Magnalenz Induction Furnace

Magnalenz Induction Furnace
GENERAL
Magnalenz Induction Furnaces are designed and produced by studying all
available existing Furnaces in the world, adapting all superior features,
adding all up to date technologies and combining the necessary needs
indicated by foundrymen. For the coming millennium years of 2000 and
beyond Magnalenz proudly presents to modern, automated foundries and
steel plants the most Economical, the most Reliable, the most Efficient
and high Quality Induction Furnace viz. FERmelt.
Benefits of Medium Frequency Induction Furnace:

 Lower power consumption and enhanced economy Modern semi-
conductor technology and an optimum furnace design minimize the power
demand and consumption, thus reducing the melting cost.
 High operational safety Safe melting operations thanks to
continuous, automatic furnace monitoring.
 Favorable price/performance ratio and long life cycle The use of
Magnalenz standard modules in the melting plant are responsible for its
favorable price. These Magnalenz furnace systems,are known to be rugged
and reliable, minimize total life cycle costs.
 Easy to install, operate and maintain The advanced furnace design
was conceived for quick and easy installation. System operation,
monitoring and control are user-friendly and simple.
Higher Yield: The absence of combustion sources reduces oxidation losses

that can be significant in production economics.
Faster Startup: Full power from the power supply is available,

instantaneously, thus reducing the time to reach working temperature.
Flexibility: No molten metal is necessary to start medium frequency

coreless induction melting equipment. This facilitates repeated cold
starting and frequent alloy changes.
Natural Stirring: Medium frequency units can give a strong stirring action
resulting in a homogeneous melt.
Cleaner Melting: No by-products of combustion means a cleaner melting

environment and no associated products of combustion pollution control
systems.
Compact Installation: High melting rates can be obtained from small

furnaces. A coreless furnace capable of melting 2,500 lbs./hr. of
aluminum has a crucible measuring 3' in diameter by 6' in depth.
Reduced Refractory: The compact size in relation to melting rate means

induction furnaces require much less refractory than fuel-fired units.
Better Working Environment: Induction furnaces are much quieter than

gas furnaces, arc furnaces, or cupolas. No combustion gas is present and
waste heat is minimized.
Energy Conservation: Overall energy efficiency in induction melting

ranges from 55 to 75 percent, and is significantly better than combustion
processes.
The Magnalenz Difference

MAGNALENZ is the best induction furnace producer to provide after
sales maintenance and service because of:
1. Magnalenz high technology design means less failure
2. Has a special system that locate the faults
3. Suitable design for fast technical aid
4. Built with care & quality workmanship means less failure
5. Testing facility
6. Clean layout ample space easy accessibility to all components
means fast & quality maintenance servicing
7. Stock of Spare parts
Key Features:
 Flexibility in Selection of Frequency to suit the stirring.
 Power factor in the range of 0.95 to 0.98.
 Short circuit proof current source inverter.
 Highest efficiency 97%.
 Liberally rated components provide extra safety margin to suit
diverse operating conditions.
 12 Pulse system for low harmonic contents (above 1500KW).
 Ability to melt different metals.
 Can be operated on DG Sets.
 Full power from start to end.
 Built-in test diagnostics.
 Instant start and stop.
 Operates under voltage fluctuation.
 No inefficient load-matching transformer.
 Highly efficient and rugged design.
 Flow switches/temperature sensors for protection against water flow
failure/Temp. rise.
 Earth leakage protection for operator safety.
 Simple design facilitates preventive maintenance.
 Continuous operation.
 Capacity: 25KW to 10000KW
 Frequency 150Hz to 1000Hz
Magnalenz Induction Furnace for Metals

Cast Iron / Steel
Type Capacity (K.G.) Power (KW) Melting Rate Kgs/hr
Cast Iron 1450 C Steel 1600 C
FER 01 100 75 110 100
FER 02 100 100 150 130
FER 03 200 150 240 210
FER 04 300 250 430 380
FER 05 500 300 510 460
FER 075 750 450 800 700
FER 1 1000 750 1410 1200
FER 1.5 1500 1000 1880 1690
FER 2 2000 1200 2350 2040
FER 3 3000 1500 2880 2450
FER 5 5000 2000 3840 3220
FER 7 7000 3000 5760 4910
FER 10 10000 4000 7690 6550
Magnalenz Products Range

