Technical basics and applications of induction furnaces

Prof. Dr.-Ing. Egbert Baake Institute of Electrotechnology Leibniz University of Hanover (Germany)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Outline
Introduction Fundamentals and application of the induction crucible furnace Fundamentals and application of the induction channel furnace Other industrial induction melting applications

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Industrial process requirements for melting in induction furnaces

Mixing and homogenisation of the entire melt Homogenisation of the temperature, avoiding of local overheating , but realizing of sufficient superheating of the entire melt Intensive stirring at the melt surface (melting of small-sized scrap, carburization process) Avoiding of erosion and clogging of the ceramic lining Avoiding of melt instabilities, splashing or pinching Intensive stirring for cleaning of the melt (zinc removing)
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Optimisation of the heat

and mass exchange in the melt

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Physical correlations in induction furnaces magnetic field meniscus shape

geometry of melt

- distribution of power - electromagn. forces

velocity field

homogenisation of melt

temperature field
- overheating - heat flow

skull formation
liquid-solid-interface

alloy composition
melt components

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Induction furnaces for melting

Induction crucible furnace Induction channel furnace

Used mainly for melting Medium high efficiency Operating frequency: 50 ... 1000 Hz

Used mainly for holding and pouring High efficiency Operating frequency: 50 Hz, 60 Hz
Source: RWE-Information Prozesstechnik

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Construction of induction crucible furnace

meniscus melt steelconstruction concrete-ring melt flow crucible induction coil magnetic yoke

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Meniscus shape and melt flow of the crucible induction furnace

Inductor current: J1

Electromagnetic force density:

F = J2 x B
Induced current density in the melt:J2

Melt flow pattern Magnetic field: B

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Example: Induction crucible furnace

Velocity v of the melt is proportional to the inductor current I: v ! I Height of meniscus is proportional to:

melt steelconstruction concrete-ring

meniscus melt flow crucible induction coil magnetic yoke

Velocity v of the melt is proportional to:

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Characteristics of turbulent flow in induction furnaces

local melt flow velocity in dependence on time
Vmax 20 cm/s

Shared in: 1. Time averaged flow velocity convective heat and mass transfer 2. Instationary fluctuations and oscillations turbulent heat and mass transfer

Spec. kinetic energy of turbulence:

k = (vx12 + vx22 + vx32)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

3D hydrodynamic model of an industrial induction crucible furnace

P = 4540 KW Hind = 1.33 m Rcr = 0.49 m Filling level 90 %

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Calculation of the melt flow velocity in the ICF: (3D transient LES)

symmetric state
Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

unsymmetric state

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Calculation of the melt flow velocity in the ICF: Melt surface (3D transient LES)

calculated time: 5 sec

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

calculated time: 40 sec

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Example of medium frequency induction crucible furnace: 12 t/9,3 MW/250 Hz

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

source: ABB Industrietechnik AG

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MF-ICF-melting installation with two furnaces: 12 t, 9,3 MW/250 Hz

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Source: ABB

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Induction crucible furnace installation for melting of grey cast iron

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Induction craucible furnace during pouring

Medium frequency-ICF Capacity: - 6 t grey cast iron Power: - 3300 kW/250 Hz

Prof. Dr.-Ing. Baake / Institute of Dortmund Electrotechnology, Leibniz University of Hannover Quelle: ABBE. Industrietechnik AG,

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Induction crucible furnace: capacity 8 t grey cast iron with charging vehicle

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz UniversitySource: of Hannover ABB Industrietechnik AG

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Back tilt position of an ICF for 8 t grey cast iron during slag cleaning process

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Source: ABB Industrietechnik AG

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Induction crucible furnace (ICF): Advantages in comparison with competitive processes

Homogenisation of the melt due to stirring of the melt Less oxidation losses (dross) because no local overheating High accurate alloying process Well defined melt temperature Simple automatic process control High quality of the melt even with cheap charge material (scrap) High throughput because fast melting and fast heating up of the melt High furnace efficiency Simple handling of the furnace and the process Well defined controlling of the power input Good working conditions for the workers at the furnace Environmental friendly (small dust emission, no exhaust gas)
Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Induction crucible furnaces melting material, capacities, power rates, frequencies

Material LFCast iron, steel furnaces: Light metal Heavy metal MFCast iron, steel furnaces: Light metal Heavy metal Capacities [t] 1,3 ... 100 0,5 ... 15 1,5 ... 40 0,25 ... 30 0,1 ... 8 0,3 ... 70 Power rates [MW] 0,5 ... 21 0,2 ... 4 0,5 ... 7 0,3 ... 16 0,2 ... 4 0,3 ... 16 Frequencies [Hz] 50 ... 60 50 ... 60 50 ... 60 150 ... 1000 90 ... 1000 65 ... 1000
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Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Charging of line-frequency induction crucible furnace

heal

starting blocks

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Energy supply of induction crucible furnaces

a) LF-Energy supply via switching transformer

b) MF-Energy supply via converter

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Energy flow diagramm of a MF induction crucible

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Parallel operation of two ICF

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Design of a melt processor control system

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Melt processor with operator

