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Scrap Preheating for Steel Melting Induction

Saving Electrical Energy as well as Heat timings by preheating the Scrap Metal charge and DRI is an established practice with EAF ( Electric Arc Furnaces). This same method can be adopted for Induction Furnaces as well, utilizing the Vertical Shaft kiln for preheating the charge using either the waste heat in case of a CAp Topped Induction Furnace or using cheap fuels like Coal or Biomass.

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INVESTIGATION OF THE ELECTRICAL INDUCTION FURNACE USED

The charge is introduced into the furnace and the melting of the aluminium scrap is done by the induction process, melting of aluminium takes nearly 7500C and it is held at that temperature for some more time for uniform melting. Once this is completed the melt can be poured. 3.4 POURING

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Design Analysis of an Electric Induction Furnace for ...

taken as 8% of furnace capacity; Gs = heat energy for slag = 18kJ/kg. Total heat energy induced (Hammond, 1978), in charge due to eddy current is given by: ..... 14 8 2 4 max 3 2 ρ π m m ec

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Saving Electrical Energy in Coreless Induction

The coreless induction furnace is essentially a refractory-lined vessel surrounded by an electrically energized, current-carrying, water-cooled copper coil. Electrical current in the coil forms an electromagnetic field, generating thermal energy that melts the charge.

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Induction Furnace Charging Systems

Manual charging and most magnets have difficulty keeping pace with large induction furnaces that are able to melt a full charge in less than 30 minutes. Furnace charging systems are available in various configurations and modes of motion. In general, popular charging system options are belt conveyors, buckets and vibrating conveyors.

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Furnace Charge Drying and Preheating Systems ...

Preheating scrap material to 1200° F can increase induction furnace melt rates by as much as 20%. 3. Reduced Electric Power Consumption Preheating to 1200° F will reduce power consumed by furnace from between 90 and 100 kWh/ton of metal melted.

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How To Make Preheating Scrap In Bucket

Scrap charging bucket for induction furnace in hyderabad.Bucket charging scrap selection plays an important role in any.High power electric arc furnaces bucket charged the relationship between active power and heat size can be as high 11.In contrast, consteel reduces the ratio to 0.51.In an analysis conducted in 2011, relevant to.

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Induction Furnace Scrap Melting

Not only do induction furnaces prove to be efficient in the melting of scrap, but they are also capable of processing two items at a time, making the whole scrap melting process much easier. These furnaces use induction heating to produce heat, which is a rather clean, energy-efficient way of producing heat.

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How to Calculate Electricity Cost ... - ELECTROHEAT

If you are melting 50 tons/month light scrap of Aluminum than monthly electricity cost can be determine using below method. 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.

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scrap charging in induction furnace

Definition of induction furnace: Metal-melting furnace in which alternating current flowing through a primary-coil generates induced current in a secondary-coil and consequently develops high temperatures in the scrap metal (charge)...

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Development of Scrap Charge Maximization Program Capable ...

Development of Scrap Charge Maximization Program Capable for Melt ... the cupola furnace, induction furnaces, and electric arc furnaces. A crucible furnace is a melting unit that uses a refractory crucible which contains the metal ... chemistry in real time and prevent production time lag leading to material and energy wastage [7].

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How To Make Preheating Scrap In Bucket

Preheating Technology Can Save Energy In The. Conventional scrap bucket charge preheating system conventional scrap preheating involves the use of hot gases to heat scrap in the bucket prior to charging it into the furnace.The source of the hot gases can be either off- gases from the electric induction furnace or gases produced by burning natural gas as shown in figure 3.

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INVESTIGATION OF THE ELECTRICAL INDUCTION FURNACE

The charge is introduced into the furnace and the melting of the aluminium scrap is done by the induction process, melting of aluminium takes nearly 7500C and it is held at that temperature for some more time for uniform melting. Once this is completed the melt can be poured. 3.4 POURING

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Induction Furnace Scrap Melting

Induction furnaces are an upgraded version of the electro furnaces and are specifically designed for the melting of precious metals, base metals and scrap metals. Not only do induction furnaces prove to be efficient in the melting of scrap, but they are also capable of processing two items at a time, making the whole scrap melting process much easier.

