energy efficient melt shop operation

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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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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


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 - 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 - 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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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 - 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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Contact:

ABP Induction Systems GmbHKanalstraße 2544147 Dortmund

Jürgen Himmelmann Phone.: 02 31 / 997 – 28 88

Fax: 02 31 / 997 – 24 67Mail: [email protected]

energy efficient melt shop operation

Business

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automatic pouring system