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Melt processor main menu

Operation modes: - sintern - starting with cold crucible - melting - overheating - holding - crucible wear detection

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Source: ABB Industrietechnik AG

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Induction channel furnace (one loop design)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Design of a single loop induction channel furnace

Channel inductor (ABP): - single loop - P = 250 kW - symmetrical channel

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Dopple loop induction channel furnace

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover Source: ABB Industrietechnik GmbH Dortmund

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Melting in the induction channel furnace

Homogenisation of the entire melt Sufficient overheating of the entire melt Avoiding of overheating of the melt in the channel Efficient heat and mass exchange between the channel and the furnace vessel is the key point

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Melt flow in a model single loop induction channel furnace (measurements)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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3D-Simulation model for electromagnetic calculation of the channel inductor (power density and electromagnetic force density)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Channel inductor: distribution of power density in the melt

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Channel inductor: distribution of electromagnetic force density

Parameters: P = 60 kW I = 850 A Melt: Wood-metal

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Channel inductor: distribution of elektromagnetic force density

Measured Melt flow distribution

Parameters: P = 60 kW I = 850 A
Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Line frequency induction channel furnace used for storing, holding and pouring of cast iron

Prof. Dr.-Ing. Baake / Institute of Electrotechnology, Leibniz University of Hannover Quelle: ABBE. Industrietechnik AG

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CIF used in non-ferrous metal industry (aluminium foundry)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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CIF used in non-ferrous metal industry (aluminium foundry)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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CIF installation used in non-ferrous metal industry (aluminium foundry)

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Source: ABB Industrietechnik AG

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Channel inductor for melting of copper and brass

power: 2400 kW frequency 50...70 Hz mass:15 t

Prof. Dr.-Ing. Baake / Institute of Electrotechnology, Leibniz University of Hannover Quelle: ABB E. Industrietechnik GmbH Dortmund

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Induction channel furnace melting material, capacities, power rates, frequencies

Melting materials Cast iron Aluminium, Al-alloys Copper, Co-alloys Zinc, Zinc-alloys

Capacities [t] 10 ... 135 5 ... 70 5 ... 160 10 ... 100

Power rates [MW] 0,1 ... 3 0,1 ... 6 0,5 ... 10 0,2 ... 10

Frequencies [Hz] 50 ... 60 50 ... 60 50 ... 60 50 ... 60

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Energy flow diagram of an induction channel furnace

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Comparison: induction crucible vs. induction channel furnace

Crucible furnace application Melting rate (power) Meltng process Furnace volume Lining live time Efficiency Operating frequencies melting, holding, all metal materials high (MF) heal, scrap pieces medium good sufficient 50 ... 1000 Hz Channel furnace Holding, melting, all metal materials medium Heal big vessel very good, Channel sufficient high 50 ... 60 Hz (60 ... 120 Hz)
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Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Design of a pressure controlled pouring installation with induction heating

1 pressure vessel with melt 2 channel inductor 3 input spout 4 output spout
Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

5 output valve 6 melt level controlling 7 main frame with rolls 8 casting mould
Source: RWE-Information Prozesstechnik

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Induction pouring installation 10 t, 500 kW

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Induction pouring installation Presspour, 2,5 t, 130 kW

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Holding processor for channel furnaces

Prof. Dr.-Ing. Baake / Institute of Electrotechnology, Leibniz University of Hannover Quelle: ABBE. Industrietechnik AG

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Practical problems: induction channel furnace

Clogging, erosion and infiltration of the ceramic lining of the channel inductor influenced by e.g.:

Heat transfer and temperature distribution in the channel and in the vessel

Mass transfer in the channel Type of alloy (purity) Type of ceramic lining and many others
Clogging and erosion of a channel inductor used for holding of grey cast iron
Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Holding processor for channel furnaces Inductor-diagram

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Crucible inductor furnace

Industrial furnace for casting of grey cast iron Industrial applications: holding and casting of grey cast iron melting and holding of non-ferrous metal reduction process in steel industry

Experimental furnace

Comparison with induction channel furnace: + flexible operation,energy saving, easier to clean due to complete emptying but: lower efficiency
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Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Features of the Induction Furnace with Cold Crucible

melt flow slit
(water cooled) (water cooled)

radiation

slitted crucible to realize efficient electromagnetic transparency free melt surface and intensive melt stirring, based on electromagnetic forces water cooled bottom and crucible segments leads to solid layer (skull) EM-forces
skull

crucible segment inductor

current

melt with meniscus shape bottom

(water cooled)

heat conduction

heat losses by radiation and conduction depending on the meniscus shape

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Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

Melting in the Induction Furnace with Cold Crucible

high reactive and high purity materials, e.g. TiAl melting, alloying, overheating and casting in one process no pre-alloys necessary, using of scrap material good homogenisation of the melt due to intensive electromagnetic stirring

Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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Cold crucible induction skull melting process

vacuum chamber crucible

inductor

High reactive and high purity materials, e.g. TiAl Melting, alloying, overheating and casting in one process
Prof. Dr.-Ing. E. Baake / Institute of Electrotechnology, Leibniz University of Hannover

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