Coreless Induction Furnace

Overview

Coreless induction furnace is used for steel melting in varied casting factories. The steel refers to constructional steel and high-alloy specialty steel.

It uses the medium frequency induction melting technology. The metal is melting in crucible of steel shell induction. The molten metal is transferred to casting production line by ladle.

Coreless induction furnace main parts

Coreless induction steel furnace body

The steel shell furnace body includes the furnace shell, induction coils, yoke, water-cooled cable, furnace cover, hydraulic system, Remote console,instruments, etc.

power supply Cabinet

The power supply cabinet includes rectifier module, inverter module, thyristors, copper busbars, Inverter capacitors, Digital control board, water-cooled cable,and a plc control system.

2 cooling towers

A cooling tower is used for cooling the furnace body. A cooling tower is used for power cooling. The cooling tower consists of the main tower body, heat exchanger, spray water pump, circulating water pump, fan and water collector, water collection trough and control system.

Transfer ladle

The medium-frequency furnace tilts out the moltrn steel directly into transfer ladle.

Our Service Processes

Our service hotline:0086-18710881451. email:alicezhang@xaabfurnace.com

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specifications of medium frequency furnace

Rated capacity ( Ton )	Rated power (kw)
0.5 ton	500
1 ton	500
1 ton Induction Melting Furnace	1000
1.5 ton	1000
2 ton	1250
2 ton	1500
2 ton	2000
3 ton	2000
3 ton	2500
5 ton Medium frequency induction furnace	2500
5 ton	3000
5 ton	3500
8 ton	5000
8 ton	6000
10 ton	6000
10 ton	8000
12 ton	8000
15 ton	10000
20 ton	12000
20 Tons-30 Tons	/
40 Tons-60 Tons	/

 

specifications of 0.5 tons induction melting furnace

Model	0.5 tons induction melting furnace
Rated capacity (t)	0.5
Rated power (kw)	500
Rated frequency (hz)	1000
Rated operating voltage (v)	750/2400
Input voltage (v)	3-phase 380 V
Melting temperature (for steel)	1550℃
Melting rate (for steel)	0.8
Power consumption  (kWh/t)	600
Transformer capacity (kva)	600

1. Coreless induction furnace transfer heat directly to the melting material without overheating, resulting in minimal burn-off loss of raw material and alloying element.

2. Electromagnetic stirring ensures uniformity in chemical composition and temperature. The process is highly effective for incorporating lightweight materials, such as chips, stampings, shredded scrap, and sponge iron. The suitable charge type makes materials into the molten metal, which creating optimal heat transfer condition.

3. When the induction furnace is powered by a frequency converter, it increases power gradually over time, preventing arcing and avoiding grid disturbances caused by inrush current. Harmonic interference to the power grid is minimal. Due to the reduced load on the grid, the furnace can be powered by diesel or gas generator.

4. Induction furnace need high standard refractory lining. Key requirements include the ability to withstand operating temperatures exceeding 1750°C, favorable thermal cycling characteristics, and resistance to penetration.

 

power supply Cabinet parts

 

rectifier SCR

inverter SCR

main control board

Customer Application Requirement: Annual production of 300,000 tons for a steel plant, and steel billets for construction industry.

Process includes Induction Melting System, Ladle Furnace, and Continuous Caster.

(1) The material is scrap with low cast iron for charge.

(2) The melting system includes 3 coreless induction furnaces, each with a capacity of 23 tons. Two furnaces operate in melting mode to produce 46 tons molten steel, and the third furnace remains on standby.

The two furnaces in operating status can melt 46-ton batch steel within a 65-minute cycle. The molten steel is then processed in a ladle furnace and the it is being transferred to the continuous casting plant.

(3) The refractory lining has a service life of 70–100 heats. The new lining requires ramming and sintering process.

equipment operation site

 

Coreless induction furnace installation site

induction furnace mouth charging 

tilting the induction furnace for tapping

Induction Melting System Data for producing billets for a Steel plant

Annual billets production	300,000 tons per year
Annual operating days	310 days per year
Raw material production	95 %
Molten steel	310,000 tons
Molten steel for a day	1,000 tons per day
Time of each material feeding	65 minutes

The requirements for producing kinds of steel in induction furnaces are different.

When melting structural steel, the process is carried out in an induction furnace based on the required chemical composition. The molten steel is typically sent directly to the continuous casting plant without further treatment. However, in most cases, the quality requirements for scrap metal necessitate the use of an intermediate ladle furnace. This unit desulfurizes and deoxidizes the molten steel, adjusts its composition and temperature, and purifies it via argon purging, preparing it for casting. Dephosphorization and decarburization are separate tasks performed during the melting stage in an electric arc furnace through oxygen blowing.

Alloy Steel Production includes Coreless induction furnace, Coreless induction furnace, AOD steelmaking furnace, and Continuous casting machine.

In alloy steel production process, the induction melting furnaces work together with the AOD converter furnace to supply molten metal to the continuous caster. Compared to electric arc furnace, the ferrite yield is higher. Advantages: The pre-melted metal has a high carbon content. This makes the tapping temperature to be reduced by 100°C, resulting in a longer service life for refractory material, and lower energy consumption.

Stainless steel is melted using induction furnace. The whole system includes 3 30-ton coreless induction furnaces, each with a power of 18 MW. Two of the 30-ton furnaces work in melting mode. It can produce 50-ton molten metal every hou. And the the molten steel is treated in an AOD converter furnace for continuous casting. The third furnace is for exchanging refractory relining and sintering. Adopting an induction melting system instead of an electric arc furnace is a wise choice, as it offers a higher yield from the input materials.

1. Can coreless induction furnace produce construction rebar, construction billets, structural steel, and alloy steel?

Induction furnace can produce construction rebar, construction billets, structural steel, and alloy steel.

2. Can induction furnace melt scrap with low cast iron content?

Induction furnace can melt scrap with low cast iron content.

3. What is the service life of the refractory material?

The service life of the refractory material is 70–100 heats.

4. Are the desulfurization and deoxidation processes for molten steel carried out in a ladle furnace?

The desulfurization and deoxidation processes for molten steel are carried out in a ladle furnace.

5. Are the dephosphorization and decarburization processes for molten steel carried out in an electric arc furnace?

Dephosphorization and decarburization of molten steel are carried out in an electric arc furnace.

5. What equipment makes up the alloy steel production line?

The alloy steel production line consists of a coreless induction furnace, an AOD furnace, and a continuous casting machine.

 

Our Certificates

Patent Certificate for A Coil Structure

Patent Certificate for A Ceramic-Insulated Support Frame for Medium-Frequency Coils

Patent Certificate for A Protection Device for Inductors in Series-Connected Power Supplies for Medium-Frequency Induction Furnaces

Patent Certificate for A Control System for Medium-Frequency Induction Furnaces

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