be placed in a vacuum chamber for custom casting applications.
Is induction heating more efficient than resistive heating?
With resistive technology, heat is created from the heater coil, then conducted to the tip. Resis- tive heating has higher thermal resistance and therefore offers lower thermal performance than inductive heating.
Which of the following is are the advantages of induction furnace?
Which of the following is/are the advantage(s) of an Induction Furnace? Explanation: Advantages offered by Induction Furnace are higher yield, faster startup, cleaner melting, natural stirring and compact installation .
What will be the disadvantage disadvantages of using core type induction furnace?
The main disadvantage is that electromagnetic forces produce high turbulence of the molten metal , which is useful up to a certain point, but it becomes too severe unless the frequency is kept low. Another disadvantage of this furnace is that a crucible is of inconvenient shape from the metallurgical point of view.
What are the advantages and disadvantages of electric arc furnace?
The arc furnace tends to be larger and more powerful ; Less investment, quick to construct and fast cost recovery; The temperature and the component of the molten steel can be controlled with accuracy. The arc furnace can also smelt various kinds of different steels.
How does electric arc furnace work?
The electric arc furnace is used to reduce iron from iron ore . Heat is generated from an electric arc between electrodes. Oxygen is blown into the furnace, and lime and other materials are added to combine with the impurities and form slag. Molten iron is extracted and poured out via a tapping spout.
What is a ladle furnace?
Ladle Refining Furnaces (LRF) are used to raise the temperature and adjust the chemical composition of molten metal . Without LRFs, higher tap temperatures are normally required from steel making furnaces due to heat losses during refining with conventional ladles.
How much electricity does it take to melt steel?
The energy required for melting recycled material was measured at 532 kWh/t, that for melting steel plus alloying materials at 494 kWh/t .
How much electricity does it take to melt aluminum?
Energy Required to Melt Aluminum
So, 500 Btu/pound are required to reach a casting temperature of 1370°F (743°C). Yet, many melt shops use a lot more energy than that.
Who invented induction heating?
The basic principle involved in induction heating was discovered by Michael Faraday as early as 1831. Faraday’s work involved the use of a switched DC supply provided by a battery and two windings of copper wire wrapped around an iron core.
How do you make induction heating coils?
- Higher flux density near the heating area means a higher current is generated in the part. ...
- The greatest number of flux lines in a solenoid coil are toward the center of the coil. ...
- The geometric center of the coil is a weak flux path.
How do you determine the power rating of a heater?
Convert the power rating of the heater to kilowatts by dividing it by 1,000 . Multiply this number by the number of hours you use the heater in one day to get a daily kilowatt-hour tally. For example, suppose your heater draws 1,500 watts and you use it for 10 hours a day.
How much energy does it take to melt 1kg of aluminum?
The heat required to raise the aluminum to the melting point (not the boiling point) is 5760 kJ. Once the aluminum is at the melting point, it takes 390 kJ/kg to turn solid aluminum into molten aluminum.
How much energy does it take to melt a ton of aluminum?
As mentioned above standard power consumption for light scrap of Aluminum melting requires 600 to 625 kWh/ ton (consider 612.5 kWh average). That means one ton of light aluminum scrap require 600 to 625 kWh.
What are the disadvantages of cupola furnace?
Disadvantages of Cupola Furnace
The main disadvantage is that sometimes it is very hard to control the temperature in this furnace . Metal elements are converted to their oxide, which is not suitable for casting.
Can a cupola melt steel?
Cupola furnaces burn coke with an air blast to melt scrap steel , cast iron, and alloys into a consistent grade of iron. ... It may result in iron that is sub-standard in quality, and thus inferior cast products, or scrapped metal, or do-over costs, or remediation.