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(PDF) Induction Furnace -A Review - ResearchGate

1) Raw Material: Induction Furnaces are using Steel melting scrap, Sponge Iron Pig Iron/Cast Irons. On an average the ratio of these items is 40% sponge Ir on + 10% Cast Irons or Pi g Iron. The ...

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GOOD PRACTICE GUIDE - lists.man.lodz.pl

Table 2 Effect of rusty scrap charge on energy consumption 16 Table 3 The effect of inadequate raw material control on iron castings quality 18 Table 4 Effectiveness of furnace lids on radiated heat losses 19 Table 5 Effect of lining performance 28 Table 6 Energy consumption in coreless induction furnaces

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Scrap Charger For Induction Furnace -

Furnace Charger is a device which help to charge an induction furnace with heavy-scrap or sponge iron, in a safe and effective manner. Read more wet charge in an induction -

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Energy Conservation in Foundry Industry by Modeling and ...

are cupola furnace, rotary furnace and induction furnace. Among these, induction furnace consumes huge power for melting scrap, steel and holding the metal and it is done at high temperature ranging from 1500°C to 1560°C depending upon the casting produced. The amount of energy consumed for melting one ton of metal is in the

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scrap charging in induction furnace

induction furnace — noun : an electric furnace heated by a current which is caused to flow through the charge by electromagnetic induction compare arc furnace * * * Metall. a type of electric furnace used for melting a charge of scrap by the heat produced by its own . Read more.

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Megatherm

Charge Yield: Average Energy Consumption at 1630°C tapping temperature: Daily Production for 10MW: Processed Scrap (96% yiel: 520 to 530 kWh/t (example: many plants in West zone, Punjab, Himachal: 395 to 405 Tons: DRI Scrap(89% yield: 600 to 610 kWh/t (example: Hyderabad: 345 to 355 Tons: Pellet, DRI, Scrap, Pig Iron (84% yield) 670 to 680 kWh/t (example: many plants

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Energy Conservation in Foundry Industry by Modeling and ...

are cupola furnace, rotary furnace and induction furnace. Among these, induction furnace consumes huge power for melting scrap, steel and holding the metal and it is done at high temperature ranging from 1500°C to 1560°C depending upon the casting produced. The amount of energy consumed for melting one ton of metal is in the

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Development of Scrap Charge Maximization Program Capable ...

Some of the more commonly used foundry melting furnaces include: crucible furnaces, the cupola furnace, induction furnaces, and electric arc furnaces. A crucible furnace is a melting unit that uses a refractory crucible which contains the metal charge. The charge is heated via conduction of heat through the walls of the crucible.

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Mathematical Model for Optimizing Charge and Heel Levels ...

The induction furnace arrangement behaves likes a transformer. The work coil is likened to the primary winding while the charge serves as secondary winding [5]. 1.2.2. The Heat (H s) needed to melts solid scrap of mass m s in Kg and raise the melt temperature from ambient temperature to a superheat temperature θs in oC.

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(PDF) Design Analysis of an Electric Induction

This paper explains modeling and control of temperature dynamics on induction furnace. Induction furnace is used for melting metal to process raw material scrap into steel ferrit rate 0.22 wt ...

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Megatherm

Charge Yield: Average Energy Consumption at 1630°C tapping temperature: Daily Production for 10MW: Processed Scrap (96% yiel: 520 to 530 kWh/t (example: many plants in West zone, Punjab, Himachal: 395 to 405 Tons: DRI Scrap(89% yield: 600 to 610 kWh/t (example: Hyderabad: 345 to 355 Tons: Pellet, DRI, Scrap, Pig Iron (84% yield) 670 to 680 kWh/t (example: many plants

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Control of Slag and Insoluble Buildup in Ladles, Melting ...

Coreless Induction Furnaces: The coreless induction furnace is a refractory-lined vessel with electrical current carrying coils that surround the refractory crucible. A metallic charge consisting of scrap, pig iron and ferroalloys are typically melted in such a vessel. Electrical current in the coil forms a

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Coreless Induction Furnaces and Metal Bath

14-11-2018  Coreless induction furnaces are commonly used in foundries for melting recycled scrap metal to provide molten metal for making castings (Figure 1). In a coreless induction furnace, electromagnetic stirring of the molten metal bath occurs when power is applied to the furnace.