Product Melt Rate Furnace
Code No Capacity In Kgs
Steel 1650 C Melt Rate C
FER/15 kw - - 10 15 -
FER/20 kw - - 15 20 -
FER/30 kw - - 20 25 30
FER/50 kw 73 kgs/Hr 82 kgs/ Hr 50 80 -
FER/75 kw 112 kgs/ Hr 125 kgs/ Hr 80 100 150
FER/2000 kw 3700 kgs/ Hr 4100 kgs/ Hr 4000 5000 -
FER/2500 kw 4700 kgs/ Hr 5150 kgs/ Hr 5000 6000 -
FER/3000 kw 5600 kgs/ Hr 6180 kgs/ Hr 6000 8000 10 TON
FER/4000 kw 7400 kgs/ Hr 8200 kgs/ Hr 10 TON 15 TON -
For othermenals, multiply the melt rate for steel by the following numbers
Aluminium : 1, Copper : 1.6, Brass : 1.9, Gold : Silver : 2.85
Based on nominal furnace size of second heat when lining is hot, charges
is dense no molten heel required. The Voltage should be as per our
specification, Melt rate for the weight of charge, dosn't include time for
initial charging, pouring super heating dislagging.
Product List
1. Coreless medium frequency induction melting furnace for
ferrous/nonferrous
2. Induction heating equipment
3. induction hardening equipment for engg, industries
Description Of Mf Installations P r o d u c
GENERAL
Medium frequency Furnaces operate at frequencies ranging from
150 To 10,000 HZ, such furnaces provide the concentration of high
power in small volumes with a definitely higher melt rate.
Magnalenz installation consists of:

1. Melting crucible.
2. Solid state power converter.
3. Power factor compensation capacitor bank.
4. Ancillary equipments.
Melting Crucibles R a n g e
Structurally it consists of three independent sections:
1. Base frame
2. Tilting Frame
3. Interchangeable inductor comprising the coil made from specially
shaped copper section featuring Higher Strength and Higher Conductivity.
The melting basin is inside the inductor with an adequately thick

refractory lining in between. The special Trip system for wear on
refractory is also provided.
For easy emptying, calm and complete pouring, a special hydraulic system
is incorporated
MF Solid State Power Converter V i e w

Converts the line/mains frequency in to medium frequency required
for efficient operation.
Basically it Consists of:

1. Converting A.C. to D.C.
2. Rectifying & Filtering D.C. Current.
3. Converting D.C. to M.F.A.C.
4. Electrical Safety, Protection, Regulation and Control circuits
5. Closed water circuit with water to water heat exchange and
deioning with D.M. water.
MF Power Factor Compensation Capacitor Bank

A set of water-cooled medium frequency capacitors connected by
Electrolytic grade copper busbars, to avoid losses, due to high
currents. It is fitted inside panel or outside, specially protected
frames, automatically compensates the low power factor to the
Furnace.
B Ancillary Equipments r o c h u r e
Those Equipments are supplied to specific client's requirements for a
better functionally of the Medium Frequency Furnaces installations:
Basically it Consists of:

 Cooling Tower
 Step-up & Step-Down Transformers
 Close loop D.M. Water circulation for crucible
 Automatic Charging Equipments
 Energy metering devices
 Control & Programming of Power absorbed during production cycle
 E.O.T. Cranes
 Water softening plant.
 Control Circuits Safety

 Components
B The Most Advanced Electronic Components
Any ideas that might improve the Performance of an already excellent
Furnace technology are applied by Magnalenz. We follow the New
Publications and search the most recent electronic components. Our main
concern is to reach tomorrow's advanced technological level and submit to
our clients only the best.
Thyristor Controlled Rectifier

FER melt furnaces rectifier are not just simple diode bridge type but fully
thyristor controlled.
Advantages
 At low input voltage the Furnaces can deliver power efficiently.
 Power adjustment can be done over a very large range (5%-100%).
 Line Voltage Fluctuations cause no damage.
 The current is limited during any failure or short circuit in the
system which prevents bigger technical problems or expenses.
 s
Safety Margin In Power

