kitashiba induction furnace system tokyo head office · kitashiba induction furnace systems...

Kitashiba induction furnace systems reducing environmental load and cost

KITASHIBA INDUCTION FURNACE SYSTEM── General brochure of electrothermal products ──

Tokyo Head Office15TH FLOOR SOLID SQUARE WEST TOWER BUILDING, 580 HORIKAWA-CHO, SAIWAI-KU, KAWASAKI-SHI, KANAGAWA, 212-0013, JAPANPHONE +81-44-380-7471FAX +81-44-380-7474e-mail: [email protected]

P-B10178

Toshiba Group will contribute to a sustainable future of the planet Earth.

　In 1930, Toshiba’s first induction furnace was born in Japan. Inheriting this

DNA, Kitashiba Electric continues to evolve its original technologies in induction

heating and melting and electric power control.

　The 21st century is being called the century of the environment. Kitashiba

Electric uncompromisingly pursues environment-friendly performance to provide

induction melting system solutions that achieve the highest levels of efficiency

and contribute to conserving the earth’s environment.

Optimal control of electrical powerto reduce power consumption

・Full use of electrical power within power contract. It is always controlled optimally by attempting peak-cutting and leveling.

・The electricity consumption is constantly monitored to automatically ensure that power consumption is within the electricity contract.

・Adaptable for any furnace and facilities

Supporting thorough visualization and optimization of overall energy consumption at cast foundry

・Achieving approx. 2% energy saving by “visualizing” the operation of ancillary facilities through the use of EMS technology

・Reducing power consumption by automatic cooling water control and optimal inverter pump operation

・Announcing the “start” and “stop” of cold charging by automatically monitoring the progress of the melting process in order to optimize it

＊ This Product is sold only in Japan.

Foundry Operation and

Energy Management System

Kitashiba Energy-Saving System Solution

At Kitashiba Electric Co., Ltd., we create a valuablefuture for mankind and the earth by offeringnext-generation induction heating technology.

Elesave Furnace

Offering the industry leading, optimized melting systems

・Achieving energy-saving as high as approx. 9%, and improving electrical power consumption rate by adopting the new, high-efficiency induction furnace facilities known as the “Elesave Furnace” series

(manufactured by Kitashiba Electric Co., Ltd.)

Certified by Toshiba Groupas “Excellent ECP” products

KITASHIBA INDUCTION FURNACE SYSTEM

KITASHIBA FURNACE SYSTEMS

Power receiving controland

transforming equipment

JP Pat. No. 5492337Int’l. Pat. App. No. PCT/JP2014/068702JP Design Registration Nos. D1514980, D1515289, D1515290

ELESAVE FURNACE SERIES

Construction

Operation

Conception and application for

facilities

Planning, design and consulting

Manufacture and procurement

Installation andtrial operation

Inspection and maintenance

Customer Technical planning and support from the conceptual stage

Procurement with the best mix of efficiency, quality, and price

Undertaking on-site construction and testing in a planned manner

Quality after-sales services

● Planning of system structure and disposition● Preparation of system specifications ● Solving of technical issues

(systematic and structural analysis, etc.)● Detailed design work

● High efficiency induction furnaces● Molten metal transfer machinery● Molding/sand treatment

● Installation ● Site management

● Periodic inspections● Maintenance services

● Material feeding devices● Automatic pouring machinery● Analysis equipment

● Commissioning testing and quality assurance

● FOMS

Total customer support

■

■

■

FOUNDRY OPERATION AND ENERGY MANAGEMENT SYSTEM

Energy-Saving System Solutions for Casting Plants Increase production by 6–8% ※ 1

The “ELESAVE FURNACE” seriesHigh-frequency induction furnaces　Kitashiba Electric provides a comprehensive

plant energy-saving solution that responds to all of our customers’ requirements such as streamlining production, saving energy, and implementing safety measures at casting plants—for all equipment, from induction furnaces to ancillary facilities.

Kitashiba Electric’s FOMS (Foundry Operation and Energy Management System) is an energy-saving operation management system that is specially designed for the processes from metal melting to casting.With the system, you always know the usage of electric power, gas, and heavy oil by the plant’s facilities, including induction furnace facilities.It even monitors the condition of the cooling water.

Realizing “visualization” of electrical power at casting plants

　Using our high-current electromagnetic field analysis technology for large capacity hot-rolling heating devices, we have optimized the entire system, taking into account every coil—right from the design phase. Characterized by its low environ-mental load, our brand new “Elesave Furnace” series can reduce your power consumption.

