Using an induction melting furnace like this saves even more power!

The induction melting furnace is popular for users because of its simple operation, convenience, and speed. However, the high power consumption is indeed the root of the user's mind. Today, Xiaobian summarizes how the operation of the induction melting furnace can save you power through 15 years of industry experience .

1.Using high-voltage, high-capacity capacitors ( 16 sets of 3150KF / 2000V , Xin'anjiang), which can reduce reactive current by 60% , smelting can save 25 degrees ofelectricity per ton of steel , high-voltage induction furnace, voltage up to 5400V, can reduce reactive With a current of 60% , each ton of molten iron can save 120degrees of electricity . The furnace shell is made of ultra-large steel (heat-resistant steel), which is sturdy and durable, and is not easy to burn. The hydraulic tilting furnace system has great strength.

2. Reasonable ingredients 

We must first grasp the chemical composition of the various charge materials used. And carry out careful and reasonable batching calculation and use a reasonable mix of various charging materials, so that the main chemical composition in the molten steel meets the requirements, the content of harmful impurity elements is as small as possible, and does not exceed the standard, to avoid delaying the melting time due to adjusting the composition Disqualification causes scrap to be scrapped, increasing material and electricity consumption. For this reason, the charge must be properly classified according to the chemical composition, the content of impurities, and the size of the block, cutting large and long scrap steel, and conditions for light and thin materials to be packed, ensuring smooth feeding and reducing melting time. The block size of the charge should be adapted to the frequency of the power supply. The frequency of the power supply used in the induction electric furnace decreases with the increase of the capacity of the furnace. Therefore, large-capacity medium-frequency induction furnaces can use large pieces of charge, and small-capacity induction furnaces use small pieces of charge.

The distribution of the induced current in the polymetallic conductor is subject to the skin application. The induced current in the charge and molten steel obeys the skin in order to decrease sequentially from the surface to the center. The distance from the point where the current strength decreases to 36.8 % of the surface current strength to the conductor surface is called the current penetration depth. The induced current in the charge is mainly concentrated in the depth layer, and the heat to strengthen the hot material is mainly supplied from the surface layer. In order to obtain the same temperature across the entire cross section of the charge, as the heating time increases, the heat lost to the surrounding medium by the charge increases, and the heat rate decreases. If the penetration depth layer and the charge geometry are properly matched, the time required for heating is short and the heat rate is high.

Study showed that a cylindrical metal material, when the cylindrical diameter d and depth of penetration al △ L ratio is 35 the total rate.

3. Extend continuous smelting time  

The single power consumption has a lot to do with the smelting method. The working method of the furnace can be divided into three cases:

1) Continuous smelting: three continuous operations per day;

2) Intermittent smelting: two shifts or shifts per day. During the non-operation period, the molten iron in the furnace is insulated with heat insulation power;

3) Intermittent smelting: after the daily completion, the net output is obvious. When operating in the above three situations, continuous smelting has a low single energy consumption, followed by intermittent smelting, and intermittent smelting is high. therefore. Where possible, centralized and continuous smelting should be arranged as far as possible. Try to increase the number of secondary smelting furnaces, extend the continuous smelting time, and reduce power consumption. The total tonnage of molten iron that can be expected during the service life of the silicon lining is estimated according to the following empirical formula: N = K (G2L) 1/3    

In the formula: IV _ total tonnage of molten iron, T ; GL -furnace capacity, kg ;    

K —— constant; cold material melting times per day, K = l_3 ～l 8 ; cold material melting times per week ( operation 6 h7 h per day ) , K = 2 . 8 — 4 . 6 : 

Cold material melting times per week ( over 18 hours of daily operation ) . K = 6 . O9 . 0 ．

From the above formula, at the furnace capacity timing, N is proportional to K , that is, the longer the melting cycle of the cold furnace. The larger Ⅳ. The longer the furnace life. Per ton of molten iron melted material consumption, lower energy consumption . To 1 . For example, the intermittent smelting of a 5 t steel smelter, the smelting time is approximately 100 minutes . Thereafter smelting furnace about 80 MLN , cold smelting furnace used in the smelting furnace hotter more time 30 min , if this time with 60 % power for heating, corresponding to 100 % power 18min , then , when the secondary smelting 5 furnace, melting the total time about 422 MLR , multi-furnace cooling time accounts 18 / 422 = 4 . 2 % of the current 10 melting furnaces, the total melting time is about 722 minutes . The multi-use time of the cold furnace accounts for 18/722 = 2.4 %. Compared. The 10 times of the secondary smelting furnace is 18 % less than that of the 5 furnaces . That is, electricity can save 18 %. The continuous smelting furnace has many times and long time. In the production timing, the number of melting times of the cold furnace is small. Due to the low and high temperature, the chance of cracking on the furnace pair is less, which is also conducive to extending the life of the furnace lining. 

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