Semiconductors
FERmelt Furnaces works on parallel circuit design. Even at the highest
power level the thyristors chosen work approximately at one third of the
current. In other words the safety margins on the thyristor are very
high. Service life of thyristors is extended due to consequent low heat
losses and lower operating temperatures.
Reduced Melting Cost With Constant Power

FERmelt Furnaces are designed to deliver maximum power from the
beginning, which reduces the melting time, resulting in lower energy
consumption.
High Electrical Efficiency
FERmelt Furnaces are designed to minimise electrical losses. Electrical
Efficiency is 97% (Over all)
High Power Factor
The reactive energy used on FERmelt Furnaces is very low and the
average power factor is Better than 0.95, thus no additional precautions
for improving power factor are needed.
Safety And Protection System

Advance parallel Inverter circuit design, result of years of experience,
enable us to present one of the Safest Induction Furnaces.
Protection Features Are:
 Over voltage protection at mains.
 Over current protection for Thyristor & Capacitors.
 Phase Protection at input.
 Over Voltage protection for Thyristor & Capacitors.
 On all main water cooling branches, temperature and water Flow are
controlled.
 Earth Leakage detector.
 Air Temp in side panel for Protection.
Furnace Selection
FURNACE SELECTION PROCESS

Step 1
The furnace capacity selection is the most common question bothering for the
buyer/prospects. Sometimes it creates confusion, because different manufacturers
suggest different combinations.
How should one select the furnace (Kw/KG/Hz) which fitted to one's requirement
technically and commercially as well?
So we suggest every one to follow the furnace selection process step by step.
• Which metal or alloy do one's want to melt and at what pouring temperature?
• Melt rates or melting speed is different for different metal & alloys at particular
applied kw, this is due to difference in specific heat of different metal.
• At the same time due to different latent heat of each metal, superheating of each
molten metal will be different, so different melt rate at particular applied kW.
For Example
For Different Metal

At particular kW Furnace Compare Brass & Steel Melting
For Steel Melting
1000 Kgs / Hour @1600ºC
Where as, Brass Melting will be, 1900 Kg / Hr @11000ºC
Summary
So At same kW, different metals, different Melt rate

For super Heating case:
At particular kW for steel melting:
At 15000ºC the melt rate will be 1000 Kgs / Hour
At 16000ºC the melt rate will be 925 Kgs / Hour
Summary
For Same metal, At particular applied kW, Different Pouring Temperature, Different
melt rate.
Once you configure your requirement i.e. melt rate @ temperature degree centigrade ºC according to
step one, Now switch to step 2.

Step -2
You must specify the liquid metal requirement in tons or in Kgs, per month with working hours in a day.
( A ) For Steel Ingot
Suppose you required 1200 Tons / Month of M.S. Steel Ingot @ 1600ºC what the
Furnace size should be?
• 1st consider working days - 25 days
• 2nd 1200 Tons 1 25 days gives 48 Tons of liquid metal Day out of 24 Hrs working.
• 3rd 48 Tons 1 24 Hrs i.e melt rate will be (48/24 = 2) 2 Tons per hour
• 4th Now consider the unproductive time of cycle, i.e. time for deslagging, charging,
sintering, lining etc. so the furnace utilization will be 80 % thus
• 2 tons 1 hr divided by 0.8. is 2.0 ÷ 0.8 = 2.5 Tons / Hour should be the required
furnace melt rate at 1600ºC .
• 5th Now refer the furnace specification table. You will find the nearest melt rate can
be achieved by 1500 kW 1 3 Tons Furnace i.e. 2.6 Tons 1 Hour Melt rate.
• We have considered here 1500kw means 1500 KVA – Exclusive power at the furnace
Input.
So the Answer is By 1500 KW 13 Ton furnace you can produce 1200 Tons of M.S. Steel Ingots @
16000C per month.
B) For Castings (Step -2)
Suppose you want to make 300 Tons / Month of finished steel casting, with an average
yield of 65% and utilizing of furnace is about to 75%.
Then what should be the furnace capacity? Pls suggest.
• So now 300 Tons ÷ yield (0.65)
• Gives total monthly molten metal requirement for casting is 465 Tons / month.
• Now 465 Tons divided by 25 working days gives 18.6 Tons of molten metal per day of
24 hours working.
• 18.6 Tons again divided by 24 hours gives required melt rate of molten metal is 775
kgs / Hour. Now considering the utilization of the furnace is 75 %, is due to sintering,
lining deslagging, recharging, composition setting etc.
• Thus actual molten metal requirement will be 775 ÷ 0.75 i.e. 1033 Kgs / Hour.
• Next step now you refer the table & from the table the nearest suitable furnace, which
can give 1033 Kgs/ Hour melt rate is FER 1.
• So you should select 600kW & 1 Ton Induction Furnace, which will give you the
suitable melt rate.
• Another main factor which one foundry men has to be decided is, what should be the
batch size?
• The batch size will be depending upon the molten metal weight you required.
For Example
If you required 600 Kgs, 750 Kgs, 1000 Kgs, metal at a time then you can select 600 kw solid state M.F.
Power source with 1000 Kgs crucible or otherwise, if your molten metal requirement is around 500 Kgs
or less, then you can select 300 kw x 2 Nos solid state M.F. Power Source with 500 Kgs crucible. Which
will cost you more, compare to buy 600 kw one unit.

