Energy lost by induction furnace during operation

Induction furnaces use the induction principle of a transformer, and when an electrical conductor is placed in a fluctuating magnetic field, a voltage is induced in the conductor. In a crucible furnace, this voltage creates strong eddy currents that, due to the electrical resistance of the material, cause the material to be heated and eventually melted.

In the process of heating steel, a large amount of electricity is required. In addition to the theoretical energy required to produce steel, energy is also required to compensate for losses that occur when producing steel. Energy loss increases specific energy consumption and reduces furnace efficiency. Today we are going to learn about the energy loss of some induction furnaces during operation.

Losses in steel production

heat loss

Furnace Coil Loss

Capacitor Bank Loss

Converter losses

Primary side transformer losses.

Heat loss is the main loss and contributes the most to the energy loss. The main heat loss of induction furnace:

Radiation loss from furnace top

Conduction loss of refractory lining

Heat Loss in Coil Cooling Water

Heat carried by removed slag

Heat carried by the gas exhausted from the furnace top

In the process of generating heat, the furnace continuously loses heat to the cooling water and to radiation from the outer casing and exposed metal surfaces on the top. Electric energy needs to be consumed to replace these heat losses. Therefore, the longer the heating time, the higher the energy consumption and the lower the efficiency of the furnace.

Factors that affect the power consumption in the furnace include

Dirt with scrap into the furnace

rusted charge

Low bulk density of waste

recarbonization

Not using full power for melting

Excessive slag formation

Produces excessive smoke and emissions

Excessive loss of metal due to spills and splashes

heating time

Because longer production cycles mean higher heat losses due to radiation and conduction

Metal loss from metal charge depends on the physical size of the part and its mass, but is typically less than 5%, with a significant portion of the loss due to spills and splashes during deslagging and pouring operations.

One factor that has the greatest impact on energy consumption is the level of furnace utilization. Higher utilization means efficient production cycles.

This is what we share today, welcome to pay attention to Luoyang Hongteng to learn more about the melting furnace.

Video of the use process of the furnace