Types of Induction Furnace

The principle of induction melting is that a high voltage electrical supply from a primary induces a low voltage, high current within the metal, or secondary. heating is just a technique of transferring heat.

Induction furnaces square measure ideal for softening and alloying a large style of metals with minimum melt losses, however, very little purification of the metal is feasible.

There are two main types of induction furnace : 

1. Coreless 

2. Channel

Coreless Induction Furnaces : 

The heart of the coreless induction furnace is that the coil, that consists of a hollow section of significant duty, high physical phenomenon copper tube that is wound into a turbinate coil. Coil form is contained inside a steel shell and magnetic shielding is employed to forestall heating of the supporting shell. to safeguard it from warming, the coil is cool, the water bing recirculated and cooled during a cooling. The shell is supported on trunnions on that the furnace tils to facilitate running.

The vessel is created by ramming a granular refractory between the coil and a hollow internal former that is liquified away with the primary heat feat a mold lining.

The power cubmicle converts the voltage and frequency of main offer, ot that needed for electrical melting. Frequencies utilized in induction melting vary from fifty cycles per second (mains frequency) to ten,000 cycles per second (high frequency). the upper the operational frequency, the bigger the most quantity of power which will be applied to a chamber of given capability and also the lower the quantity of turbulence elicited.

When the charge material is liquified, the interaction of the magnetic flux and also the electrical currents flowing within the coil manufacture a stirring action inside the liquified metal. This stirring action forces the liquified metal to rise upwards within the centre inflicting the characteristic gristle on the surface of the metal. The degree of stirring action is influenced by the ability and frequency applied further because the size and form of the coil and also the density and viscousness of the liquified metal. The stirring action inside the tub is vital because it helps with combination of alloys and melting of turnings further as homogenising of temperature throughout the chamber. Excessive stirring will increase gas obtain, lining wear and oxidisation of alloys.

The coreless induction chamber has for the most part replaced the vessel chamber, particularly for melting of high temperature alloys. The coreless induction chamber is often wont to soften all grades of steels and irons further as several non-ferrous alloys. The chamber smart} for remelting and alloying attributable to the high degree of management over temperature and chemistry whereas the induction current provides good circulation of the soften.

Channel Induction Furnaces :

The channel induction chamber consists of a refractory lined steel shell that contains the liquified metal. connected to the steel shell and connected by a throat is an induction unit that forms the melting part of the chamber. The induction unit consists of AN iron core within the variety of a hoop around that a primary coil is wound. This assembly forms an easy electrical device within which the liquified metal loops includes the secondary part. the warmth generated inside the loop causes the metal to flow into into the most well of the chamber. The circulation of the liquified metal effects a helpful stirring action within the soften.

Channel induction furnaces square measure usually used for melting low temperature alloys and or as a holding and superheating unit for higher temperature alloys like forged iron. Channel induction furnaces are often used as holders for metal molten off peak in coreless induction induction units thereby reducing total melting prices by avoiding peak demand charges.

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Introduction to Modern concept of Steel Making through Induction Furnaces

l . Introduction

The different sorts of Induction Furnaces utilized for Steel making are medium frequency and high frequency. Gentle steel, Stainless Steel and low and high combination Steel can be produced using this furnaces. Crude materials utilized are Steel dissolving Scrap and Direct Reduced Iron. Alloying components included according to prerequisite.

2. Brief history of making steel by Induction Furnaces course

2.1 In India we began utilizing Mains Frequency Induction Furnaces from mid?sixties and medium frequency imported induction furnaces from mid-seventies however a sudden development occurred from mid eighties upto mid?nineties when indigenous production of Induction Furnaces initiated. At first we were utilizing them for using so as to dissolve and making Stainless steels imported stainless steel scrap yet economic situation from mid-eighties urged business people to make gentle steel. On the other hand, after liberalization there was extensive increment in the quantity of induction furnaces furthermore limit per charge. Presently a-days, furnaces upto a most extreme of 16-ton/charge are being utilized.

3. Current status of Induction Furnaces

3.1 Modernisation has been did by utilizing refining, hardware and in addition ceaseless casting of billets. To make great nature of gentle steel, refining by utilizing (LRF) scoop refining furnaces are being used and for production of stainless steel, AOD refining vessels are utilized. It is fitting to utilize family synthetic sythesis medium and substantial steel softening scrap. Preceding creation of Direct Reduced Iron (DRI), it was hard to control science of melt however now the innovation of utilizing DRI to modify science has been comprehended. Carbon would he be able to balanced according to particular and tramp components are controlled in light of the fact that DRI does not have tramp metals and components.