Step - 3
Now what should be the right frequency?
Normally frequency selection is not available, and is not an important constraint too.
There are many combinations of Kw and Kgs available at different frequencies.
Basically frequency is one parameter which affects stirring.
In a coreless Induction furnace stirring is produced by magnetic forces acting on a
molten metal because of interaction between the coil current and the current flowing in
the molten metal bath. The force is the strongest at middle part of the coil so metal is
forced at the central side of the bath from where it is resolved to upward and
downward. Metal moves up because of upward resolved force. The upward movement
of the metal in the center creates meniscus a unique characteristic know as a stirring
effect is measured by h/D ratio (h by D ratio).
Stirring effect is depending upon the power frequency applied, the induction coil &
molten bath as well as density and viscosity & molten metal. The three major variable
which Effect stirring are
1) Power 2) Frequency 3) Furnace Size
Stirring can be change with charging anyone of the major variable.
WHAT IS EFFECT OF STIRRING

INADEQUATE STIRRING CAUSE
1. Insufficient Mixing of Alloys

2. Temperature difference in molten metal bath
3. difficulty to melt light weight scrape
EXCESSIVE STIRRING CAUSES
1. Frequent lining erosion

2. Metal oxidized and splashing of metal
3. Lining or slag inclusions in casting found
• Once you decide the kW/Kg of the furnace & according to your mixing or alloying requirement, metal
properties, operating frequency can be decided.
Role of Frequency in Melting

High power density melting allows better utilization of the equipment, minimizing the
amount of time needed to perform a melt. This also improves the efficiency since the
energy loss due to heat conduction and radiation is also minimized because the molten
metal is not kept in the furnace for a long time. This method of quick high power density
melting and complete emptying of a furnace became known as "batch" melting. The
older technique, called "heel" melting, involved large furnaces which were only partially
emptied and then topped by a load of solid metal charge. The batch melting method
requires larger power supplies operation on higher frequencies.
High power density i.e. produced melting power kw/kg or per ton of charge, gives better
utilization of the furnace, and so takes less time to melt the metal in particular batch
size. This too improves the overall effective of the melting operation as energy loss due
to conduction of heat through lining and radiation loss is reduced, reason is less
holding time of molten metal in the furnace. The lining life of the furnace is also gone
up and so over all efficiently of the melting operation is gone up so the melting cost per
kg totality has to be reduced. This method of quick high power density melting or hatch
melting requires larger power supplies (kw/kg) on high frequency.
Because produced melting power or power density is a function of the product of
sensitivity of the metal and the operational of frequency metal.
Pm = Const × resistivity of metal × Frequency
Plays significant role for effective melting at a particular power on a particular
batch size.
HOW TO CALCULATE THE FURNACE.EFFICIENCY

THEORETICAL TOTAL HEAT REQD FOR MELTING (H T) IN
KWH. FOR THE MELTING OF THE METAL IN KWH
----------------------------------------------------------------------------------------
FURNACE EFFICIENCY =
----
ACTUAL CONSUMED ENERGY BY THE FURNACE FOR
MELTING OF THE METAL IN KWH (H A)

