Furnaces induction

Induction furnaces utilize the phenomena of electromagnetic induction to produce an electric current in the load or workpiece. This current is a result of a varying magnetic field created by an alternating current in a cod that typically surrounds the workpiece. Power to heat the load results from the passage of the electric current through the resistance of the load. Physical contact between the electric system and the material to be heated is not essential and is usually avoided. Nonconducting materials cannot be heated directiy by induction fields. 

Utdity power distribution grids normally operate at a fixed frequency of 50 or 60 Hz. These frequencies can be utilized directiy for the induction process if the load characteristics are appropriate. If they are not, specific appHcations can be optimized by the use of variable and higher frequencies produced by soHd-state frequency power converters connected between the supply and the load. 

P = power input P = electrical loss P = induced power and P = thermal loss. 

Kirk-Othmer Encyclopedia of Chemical Technology (4th Edition) 

Power Supplies and Controls. Induction heating furnace loads rarely can be connected directiy to the user s electric power distribution system. If the load is to operate at the supply frequency, a transformer is used to provide the proper load voltage as weU as isolation from the supply system. Adjustment of the load voltage can be achieved by means of a tapped transformer or by use of a solid-state switch. The low power factor of an induction load can be corrected by installing a capacitor bank in the primary or secondary circuit. 

Some induction heating furnaces must operate at frequencies higher than the supply frequency. Formedy, rotating motor alternator frequency converters were used. Now the availability of high speed, high power silicon controlled rectifiers for use in frequency converters has made rotary converters obsolete. Modem units operate at higher efficiency, cost less, require less factory space, and coordinate readily with process controls (2). 

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These are called high temperature induction furnace methods which differ only as to the kind of furnace used and employ the same ASTM procedure. The sample is heated to over 1300°C in an oxygen stream and transformed to SO2 which is analyzed with an infra-red detector. 

Total sulfur NF M 07-025 ASTM D 1552 Combustion at high temperature (induction furnace) and analysis... 

Induced anisotropy Induction Induction furnaces Induction heating Induction melting... 

Fig. 1. Main types of electric furnaces (a) resistance furnace, indirect heat (resistor furnace) (b) resistance furnace, direct heat (c) arc furnace (d) induction furnace. A, charge to be heated or melted B, refractory furnace lining C, electric power supply D, resistors E, electrodes F, electric arc G,...

The efficiency of an induction furnace installation is determined by the ratio of the load usehil power, P, to the input power P, drawn from the utihty. Losses that must be considered include those in the power converter (transformer, capacitors, frequency converter, etc), transmission lines, cod electrical losses, and thermal loss from the furnace. Figure 1 illustrates the relationships for an induction furnace operating at a constant load temperature with variable input power. Thermal losses are constant, cod losses are a constant percentage of the cod input power, and the usehd out power varies linearly once the fixed losses are satisfied. 

Fig. 1. Induction furnace efficiency. Typical characteristics of a 1000 kW furnace. Example = 15% of P and = 100 kW. P = useful power ...

Fig. 8. Small coreless-induction furnace, 500-kg high, frequency furnace with insulating board housing and cmcible.

Frequency Selection. When estabhshing the specifications for a coreless induction furnace, the material to be melted, the quantity of metal to be poured for each batch, and the quantity to be produced per hour must be considered simultaneously. Graphs have been developed that combine these factors with practical experience to indicate possible solutions for a specific requirement. 

The term channel induction furnace is appHed to those in which the energy for the process is produced in a channel of molten metal that forms the secondary circuit of an iron core transformer. The primary circuit consists of a copper cod which also encircles the core. This arrangement is quite similar to that used in a utdity transformer. Metal is heated within the loop by the passage of electric current and circulates to the hearth above to overcome the thermal losses of the furnace and provide power to melt additional metal as it is added. Figure 9 illustrates the simplest configuration of a single-channel induction melting furnace. Multiple inductors are also used for appHcations where additional power is required or increased rehabdity is necessary for continuous operation (11). 

Hearth. The hearth of a channel induction furnace must be designed to satisfy restraints that are imposed by the operating inductor, ie, the inductor channels must be full of metal when power is required, and it is also necessary to provide a sufficient level of metal above the channels to overcome the inward electromagnetic pressure on the metal in the channel when power is appHed. Once these requirements are satisfied, the hearth can then be tailored to the specific appHcation (13). Sizes range from stationary furnaces hoi ding a few hundred kilograms of aluminum to rotating dmm furnaces with a useful capacity of 1500 t of Hquid iron. 

HBI has been successfully melted in cupolas (hot or cold blast), induction furnaces (coreless or channel), and electric arc furnaces. It can be a valuable charge material for ductile and malleable irons as well as steel. It is of particular value in making ductile iron castings because of its very low residual element content. 

Induction Furnace. The high frequency coreless induction furnace is used in the production of complex, high quaUty alloys such as tool steels. It is used also for remelting scrap from fine steels produced in arc furnaces, for melting chrome—nickel alloys and high manganese scrap, and more recentiy for vacuum steelmaking processes. 

The induction furnace was first patented in Italy in 1877 as a low frequency furnace. It was first commercially appHed, installed, and operated in Sweden. The first installation in the United States was made in 1914 by the American Iron and Steel Company in Lebanon, Pennsylvania however, it was not successhil. Other low frequency furnaces have been operated successhiUy, especially for stainless steel. 

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