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Agenda
Energy balance for melting iron
Energy balance of a state of the art Induction melting system
State of the are melting system ABP
Energy balance of a melting system
Energy effective melt process
Integration of the melt operation into the total process
Automatic pouring system АВР
Pouring via OptiPour®
Energy - Benchmark
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Energy balance for melting iron
Enthalpy for melting 1to of iron at 1.500 °C: 396 kWh/t
0
200
400
600
800
1.000
1.200
Cupolafurnace - cold
wind
Cupolafurnace - hot
wind
Ind. furnaceLF
Ind. furnaceMF
Rotaryfurnace
Additions
Material losses
Gas / oel
electrical Engergy
Koke
kWh/t
Source University of Hannover
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100
200
300
400
500
600
Cupola furnace- cold wind
Cupola furnace- hot wind
Ind. FurnaceLF
Ind. furnaceMF
Rotary furnace
Energy balance for melting iron
Specific CO2 Emission for melting of one ton iron
Including the emission of power plans with today's energy mix
gr/t
Source University of Hannover
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Agenda
Energy balance for melting iron
Energy balance of a state of the art Induction melting system
State of the are melting system ABP
Energy balance of a melting system
Energy effective melt process
Integration of the melt operation into the total process
Automatic pouring system АВР
Pouring via OptiPour®
Energy - Benchmark
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Parts of a MF induction furnace system
Mechanic: Furnace body, lining material
hydraulic and tilting frame
Electric: Transformer, Converter
Capacitor bank, high current connection, Coil
Control systems: Weighing system, Process-
Control
Auxiliary equipment: Cooling system, charging
system, exhaust system
tons
-
-
~
~
Transformer
MF-Converter
Capacitor bank
Cruciblefurnace
Cooling system electrics
Cooling system furnace
Melt processorWeighing system
Charging systemExhaust hood
Circuit breaker
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Latest ABP melting furnaces
Furnace capacity 0,3 … 0,8 t 1 t … 6 t 8 t … 65 t 30 t … 70 t
Type Smart FS FS IFM LFS
Power supply IGBT MF Thyristor Converter
Single Power
Twin PowerSingle Power
Twin Power
250 kW – 500 kW
750 kW – 3.500 kW
810 kW – 42.000 kW
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Comparison between LF and MF
MF LF
Energy consumption 520 - 580 kWh/t 570 – 700 kWh/t
Power density 600 - 1000 kW/t 150 – 300 kW/t
Melt rates 300 % 100 %
Melt conditions Batch type Heel
Flexibility High Low
Changing of alloy Good Bad
Lining live per molten t High Low
5 т12 т
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Comparison between LF and MF
MF LF
Melting of chips Low heel High heel
Material density in the furnace
High Low
Maintainance Low, no mechanical wear
High, mechanical switches
12 т5 т
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Energy balance of a state of the art induction melting system
State of the art technology Efficiency:
80% …75 %
Development tasks Reduction of coil losses New lining material Reduction of power supply
losses Reduction of transformer losses
Aim: Reduction of installation losses
of 60…90 kWh/t Increasing of efficiency to 87%…
81 %
8 kWh/t losses transformer
17 kWh/t losses converter
5 kWh/t losses capacitor bank
89 kWh/t electrical losses coil
9 kWh/t thermo losses
517 kWh/t
500 kWh/t
495 kWh/t
405 kWh/t
Energy consumption mains side 525 kWh/t
396 kWh/t Enthalpy at 1.500 °C
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Energy efficient induction furnaces – Coil losses
Coil losses are app. 70 % of the total installation losses New lining material that covers higher
induction power New coil design New coil material
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Energy efficient induction furnaces – converter losses
Today‘s converter losses 3….4 % of the installed power
New generation of power electronic components (IGBT, IGCT) Improved control systems
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ABP power supply: IGBT technology
IGBT = Insulated Gate Bipolar Transistor Technical features of IGBTs:
Rapid switching low on- and off switching losses low conducting losses
Rectifier, filter circuit and inverter in a single module with 250 kW or 750 kW, next generation up to 1.500 kW
Power range: 250 kW – 3.000 kW Future up to 6.000 kW
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Benefits of IGBT converters
Modular structure using standardized components quick and easy maintenance possible
No de-ionizer water required No elements on potential are in direct contact with the cooling water Single cooling circuit for the converter and the furnace
Cos φ always as good as > 0,95
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500 kW converter layout
Control unitIGBT modulesCoupling chokeCapacitors
Compact Layout for an easy integration into an existing plant
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Agenda
Energy balance for melting iron
Energy balance of a state of the art Induction melting system
State of the are melting system ABP
Energy balance of a melting system
Energy effective melt process
Integration of the melt operation into the total process
Automatic pouring system АВР
Pouring via OptiPour®
Energy - Benchmark
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Energy (in) efficient Melt process
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Energy efficient Melt (foundry) process
2,0t
1,5t
Charge preparation Charging Melting Preparation of the melt Furnace emptying Metal transport Pouring process
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Energy efficient Melt process – Charge preparation
Big or small charge material
The right mix influences the melt time up to 10 min and more
additional >100 kWh/t
shot blasting of returns
If returns are not shot blasted they consist a lot of sand
About 10 % of the returns is sand, that are supplied to the furnace
The molten sand creates additional slag
Example: 10 t scrap with 5 t returns and 10 % sand
25 kWh/t additional for melting of the sand
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Energy efficient Melt process – Charging
Charging when requested
Avoiding bridges!