THEORETICAL HEAT REQD FOR MELTING:

W X SPECIFIC HEAT OF THE METAL X ( T2- T1) + LATENT
HEAT OF
THE METAL XW
H.1 IN KWH =
----------------------------------------------------------------------------------------
----
3600 ( 3600 KJ = 1KWH)

HEAT REQD FOR SLAG TO.HEAT AND MELT WILL BE 1.65X
H2 IN KWH =
WSLG X3.6 ( WHERE 3.6 MJ = 1 KWH)

WHERE
W = WEIGHT OF THE METAL TO MELT
T2- = MELTING FINAL TEMP OFTHE METAL.
T1 = INITIAL OR CHARGING TEMP OFTHE METAL.
WSLG = WEIGHT OF SLAG GENERATED IN OPERATION.
HERE,
H T = H1 + H2
AND
• ACTUAL CONSUMPTION OF THE MELTING CAN BE MEASURED FROM THE INPUT
BUSBAR OF THE FURNACE PANEL IN KWH. (H A IN KWH) WHICH IS HIGHER
THAN H.T.
• SO DIFFERENCE BETWEEN HA AND HT (HA - HT) IS LOSS DUE TO CONDUCTION
RADIATION AND OTHER LOSSES,
• AND SO FURNACE EFFICIENCY IS RATIO OF THEORETICAL HEAT REQD FOR
MELTING IN KWH TO ACTUAL CONSUMED HEAT IN KWH.
i.e.,
HT
----------------------------------------------------------------------------------------
FURNACE EFFICIENCY =
----
HA

55% TO 65% (MAX) OVERALL ENERGY EFFICIENT FURNACES ARE AVAILABLE.

FOR M.S. SCRAP
SPECIFIC HEAT = 0.682 KJ / KG DEG CENTI.
LATENT HEAT = 272.0 KJ / KG
SPECIFIC HEAT REQD TO MELT 1000KGS OF M.S SCRAP WILL BE, @ 1650ºC
= 100 × 0.682 × (1650 - 30)
-------------------------------------- KWH
3600
= 307 KWH
LATENT HEAT REQD,
272 × 1000 / 3600
76 KWH.
HEAT FOR SLAGE
1.6 × 25 / 3.6
12 KWH.
TOTAL KWH THEORETICALLY REQD FOR MELTING IS 395 KWH.
APPROX 400 KWH REQD TO MELT M.S OF 1000KGS TO 1650DEG CENTIGRADE.
IF THE FURNACE CONSUMES 625 KWHITON THAN THE FURNACE IS OVERALL
ENERGY EFFIECIENT 65%.
[ i.e. 400 ÷ 625 = 64 % ]

DISTRIBUTION OF LOSSES IN INDUCTION FURNACE:

LOSSES IN INDUCTION FURNACE

The theoretical energy require to melt one Ton of steel is 385 TO 400 KWH / Ton. However
in actual practice, the specific energy consumption is remarkably higher to 550 KWH / ton
to 950 KWH / ton.

THE POWER LOSS IN INDUCTION FURNACE SYSTEM

1. Power loss in generator / panel 2% to 4%
2. Power loss in capacitor Bank 1.0% to 3%
Power loss in Crucible
3. (Water cooled cables, Bus bar, change over 18% to 25%
switches)
4. Radiation loss 7% to 9%

Above figures can vary according to
1. Manufactureroffurnace.
2. Sizeofthefurnace.
3. Scrapquality.
4. Plant operational specific issue.

FACTORS EFFECTING THE FURNACE EFFICIENCY.

In foundry the tool or unit of efficiency measurement is kwh/ton.