4. Why steel in India is produced using I.F. course ?

4.1 India is the first nation utilizing Induction Melting Furnaces for making mellow steel. In actuality, EAFs are not making mellow steel of basic quality for over 10 years now. The heft of basic quality mellow steel for long items is made by Induction Melting Furnaces. Amid 2001?2002 period more than 4.5 million tons of steel were created by Induction Furnaces. The EAF units have likewise introduced Induction Melting Furnaces. There are a few explanations behind the fame of Induction Melting Furnaces for making steel. They expend less power contrasting EAFs. Consumption on terminal is nil. They utilize lesser amount of stubborn. Introductory speculation is less on plant and hardware. Accordingly, there are financial points of interest in making steel through Induction Furnaces course. The main tangle is that at present mass amount steel can't be delivered through Induction Furnace course. May be that in future it might be conceivable to do as such.

5. Smaller than normal coordinated steel plant idea

5.1 another pattern of making steel in India is developing. This new innovation is utilizing Direct Reduced Iron (DRl) - Induction Melting Furnaces (vast limit) Continuous Casting of Billets or Rolling Mills to Make Billets and Bars, Fods and Sections.

5.2. At first M/s Essar Gujarat introduced DRI unit and utilized EAF (150 tons) to make steel for level items. Some all the more such steel plants have been introduced. Some unmistakable DRI makers have likewise introduced Induction Melting Furnaces to make gentle steel ingots or billets. Amid the last a few years numerous DRI making plants have been introduced in States like Chattisgarh (cut Out of Madhya Pradesh), Jharkhand (cut out of Bihar), Orissa and West Bengal differing from 20,000 tons upwards. These states are rich in Iron metal and coal. Amid DRI making from coal, waste gasses turning out are rich in carbon monoxide/dioxide, Methane?Ethane, and so on., and henceforth have parcel of calorific qualities to produce influence taking and by amount of influence from State Electricity Boards and utilizing its own particular created influence, DRI plants are introducing different limit Induction Furnaces. Some have likewise descending manufacturing units like concast or moving factories. Accordingly a kind of Mini Integrated Steel Plants are coming up. This innovation is quick getting to be well known and may alter our old and set up idea of making steel. The mellow steel delivered by such plants is modest and of good duality. Notwithstanding, much will rely on economies of generation and business sector strengths. Numerous, different advances are coming up which all have introduction to nearby conditions and assets accessibility. Induction Furnaces industry needs to confront numerous difficulties in this period of rising new innovations for making steel.

6. Different sorts of steel and cast iron creation by I.F.

6.1 Mild Steels: with a specific end goal to control science of finished item, compound investigation of all info metallic is taken before winding the charge-blend. After half charging is finished a shower test is
sent to research facility. The synthetic examination is analyzed, computations made tin further augmentations are made of info metallics. On the off chance that it has high carbon, Sulfur and phosphorous, rate Sponge iron in the charge is expanded. At the point when 80% softening is finished a last shower test is taken. In the event that carbon is still high a greater amount of wipe iron fines are charged in the event that carbon is less, cast iron scrap and turnings are charged. Along these lines, the science is controlled. Since no
overwhelming arcing like Electric Arc Furnace:; happens in Induction Melting Furnaces, the oxidation of iron a great deal less and misfortunes are likewise insignificant. Silicon a Manganese in metal are oxidized by FE2 O3 and FeO Carbon is lessened by iron oxide of DRI. Sulfur and phosphorous are weakened by DRI. There are no cable car components in the last item.

6.2 Low Alloy Steels :
6.2.1 At present Low composite steels are by and large frequently created by Induction Furnace Units in India. The incorporate EN18, EN19, EN8, EN9, and so on. Compound arrangement is entirely controlled by utilizing spectrometer. Size of ingots differs 3½ x 4½ to as much
6 ½" x 7½". So far none of the Induction Furnaces units have delivered these steels by concast prepare however some Induction Furnaces units are introducing spoon refining and concast gear to make concast billets.

