ABP Induction Systems GmbHDortmund - Germany

Stoperikongress Hamar8. – 9. June

Energy efficiency using Induction Furnaces

Hamar,

09. June, 2010

Hermann-Josef Kroes

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Company history

� The name of АВР Induction Systems GmbHAsea Worldwide first manufacturer of induction furnaces

(1903)

� Brown Boveri The most successful manufacturer of big inductions furnaces systems worldwide

� Pillar Worldwide first manufacturer of MF converters

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ABP Induction systems worldwide

� 2007: 270 Employees

� 2008: 470 Employees

� 2010: 470 Employees

� 2011: 500 Employees

� Consisting of two divisions: Melting and heating

ABP InductionSouth Africa

ABP InductionCHINA

ABP InductionS. de R.L.MEXICO

ABP InductionSystemsRUSSIA

ABP Induction Ltd THAILAND

ABP Induction

Sistemas deFundicao Ltda

BRAZIL

ABP Induction

Systems GmbH

GERMANY

ABPInduction

Japan

ABP Induction LLC

USA

ABP Induction AB

SWEDEN

ABP Induction

Systems PtyINDIA

ABPInduction

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Agenda

� Energy balance for melting iron

� Energy balance of a state of the art Induction melting system

� State of the are melting system ABP

� Energy balance of a melting system

� Energy effective melt process

� Integration of the melt operation into the total process

� Automatic pouring system АВР

� Pouring via OptiPour®

� Energy - Benchmark

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Energy c for melting iron

� Enthalpy for melting 1 to of iron at 1.500 °C: 396 kWh/t

0

200

400

600

800

1.000

1.200

Cupola

furnace - cold

wind

Cupola

furnace - hot

wind

Ind. furnace

LF

Ind. furnace

MF

Rotary

furnace

Additions

Material losses

Gas / oel

electrical Engergy

Koke

kWh/t

Source University of Hannover

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Energy balance for melting iron

� Specific primary energy request for melting one ton iron

� Using induction furnaces conventional energy (oil, Coke) can be avoid (alternative

energy or atomic energy)

0

200

400

600

800

1.000

1.200

1.400

1.600

1.800

2.000

Cupola furnace

- cold wind

Cupola furnace

- hot wind

Ind. furnace

LF

Ind. furnace

MF

Rotary furnace

kWh/t

Source University of Hannover

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Energy balance for melting iron

� Reduktion of CO2 – Emission

� Development of the regenerated energy production of the total energy

request in Europe from 2007 to 2020 (2020: Tendency)

� The development of energy production „green energy“:

� Using induction furnaces, saving raw material

� Using induction furnaces, reduces CO2 – Emission

0%10%20%30%40%50%60%

Sweden Finnland Austria France Spain Germany Greece Italy Poland Great-

Britain

Netherland Malta

2007 2020

Source University of Hannover

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0

100

200

300

400

500

600

Cupola furnace

- cold wind

Cupola furnace

- hot wind

Ind. Furnace

LF

Ind. furnace

MF

Rotary furnace

Energy balance for melting iron

� Specific CO2 Emission for melting of one ton iron

� Including the emission of power plans with today's energy mix

gr/t

Source University of Hannover

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Agenda

� Energy balance for melting iron

� Energy balance of a state of the art Induction melting system

� State of the are melting system ABP

� Energy balance of a melting system

� Energy effective melt process

� Integration of the melt operation into the total process

� Automatic pouring system АВР

� Pouring via OptiPour®

� Energy - Benchmark

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Parts of a MF induction furnace system

� Mechanic:

� Furnace body, lining material hydraulic and tilting frame

� Electric:

� Transformer, Converter Capacitor bank, high current

connection, Coil

� Control systems:

� Weighing system, Process-

Control

� Auxiliary equipment:

� Cooling system, charging

system, exhaust system

tons

-

-

~

~

Transformer

MF-Converter

Capacitor bank

Cruciblefurnace

Cooling system electrics

Cooling system furnace

Melt processorWeighing system

Charging systemExhaust hood

Circuit breaker

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Todays ABP melting furnaces

Twin PowerSingle Power

Twin PowerSingle Power

MF Thyristor ConverterIGBTPower supply

LFSIFMFSSmart FSType

810 kW – 42.000 kW750 kW –6.000 kW

250 kW –500 kW

30 t … 70 t8 t … 60 t1 t … 6 t0,3 … 0,8 tFurnace capacity

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Energy balance of a state of the art induction melting system

� State of the art technology

� Installation losses:

100…130 kWh/t

� Efficiency:

80% …75 %

� Development tasks

� Reduction of coil losses

� New lining material

� Reduction of power supply

losses

� Reduction of transformer losses

� Aim:

� Reduction of installation losses

of 60…90 kWh/t

� Increasing of efficiency to

87%…81 %

8 kWh/t losses transformer

17 kWh/t losses converter

5 kWh/t losses capacitor bank

89 kWh/t electrical losses coil

9 kWh/t thermo losses

517 kWh/t

500 kWh/t

495 kWh/t

405 kWh/t

Energy consumption mains side 525 kWh/t

396 kWh/t Enthalpy at 1.500 °C

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Energy efficient induction furnaces – Coil losses

Coil losses are app. 70 % of the total installation losses

� New lining material that covers higher

induction power

� New coil design

� New coil material

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Energy efficient induction furnaces – converter losses

�Converter losses are approx. 3 % … 4 % of installed power

� New generation of power electronic components (IGBT, IGCT)

� Improved control systems

8.000 kW SCR converter 750 kW IGBT converter

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ABP power supply: IGBT technology

�IGBT = Insulated Gate Bipolar Transistor

�Technical features of IGBTs:

� Rapid switching

� low on- and off switching losses

� low conducting losses

�Rectifier, filter circuit and inverter in a single module with 250 kW to 1.500 kW

�Power range: 250 kW – 6.000 kW

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Benefits of IGBT converters

�Modular structure

� using standardized components

� quick and easy maintenance possible

�No de-ionizer water required

� No elements on potential are in direct contact with the cooling water

� Single cooling circuit for the converter and the furnace

�Cos φ in every operating condition > 0,95

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500 kW converter layout

�Control unit

�IGBT modules

�Coupling choke

�Capacitors

�Compact Layout for an easy integration into an existing plant

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Agenda

� Energy balance for melting iron

� Energy balance of a state of the art Induction melting system

� State of the are melting system ABP

� Energy balance of a melting system

� Energy effective melt process

� Integration of the melt operation into the total process

� Automatic pouring system АВР

� Pouring via OptiPour®

� Energy - Benchmark

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Energy efficient Melt process

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Energy efficient Melt process

2,0t

1,5t

� Charge preparation

� Charging

� Melting

� Preparation of the melt

� Furnace emptying

� Environmental emptying

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Energy efficient Melt process –Charge preparation

Big or small charge material

� The right mix influences the melt time up to 10 min and more

� additional >100 kWh/t

shot blasting of returns

� Returns not shot blasted consist a lot of sand

� Mostly 10 % of the returns are sand, that are supplied to the furnace

� The molten sand creates additional slag

� Sample: 10 t scrap with 5 t returns and 10 % sand

� 25 kWh/t additional for melting of the sand

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Energy efficient Melt process –Charging

� Charging when requested

� Avoiding bridges!

� Process control with melt processors avoids interruptions

� Influence of 2 – 4 min interruptions

� Additional 25…50 kWh/t

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Energy efficient Melt process –Melting

� Using the melt processor to get optimal power to the material

� Always if possible:

� Close cover!

� Open cover (12 t furnace)

� 600 kW heat losses

� 5 min with open cover

� 50 kWh additional losses

� Exhaust amount to be reduced at closed cover

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Energy efficient Melt process –Preparation of the melt

� Time is money!

� If possible, auxiliary equipment using

� Slag gripper

� Online connection between spectrometer and melt processor

� Melt processor calculates automatically the amount of additions

� Always if possible:

� Close cover!

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Energy efficient Melt process –Preparation of the Melt

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Energy efficient Melt process –Preparation of the Melt

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Energy efficient Melt process –Empting of the furnace

� Optimization of the ladle size to minimize heat losses

� No fire work at the furnace during empting!

� Optimization of ladle transport

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Energy efficient Melt process –Empting of the furnace

� Environmental empting of furnace

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Energy efficient Melt process –Results

15 kWh/t5 kWh/t� Empting of the furnace

190 kWh/t50 kWh/t� Additional process losses

50 kWh/t 10 kWh/t� Preparation of the melt

70 kWh/t 15 kWh/t� Melting

30 kWh/t 10 kWh/t� Charging

25 kWh/t 10 kWh/t� Charge preparation

Inefficient melt process

State of the arte technology

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Agenda

� Energy balance for melting iron

� Energy balance of a state of the art Induction melting system

� State of the are melting system ABP

� Energy balance of a melting system

� Energy effective melt process

� Integration of the melt operation into the total process

� Automatic pouring system АВР

� Pouring via OptiPour®

� Energy - Benchmark

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Integration of the melt operation into the total foundry process

� Tandem melting plant with variable power distribution

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Integration of the melt operation into the total foundry process

� Tandem melting process for hand forms - not recommended

� The melt must be app. 50 – 70 Ksuperheated, to cover the temperature losses during transportation and pouring

� Additional losses: 20…30 kWh/t

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Integration of the melt operation into the total foundry process

� Pouring furnace (heated or unheated) as additional storage at the molding line

� The melt must only be superheated of 20 K because a temperature equalization happens in the pouring furnace itself (with a better efficiency)

� Energy saving!

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Pouring with OptiPour®

� Regulated pouring

� Aim: level of liquid metal in the cup

constant during whole pouring time

� Changing of pouring conditions in the cup

mainly based on opposite pressure inside

of the cup � should be reproducible from

cup to cup

� No big differences for stopper, nozzle and level of liquid bath

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Pouring with OptiPour®

� Different systems for automatic pouring

� OptiPour® - L (with laser)

� High speed molding lines with extreme small

cup diameter and measure nose for the laser

� OptiPour® - C (with camera)

� Flask lines with big cup diameters

� OptiPour® - LL (with Line-Laser)

� High speed molding lines with extreme small cup diameter

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Pouring with OptiPour®

� Sample: Production of 30.000 t/á

pouring weight 25 kg:

� Avoiding of over pours of 0,25 kg

� 300 t/á savings

� Smaller cup diameter, material saving: 0,375 kg

� 450 t/á savings

� Losses by under pour and slagging: 1,25 %

� 375 t/á savings

� Total savings:1.125 t/á(590.625 kWh/á)

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Agenda

� Energy bilanz for melting iron

� Energy balance of a state of the art Induction melting system

� State of the are melting system ABP

� Energy balance of a melting system

� Energy effective melt process

� Integration of the melt operation into the total process

� Automatic pouring system АВР

� Pouring via OptiPour®

� Energy - Benchmark

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Energy – Benchmark, foundries

Theoretically Energy consumption

Equipment losses

Process losses

Integration losses

� Aim: specific energy consumption < 580 kWh/t

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Thank you for your attention…

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Contact:

ABP Induction Systems GmbHKanalstraße 2544147 Dortmund

Hermann-Josef Kroes Phone.: 02 31 / 997 – 24 75

Fax: 02 31 / 997 – 24 67Mail: hermann-josef.kroes@abpinduction.com