High-efficiency equipment Safety equipment (Option)

Our brand new “Elesave Furnace” series is characterized by low environmental load, and is able to reduce power consumption.

※ 1 The above values may vary depending on operating conditions on the client side.

Improve 6-8% of melting basic unit. (compared with our furnace)

Prevent falling into the pit during furnace tilting.

Magnetic flux andheat analysis

Analysis figure

Coil

Iron core Moving-up type guard Tip-up type backside platform

Side guard

The “Elesave Furnace” series are certified by Toshiba Group as “Excellent ECP” products. (as of November 2013)

Toshiba Group is making efforts to develop a product with the best environmental performance by thoroughly and constantly improving environmental performance. In this way, we certify those with the best environmental performance as “Excellent ECP” products when they are launched on the market (or officially unveiled). The “Elesave Furnace” series are certified by Toshiba Group as “Excellent ECP” products.

KITASHIBA INDUCTION FURNACE SYSTEM

Kitashiba Electric

Standard Type High-Frequency Furnace

1. Free layout of equipments.

2. Production on customer’s specifications.Free choice of furnace power, frequency, melting volume, and number of furnace.

3. Can be used as an automatic molten metal charger.


The “ELESAVE FURNACE” seriesHigh-frequency induction furnaces

The minute construction with castable cement provides high strength with minimal cracking, and is tolerant of corrosive gas.It also has high heat conductivity to reduce the temperature at the back of the layer, which contributes to safety and longevity.

Normally, detection sensor is attached the inside of coil cement. Our detection sensor is between the coil cement and the chamber. Can be molten metal is sensed before leak the coil cement, detection sensitivity is high.

Brazing is the most important technique for the manufacture of melting furnaces. Highly reliably brazing is essential for melting furnaces to withstand electric vibrations and thermal fatigue.Above all, the brazing of inductive coils requires sophisticated skills, taking the shape of copper pipes, temperature, tempera-ture rise time and metal characteristics into consideration. At Kitashiba Electric, a strict qualification test is carried out for the certification of brazing technicians. Kitashiba has won one of the top prizes at the Toshiba Group Skills Competition and continually endeavors to maintain and further improve its skills.

A non-flammable glass tape for coil insulation is applied without the use of varnish, which causes more damage due to molten metal and discharge.

Coil protection technology

Others

Rating and characteristics

Cast iron and steel melting

Frequency［Hz］

Melting amount［kg］

Electric power［kW］

Cast iron　＊ 1,500℃ Cast steel　＊ 1,600℃Electric power consumption rate

［kWh/t］Melting period

［min］Electric power consumption rate


［min］

1,000

500 600 533 28 563 30

1,000 900 520 36 550 39

1,500 1,200 513 41 543 43

2,000 1,800 486 34 504 35

500/300

1,000 600 533 56 565 59

1,500 900 505 53 530 56

2,000 1,200 504 53 526 55

3,000 2,400 473 37 488 39

5,000 3,000 478 50 496 52

8,000 5,000 486 48 509 52

10,000 6,000 493 50 518 53

15,000 Varies with electric power and design specifications. For details, contact Kitashiba Electric.

Copper alloy melting and Holding furnaces (Brass and bronze)

Frequency［Hz］

Melting amount［kg］

Electric power［kW］

Brass 　＊ 1,050℃ Bronze　＊ 1,250℃Electric power consumption rate


［min］Electric power consumption rate


［min］

500

500 300 304 34 368 41

1,000 600 291 31 349 39

1,500 900 284 30 338 38

300

2,000 1,200 276 31 329 37

3,000 1,800 269 30 319 35

5,000 2,400 268 37 318 44

Note 1: Values marked with an asterisk ( ＊ ) refer to approximate melting values attained when melting of cold charge of the second cycle later which furnace is warmed, and operations including material input, retention, slag removal and molten metal output are not included.The above values may vary depending on operating conditions on the client side.

Note 2: Products having characteristics other than those indicated above may also be manufactured. Contact Kitashiba Electric.

Melting furnaces for aluminum and special metals can also be manufactured.We will manufacture optimal melting furnaces according to your specific requirements. Contact Kitashiba Electric.

Note 1: Values marked with an asterisk ( ＊ ) refer to approximate melting values attained when melting of cold charge of the second cycle later which furnace is warmed, and operations including material input, retention, slag removal and molten metal output are not included.The above values may vary depending on operating conditions on the client side.

Note 2: Products having characteristics other than those indicated above may also be manufactured. Contact Kitashiba Electric.