6.3 Stainless Steels :
6.3.1 Induction Melting Furnaces before making Mild Steel ingots began creating Stainless Steel subsequent to 1979?80 period utilizing little size Induction Furnaces. The crude material was foreign made SS scrap and purging so as to cast ingots fluid metal in spoon, including alloying components and so on and softening mellow steel scrap and including ferro?allow and exchanging the fluid metal to AOD vessels for refining. After AOD treatment a few units do further refining in LRF and afterward creating billet by concast process. All units having scoop refining framework have introduced spectrometer for exact and faster shower investigation. Gas levels such N2H2 and O are additionally dictated by the recently introduced instruments. The greater part of the Induction Furnaces units are creating utensils grade SS. Two Induction Furnaces units making SS have sent out bars and wires. More butt-centric more Induction Furnace units are modernizing and also expanding to esteem included items.

6.4 Grinding Media :

6.4.1 Five Induction Furnace units are creating Grinding Media MnCr5, 20 MnCr5, and so forth situated at Ghaziabad. Jhansi, Ahmedabad and Bangalore. what's more, trading. It meets the quality prerequisites of world standard.

6.5 Special Cast Iron and S.G. Iron castings:
6.5.1 While numerous cast iron casting foundries have introduced mains frequency Induction Furnaces to make exceptional cast presses, some have introduced medium frequency Induction furnaces to make
S.G. iron. These foundries have compound testing, sand testing and physical testing gear alongside ultrasonic testing supplies. It is learnt that these Induction Furnace units have traded unique Cast iron and SG iron worth crores of rupees throughout the years.

7. Conclusion

7.1 Steel making procedure is tinder going extensive changes, New procedures are being created to utilize different sorts of Iron metals, coal and gas. Iron metal fines are utilized for making Pig Iron. These are produced by European Countries, In India National Mineral Development Corporation have a concurrence with Russia to receive Romalt process by utilizing fines of Iron metals. Ideally the generation will start without further ado. Jindal's have bought an innovation called Corex process. Steel has been delivered effectively by Jindal's. It is to be seen whether new procedures are econornicaly feasible contrasting with old frameworks i.e. Coke over, Blast furnaces, steel making by BOF converters' M/s Usha Martin organization are making pig iron in cupela and it is charged hot in Electric Arc Furnace to mak steel. Every one of these procedures trim to make less expensive steel and discussion of vitality. Duplexing and Tripplexing procedure is may get to be important to make steel in future.

About Stead Fast Engineers Pvt Ltd :

Established in 1990, Stead Fast Engineers Pvt Ltd is an engineering company engaged in designing and manufacturing of Induction Melting furnaces, Induction Billet Heaters and Refractory Lining Machines for Foundries, Steel Plants and Forging units. With the help of years of experience and a highly skilled team, we create products with attention to every minute detail thereby making the products both user friendly and economical.  http://www.steadfastengg.com/

MAGNETIC HEATING OF BILLETS

INTRODUCTION

In July 2008 the new innovation – magnetic billet heater – was put into business operation in Germany (German aluminum expulsion works Weserlau GmbH and Co. KG). The second framework has been requested by Italian backup of Sapa in Bolzano. The beginnings of this innovation can be found in 2004. Organizations Zenergy Power and Bültmann got financing from Germany's ecological financing organization DBU to add to another innovation for billet heating. The main model was appeared in April 2005 at the Hannover Fair. Further with the support from the DBU, the gadget was produced and put into administration at Wese

HISTORY AND ADVANTAGES OF MAGNETIC HEATING :

In July 2008 the new innovation – magnetic billet heater – was put into business operation in Germany (German aluminum expulsion works Weserlau GmbH and Co. KG). The second framework has been requested by Italian backup of Sapa in Bolzano. The beginnings of this innovation can be found in 2004. Organizations Zenergy Power and Bültmann got financing from Germany's ecological financing organization DBU to add to another innovation for billet heating. The main model was appeared in April 2005 at the Hannover Fair. Further with the support from the DBU, the gadget was produced and put into administration at Wese.

