Scrap Melting Induction Furnace

Scrap melting induction furnace: Higher electrical efficiency. Because the resistance of lump charge is relatively high, and the current penetrates deeper in the ferromagnetic state, the electrical efficiency during the charging stage is about 7.5% higher than that of residual-liquid melting operation. In the residual-liquid method, electrical energy is transferred into the molten iron through induction throughout the entire melting cycle.

Improved lining life of Scrap melting induction furnace. During the entire melting time, except for the superheating stage, the temperature inside the furnace remains below the melting temperature, and therefore is lower than that in the residual-liquid melting method. The temperature shock caused by charging cold material into a hot furnace is kept within an acceptable range by rapidly raising the cold charge to a red-hot state through restarting power.

Ideal crystal nucleus state. Due to the relatively low temperature during the melting process mentioned above and the one-time rapid temperature rise before tapping, the vast majority of crystal nuclei present in the molten iron are well preserved. Scrap melting induction furnace has a very favorable effect on the solidification process after the molten iron enters the mold.

The example of Scrap melting induction furnace illustrates the energy savings brought about by the better electrical efficiency and thermal efficiency of medium-frequency electric furnaces. With an hourly melting rate of 8 t, a two-shift system, and an electric furnace equipped with a power of 4800 kW, the first is melted in an 18 t capacity mains-frequency furnace, and the second is melted in a 6 t capacity medium-frequency furnace. The table analysis results show that the medium-frequency furnace saves 1,974,000 kWh per year, or 64 kWh/t per ton of molten iron.

The materials melted in Scrap melting induction furnace include scrap steel, pig iron, small scrap castings, bar stock, and recycled material. Additives usually include silicon carbide, coke, ferrosilicon, and other ferroalloys such as ferromanganese and ferrochrome. Charging has a great influence on melting quality, and thus on the service characteristics of the castings. Therefore, residual water, oil, rust, as well as other harmful accompanying impurities and non-metallic surface layers in the material should be avoided as much as possible. The higher the density of the lump charge, the better, and the size should match the furnace specifications as closely as possible: the maximum edge length should be 0.5 to 0.7 times the inner diameter of the furnace.

Since a large part of the cost of producing molten iron is caused by the charged materials, it is natural to save costs by reducing the quality of the molten iron. This economic choice obviously reaches its limit, namely when the reject rate begins to rise due to gas bubbles, oxide inclusions, or unacceptable trace elements (which cannot be eliminated even after all targeted melting control measures have been taken).

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