1) Detection sensor of molten metal leak 2) Castable lining layer (Coil cement)

Providing superior heat-resistance and fireproofing characteristics, the materials used in the product also provide sufficient resistance against moisture absorption and mine dust.

3) Coil insulation

4) Core insulating plate

KITASHIBA

MICROMELTER SERIESELESAVE FURNACE SERIES

“MICROMELTER” seriesCompact System for Research Activities

We offer a compact system integrating a series of components including a power supply and furnace body on a common base.

2400

2000

IGBT inverter power supply

Harmonic filter

Furnace body

2600

1000

Major characteristics

Facility Outline

Power supplycapacity 30 to 100 kW

Power supply frequency 1,000 to 3,000 Hz (100 kW is 1,000 Hz.)

Input voltage AC 220V - 60Hz - 3-phase

Melting volume 5 to 100 kg (for cast iron)

Melting materials cast iron, cast steel, copper alloy, etc.

External dimensions Width　　 2,000 mm

Depth　 2,400 mm

Height　 2,600 mm (with filter)

Furnace height　1,000 mm

1. The furnace modules are constructed with built-in power receiving unit, power supply unit and furnace unit. Wiring and piping inside each module is already complete.

2. Easy foundation work and minimum installation period, taking just six days before molten metal discharge.

3. The upper part of the facility is constructed from checkered steel plate, negating the need to install a platform. We can also lay the railing for the feeding cart.

4. Required space for installation is about 70% of the standard design furnace.

KITASHIBA’s unique design. Installation takes only about a third of the time of the free layout design.

“ELESAVE FURNACE” series module typeHigh-frequency induction furnace

Dimensions of super unit furnaces

Rated power range Less than 600 kW 600 to 1,400 kW 1,400 to 2,400 kWMelting amount

range 300 to 750 kg 750 to 2,000 kg 2,000 to 3,000 kg

Single power

supply for one

furnace

Single power

supply for two

furnaces

＊ A device requires a space of at least 600 mm width around it for maintenance work.＊ The power receiving unit, the transformer and the hydraulic unit may be installed separately　(Hydraulic units with large capacities must be installed separately).

Power receiving unit

Inspection passage

Power supply unit

Furnace unit

High voltage receiving unit

DC reactor

Thyristor inverter

Heat exchanger

High frequency matchingtransformer

Harmonic filter

Rectifier transformer

6600

2200

1600

2000

800

3600

1500

3400

Power receivingunit

Inspection passage

Power supply unit

Furnace unit

6600

3600

1500

34002600

7300

2200

1600

2300

1200

3900

2000

4000

Inspection passage Inspection passage

Power supply unit

Furnace unit

7300

3900

2000

40003050

9150

2200

2000

2300

1750

900

4300

2350

4000


Transformer

Power supply unit

Power supply unitPower supply unit

Furnace unit

Transformer

9150

4300

2350

4000

710070506000

3100


Power receivingunit



Inspection passageInspection passage Inspection passage

Power supply unit

Furnace unitFurnace unit Furnace unit

Unit of dimensions: mm

Configuration of super unit furnaces

■ Use low-voltage power supplyNo need for a massive power project

■ The power supply and the furnace casing are installed in one base.

■ Abundant options matched to research content

■ The small size machine, it is highly effective.

02 Elesave Furnace Series

The power receiving control, and power receiving and transforming equipment we developed by applying our wide experience and achievements, are widely adopted by a number of domestic and overseas clients. By allowing full use of electrical power within the electricity supply scheme, peak-cut and leveling of power consumption can be achieved.We are able to flexibly adapt to induction furnaces and load systems developed by our competitors.

Unexpected problems in your melting facilities lead to huge production losses due to recovery work and expenses.To ensure the reliability of your Kitashiba furnace system, we cooperate with a service partner in North America.

We provide speedy response to trouble, inspections, and repairs, thanks to Ajax TOCCO’s service group and its globally operating service centers, as well as our company’s other affiliate service partners. Fully equipped staff will visit you to handle all of your needs, from preventive maintenance inspections to urgent on-site repairs.

1　Field troubleshooting and repairs

2　Preventative maintenance

3　Coil/inductor change out

4　Power supply tune up and meter calibration

5　Implement engineered system updates, upgrades, and improvements

6　Energy audits

7　Safety and technical training schools on-site

Power receiving control system

6.6kV - 50/60Hz

Electric power company

Demand meter

Power converter

Transaction meter

PCT

Load systemLoad systemLoad system Load system Induction furnace system

Client’s demand meter

Pulse detectionSynchronization

signal

Operated arbitrarily

By constantly measuring electric power consumption at the power receiving point, the power supplied to the high-frequency furnace is constantly controlled in order to ensure that it always complies with the electricity supply scheme.