CONVENTIONAL INDUCTION HEATING (AC HEATING) :

Electrically conductive materials are today heated or dissolved in routine incitement heating gadgets. Billet is put inside copper curl. The curl is supplied by AC current and creates electromagnetic field that alters course in time. The field affects vortex currents in the workpiece (Faraday's law) what's more, vortex currents heat up the billet because of its electrical resistivity (Joule's law). In both parts of the gadget (inductor loop, workpiece) electrical misfortunes happens. The heating of the curl is the principle wellspring of vitality misfortunes in traditional AC incitement heating frameworks. Thus, loop must be cooled with water to keep from softening. The degree of the misfortunes relies on upon the proportion of the resistances of the loop and the billet. The proficiency of the framework is 50 – 60%. Traditional gadgets have a few impediments. Air conditioning heaters working with basic force network frequencies create whirlpool currents for the most part near to the surface of the workpiece – it delays the time of heating. AC induction heating further requires a medium voltage power supply and VAR compensation.

DC MAGNETIC HEATING :

Magnetic heater in Weserlau comprises of DC fueled superconductive magnetic curl cooled to low temperature. The loop produces an adequately solid magnetic field with a force information of 10W.

Magnetic field of a DC fueled curl is not fluctuating in time, the billet is pivoted inside of the field in request to affect vortex currents. Vortex currents work to contradict the revolution and make an in number braking  torque. This is overcome by mechanical electric engines of a size of 100 – 50 kW. Engines are supplied by standard recurrence converters (misfortunes 2-3% of the aggregate influence utilization of the heater). Cooling framework and power supply devour around 13 kW, the aggregate productivity (counting all misfortunes brought on by fringe specialized gadgets) is more prominent than 80%. The heating procedure is speedier, more homogeneous Furthermore, exactly controllable. The framework doesn't require expansive cooling establishments, complex vitality supply and VAR pay. The heater comprises of four fundamental parts – superconducting magnet, refridgerator, engine and heating chamber. The fundamental part is the superconducting magnet that is kept at its working temperature by the refridgeration framework. The billets pivot in two thermally protected heating chambers, the rotational vitality is given by electric engines on either side. The engines can slide in also, out to oblige diverse billet lengths. No segment in the heater is subjected to noteworthy temperature expand, vibrations or some other mechanical anxiety compone

MAGNETIC HEATING ADVANTAGES:

• Low frequencies
• Wide material range
• Temperature tapers
• Low maintenance requirements
• Reliabilit

Stead Fast Engineers provides world class induction heating and melting solutions for both ferrous and Non ferrous with a great focus on customization so that every machine is nothing less than perfect. With a family of more than 400 satisfied customers all over the country and abroad, Stead Fast Engineers is expanding at a rapid pace. With offices located in major cities we ensure that the service is quick and effective and breakdown time is negligible. Adopting stringent quality management systems during different stages of production - the pre-process, In-process and pre-dispatch stage we believe in manufacturing the best quality every time. http://www.steadfastengg.com/

INTRODUCTION AND PRINCIPLE OF INDUCTION FURNACE

The electric induction furnace is a kind of melting furnace that uses electric streams to liquefy metal. Induction furnace are perfect for liquefying and alloying a wide assortment of metals with least soften misfortunes, be that as it may, small refining of the metal is conceivable.
The principle of induction heating is mainly based on two phenomena:
1. Electromagnetic induction
2. The Joule effect

1) ELECTROMAGNETIC INDUCTION :
The transfer of energy to the object to be heated occurs by method of electromagnetic induction. ​Any electrically conductive material put in a variable attractive field is the site of induced electric current.

2) JOULE HEATING :
​Joule heating, also known as ohmic heating and resistive heating, is the process by which the passage of an electric current through a conductor releases heat. The heat produced is proportional to the square of the current multiplied by the electrical resistance of the wire. ​

Star Point : 
Induction heating depends on the one of a kind qualities of radio frequency (RF)energy that divide of the electromagnetic range underneath infrared and microwave energy. 
Since heat is exchanged to the item by means of electromagnetic waves, the part never 
comes into direct contact with any fire, the inductor itself does not get hot and there is no item tainting. Induction heating is a quick, clean, non-contaminating heating. 
The induction coil is cool to the touch; the heat that develops in the coil is always 
cooled with flowing water.

Stead Fast Engineers Pvt Ltd is an engineering company engaged in designing and manufacturing of Induction Melting furnaces, Induction Heater and Lining Machines for Foundries Steel Plants and Forging Plants. http://www.steadfastengg.com/