Process control with melt processors avoids interruptions
Influence of 2 – 4 min interruption
Additional 25…50 kWh/t
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Energy efficient Melt process – Melting
Using the melt processor to get optimal power to the material
Always if possible:
Close cover!
An open cover adds (12 t furnace)
600 kW heat losses
5 min with open cover
50 kWh additional losses
Exhaust volume has to be reduced at closed cover
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Energy efficient Melt process – Preparation of the melt
Time is money!
If possible,use auxiliary equipment
e.g. Slag grapper
Online connection between spectrometer and melt processor
Melt processor calculates automatically the amount of additions
Always if possible:
Close cover!
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Energy efficient Melt process – Preparation of the Melt
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Energy efficient Melt process – Empting of the furnace
Optimize the ladle size to minimize heat losses
No fire work at the furnace during empting!
Optimize the transport ladle (size)
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Energy efficient Melt process – Empting of the furnace
Environmental empting of furnace
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Energy efficient Melt process – Results
State of the arte technology
Inefficient melt process
Charge preparation 10 kWh/t 25 kWh/t
Charging 10 kWh/t 30 kWh/t
Melting 15 kWh/t 70 kWh/t
Preparation of the melt 10 kWh/t 50 kWh/t
Empting of the furnace 5 kWh/t 15 kWh/t
Additional process losses 50 kWh/t 190 kWh/t
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Agenda
Energy balance for melting iron
Energy balance of a state of the art Induction melting system
State of the are melting system ABP
Energy balance of a melting system
Energy effective melt process
Integration of the melt operation into the total process
Automatic pouring system АВР
Pouring via OptiPour®
Energy - Benchmark
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Integration of the melt operation into the total foundry process
Tandem melting plant with variable power distribution
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Pouring with OptiPour®
Regulated pouring
Aim: level of liquid metal in the cup constant during whole pouring time
Changing of pouring conditions in the cup mainly based on opposite pressure inside of the cup should be reproducible from cup to cup
No big differences for stopper, nozzle and level of liquid bath
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Pouring with OptiPour®
Different systems for automatic pouring
OptiPour® - L (with laser) High speed molding lines with extreme small
cup diameter and measure nose for the laser
OptiPour® - C (with camera) Flask lines with big cup diameters
OptiPour® - LL (with Line-Laser) High speed molding lines with extreme small
cup diameter
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Agenda
Energy bilanz for melting iron
Energy balance of a state of the art Induction melting system
State of the are melting system ABP
Energy balance of a melting system
Energy effective melt process
Integration of the melt operation into the total process
Automatic pouring system АВР
Pouring via OptiPour®
Energy - Benchmark
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Energy – Benchmark, foundries
0
200
400
600
800
1.000
1.200
State of the art Future destroyer
kWh/t
Melting - Pouring
Process
Equipment
Specific Enthalpie
Old fashioned
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Thank you for your attention…
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Contact:
ABP Induction Systems GmbHKanalstraße 2544147 Dortmund
Jürgen Himmelmann Phone.: 02 31 / 997 – 28 88
Fax: 02 31 / 997 – 24 67Mail: [email protected]