Load system

Comprehensive electric power

Monitoring device

Automatic electric power control

＊Able to adapt to a large number of furnaces

Target electric power(Within electricity supply scheme)

Target electric power(Within electricity supply scheme)

Demand controlControlled according to the electric power

consumed in 30 minutes

Power receiving controlControl instantaneous electric power in compliance

with the electricity power scheme

Time Time

The time is not limited to 30 minutes.

Load power

Load power

Difference between demand control andpower receiving control

30 minutes

Trend in electric powerduring demand control

The furnace is turnedoff in this status.

The power supply to the furnace is constantlycontrolled so that the target electric power is

not exceeded. (approx. 97%)

POWER RECEIVING CONTROL / POWER RECEIVING and TRANSFORMING EQUIPMENT

Power receiving control / Power receiving and Transforming equipment

Aftermarket Support Partner

Touch panel screen

Service Partners Strategically Located in North America

Comprehensive on-site diagnostics, troubleshooting and repairs of your induction furnace system

Increase your uptime with reliability services provided by KITASHIBA’s service partners, including:

ATM Cleveland, OHWickliffe, OH., USA

Phone: (01) 440-833-0386

ATM Queretaro, Mexico

TEMIM S. A. DE C. V.Aguascalientes, AGS., MEX

Cell Phone: (52) 1-449-137-0226 (52) 1-449-111-1246

Office Phone: (52) 449-913-6907

MEXICANA DE INDUCCIÓN S. A. DE C. V.

ATM Madison Heights, MIMadison Heights, MI., USAPhone: (01) 248-399-8601

ATM Albertville, ALAlbertville, AL., USA

Phone: (01) 256-279-1200 (01) 800-255-0994

ATM HeadquartersWarren, OH., USA

Phone: (01) 330-372-8695

On-site Services

ATM Longview, TXLongview, TX., USA

Phone: (01) 903-297-2526/2527

Eng. German Garcia

Kitashiba induction furnace systems reducing environmental load and cost

KITASHIBA INDUCTION FURNACE SYSTEM── General brochure of electrothermal products ──

Tokyo Head Office15TH FLOOR SOLID SQUARE WEST TOWER BUILDING, 580 HORIKAWA-CHO, SAIWAI-KU, KAWASAKI-SHI, KANAGAWA, 212-0013, JAPANPHONE +81-44-380-7471FAX +81-44-380-7474e-mail: [email protected]

P-B10178

Toshiba Group will contribute to a sustainable future of the planet Earth.

Safety precautions

・In this facility, high temperature metals, high voltage current, water, oil, etc., are used. Please use this facility correctly, otherwise it may cause serious physical injury or death.

・To operate the product correctly, please read the “Operation Manual” carefully before using it.・Please note that some electrical devices must be maintained and inspected only by qualified persons.・To operate this product properly, electrical work by experts is required.・Please contact us if you plan to transfer the facility to a region where different power supply frequencies are applied.

If you use the facility in a different operating environment, it may cause smoke or fire.・The information contained herein is as of January 1, 2014.・The information contained herein is subject to change without notice.・The information contained herein is presented only as a guide for the applications of our products. No responsibility

is assumed by KITASHIBA for any infringements of patents or other rights of the third parties which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of KITASHIBA or others.

・KITASHIBA products should not be embedded to the downstream products which are prohibited to be produced and sold, under any law.

・KITASHIBA does not take any responsibility for incidental damage (including loss of business profit, business interruption, loss of business information, and other pecuniary damage) arising out of the use or disability to use KITASHIBA products.

・The products described in this document may include products subject to the foreign exchange and foreign trade laws.

・The products described in this document may contain components made in the United States and subject to export control of the U.S. authorities. Diversion contrary to the U.S. law is prohibited.

Order instructions

Please inform us of the following information when ordering the High Frequency Induction Furnace Facility.

⑴ Purpose of installation and use of the melting furnace facility.

⑵ Types and shapes of materials to be melted

⑶ Production volume (tons per hour, tons per day or tons per month)

⑷ Melting temperature (℃ )

⑸ Quantity of molten metal output at a time (tons)

⑹ Molten metal output cycle period (minute)

⑺ Power supply voltage and frequency (V, Hz)

⑻ Brief description of the installation space

⑼ Desired delivery time

⑽ Other

The information contained herein is as of May 1, 2015.

kitashiba induction furnace system tokyo head office · kitashiba induction furnace systems...

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