hermann-josef kroes energy efficiency using induction ... · cupola furnace - hot wind ind. furnace...
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ABP Induction Systems GmbHDortmund - Germany
Stoperikongress Hamar8. – 9. June
Energy efficiency using Induction Furnaces
Hamar,
09. June, 2010
Hermann-Josef Kroes
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
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ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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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BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
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ms G
mbH
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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BP
Inductions S
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ms G
mbH
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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Inductions S
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mbH
500 kW converter layout
�Control unit
�IGBT modules
�Coupling choke
�Capacitors
�Compact Layout for an easy integration into an existing plant
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
Energy efficient Melt process
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Inductions S
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mbH
Energy efficient Melt process
2,0t
1,5t
� Charge preparation
� Charging
� Melting
� Preparation of the melt
� Furnace emptying
� Environmental emptying
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Inductions S
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mbH
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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BP
Inductions S
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mbH
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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BP
Inductions S
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mbH
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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BP
Inductions S
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ms G
mbH
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!
©A
BP
Inductions S
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ms G
mbH
Energy efficient Melt process –Preparation of the Melt
©A
BP
Inductions S
yste
ms G
mbH
Energy efficient Melt process –Preparation of the Melt
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
Energy efficient Melt process –Empting of the furnace
� Environmental empting of furnace
©A
BP
Inductions S
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ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
Integration of the melt operation into the total foundry process
� Tandem melting plant with variable power distribution
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BP
Inductions S
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mbH
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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BP
Inductions S
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ms G
mbH
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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BP
Inductions S
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mbH
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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BP
Inductions S
yste
ms G
mbH
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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BP
Inductions S
yste
ms G
mbH
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)
©A
BP
Inductions S
yste
ms G
mbH
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
©A
BP
Inductions S
yste
ms G
mbH
Energy – Benchmark, foundries
Theoretically Energy consumption
Equipment losses
Process losses
Integration losses
� Aim: specific energy consumption < 580 kWh/t
©A
BP
Inductions S
yste
ms G
mbH
Thank you for your attention…
©A
BP
Inductions S
yste
ms G
mbH
Contact:
ABP Induction Systems GmbHKanalstraße 2544147 Dortmund
Hermann-Josef Kroes Phone.: 02 31 / 997 – 24 75
Fax: 02 31 / 997 – 24 67Mail: [email protected]