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Air Pollution Control Device - Air Pollution

The energy required for the melting process is provided by electrical induction furnace. The feeding of raw material in the induction furnace is on intermittent basis. As one charge of scrap melts, slag is removed from the molten metal and certain alloys are added to achieve the desired grade of steel.

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The Gap Narrows Between Induction and EAF

However, lately induction furnaces in the U.S. are seeing an increase in use mainly for energy and environmental reasons, as well as to increase capacity. 3. Pollution control , Estimates are that the steel industry spent more than $7 billion for environmental control over three decades to adhere to national standards requirements.

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Furnaces for production of secondary aluminum –

Crucible induction furnace Crucible induction furnace can be operated with a pure scrap, ingots or molten aluminum. Due to limitations in size induction furnaces have a maximum capacity 8-10 tonnes, that may be insufficient for large-scale production of secondary aluminum.

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Energy Conservation in Foundry Industry by Modeling and ...

are cupola furnace, rotary furnace and induction furnace. Among these, induction furnace consumes huge power for melting scrap, steel and holding the metal and it is done at high temperature ranging from 1500°C to 1560°C depending upon the casting produced. The amount of energy consumed for melting one ton of metal is in the

More

(PDF) Design Analysis of an Electric Induction

This paper explains modeling and control of temperature dynamics on induction furnace. Induction furnace is used for melting metal to process raw material scrap into steel ferrit rate 0.22 wt ...

More

Megatherm

Charge Yield: Average Energy Consumption at 1630°C tapping temperature: Daily Production for 10MW: Processed Scrap (96% yiel: 520 to 530 kWh/t (example: many plants in West zone, Punjab, Himachal: 395 to 405 Tons: DRI Scrap(89% yield: 600 to 610 kWh/t (example: Hyderabad: 345 to 355 Tons: Pellet, DRI, Scrap, Pig Iron (84% yield) 670 to 680 kWh/t (example: many plants

More

Control of Slag and Insoluble Buildup in Ladles, Melting ...

Coreless Induction Furnaces: The coreless induction furnace is a refractory-lined vessel with electrical current carrying coils that surround the refractory crucible. A metallic charge consisting of scrap, pig iron and ferroalloys are typically melted in such a vessel. Electrical current in the coil forms a

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Melting behaviour of sponge iron in - EPrints

It is one of the alternative charge materials to scrap in induction furnaces. National Metallurgical Laboratory has made an attempt to melt sponge iron in induction furnaces and optimize its melting behavour. It is possible to use continuous charging arrangements for melting of l(X)% sponge iron in induction furnace.

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Coreless Induction Furnaces and Metal Bath

14-11-2018  Coreless induction furnaces are commonly used in foundries for melting recycled scrap metal to provide molten metal for making castings (Figure 1). In a coreless induction furnace, electromagnetic stirring of the molten metal bath occurs when power is applied to the furnace.

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Blog: The future of global scrap availability

Hi Oleg - many thanks for your comment. Allegedly induction furnaces consumed about 70 Mt of scrap in China in 2016. And reportedly average scrap charge increased in both steel production routes in China, reflecting the increased availability after the closure of induction furnaces in 2017. BB CIFTCI May 16, 2018, 9:25:39 AM Reply

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Note:Meltingtechniquesintheironfoundry

but lessthan for coreless induction furnaces. Carburization ofthe melt can be achieved by the charging ofelectrode scraporcarbon granules, orbyinjection ofgraphite into the melt bymeans ofadispenser. Coreless Induction Furnaces Induction furnaces ofthe crucible type can be divided into three categories: those operating onmains frequency at50Hz,those operating

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Air Pollution Control Device - Air Pollution

The energy required for the melting process is provided by electrical induction furnace. The feeding of raw material in the induction furnace is on intermittent basis. As one charge of scrap melts, slag is removed from the molten metal and certain alloys are added to achieve the desired grade of steel.

More

The Gap Narrows Between Induction and EAF

However, induction furnaces require smaller, cleaner, scrap, both of which are more expensive, and while induction furnaces are more efficient and cost-effective in the long-run, there is significant initial cost to convert from an EAF to an IF.

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