In foundry most of the power is consumed by the induction furnace is around 65% of
the power.
The factors, which effects the furnace efficiency are as under;
1. Wrong selection of the furnace & operational practice:
i. Small power supplied unit & big crucible.
ii. furnace top extension and relative slow charging.
iii. wrong lining thickness.
Results:
a/slowermelting
b/reducedlininglife
c/poorutilizationofpowerduetoincreaseinfurnacelosses.
d / poor power transfer/coupling increase melting time.
Optimum furnace size, approximately to be;
For up to 1000 kw -1.5 times the kw applied
Above 1000 kw furnace - 2.0 times the kw applied.
2. Furnace down time:

(1) molt sintering and pateching.
Higher sintering & patch in g increases the cost of production and reduces the
efficiency.
3. Break down time :
due to poor maintenance the total production stops sometimes.
Higher breakdown results in increasing the' cost of production
4. Low supplied power :
some time supplied voltage is low, so furnace draw less power. Causes slow melting &
inefficient operation resulting; increase cost of production
5. Wrong lining :
some time lining material selection is wrong with respect to metal.
Basic lining is better conductor of heat compared to acidic lining

Wrong lining selection increases breakdown,
Furnace down time and furnace losses,
Resulting in inefficient operation.
Besides above all points some more factors which can also effect the energy
consumption per MT are:
A ) poor coordination between melting staff & contractor
B ) absence of material handling equipment
C ) poor molding efficiency so furnace on hold
D ) poor quality scrap, reducing lining life, takes more time to melt.
E ) absence of thermal insulation between lining & coil.

Total absolute energy required to turn 1 Ton of different. Solid metals to
melt @ different molten temperature.

Type of metal Specific heat require Latent heat require Total require kwh/Ton
1000 x 0.682 x 16200C
272 x 1000 ÷ 3600
÷ 3600
Mild steel @ kwh
∆T=1650-30
1650ºC Melting Latent Heat = 272 307 + 76 = 383 kwh
Speci heat = 0.9
temp. kj/kg
kj/kg0C
= 76 kwh
= 307 kwh
1000 x 0.9 x 6800C ÷
396.9 x 1000 ÷ 3600
3600 kwh
kwh
Aluminum @ 710ºC ∆T=7100C-300C 170 kwh + 110 kwh =
Latent Heat = 396.9
Melting temp. Speci heat = 0.9 280 kwh
kj/kg
kj/kg0C
= 110 kwh
= 170 kwh
1000 x 0.386 x 11000C
212 x 1000 ÷ 3600
÷ 3600 kwh
kwh
Copper @ 1130ºC ∆T=11300C-300C 118 kwh + 59 kwh =
Latent Heat = 212
Melting temp. Speci heat = 0.386 177 kwh
kj/kg
kj/kg0C
= 59 kwh
= 118 kwh
Gold @ 1130ºC 1000 x 0.131 x 11300C 67.62 x 1000 ÷ 3600 36.38 kwh + 18.78
÷ 3600 kwh
kwh
∆T=11300C-300C
Latent Heat = 67.62
Melting temp. Speci heat = 0.131 kwh = 55.16 kwh
kj/kg
kj/kg0C
= 18.78 kwh
= 36.38 kwh
Aluminum Melting
INDUCTION MELTING FURNACE FOR THE MELTING OF ALUMINUM

AVAILABLE CAPACITY:
50 KGS TO 3 TONS
IN KGS:
IN KW: 20 KW TO 1500 KW
UNIT CONSUMPTION IN
MANGALENZ INDUCTION
500 KWH/TON TO 550 KWH/TON
MELTING FURNACE @NORMAL
OF ALUMINUM MELTING
CONDITIONS:
*IN ACTUAL RUNING CONDITION:
POURING TEMP FOR ALU. : 6600C TO 7200C (MAX)
1. ALUMINUM SCRAP OF WIRES/CABLES/STRIPS ETC.
WHICH TYPE OF MAT. CAN MELT 2. ALUMINUM SWARF/ CHIPS/ TURNINGS.
IN THE MAGNALENZ INDUCTION 3. ALUMINUM TINS (PREFERABLY BAIL COMPRESSED)
MELTING FURNACES: 4. ALUMINUM FOILS (-------------------DO------------------)
5. ALUMINUM UTENSIL ETC.
1. HIGH ALUMINA.
2. NEUTRAL.
RECOMMENEDED LINING FOR 3. ACIDIC.
ALUMINUM MELTING SHOULD HAVE EXCELLENT RESISTANCE TO CHEMICAL,
THERMAL AND MECHANICAL DAMAGE, WITH A LOWER
SINTERING TEMP. TO SUIT TO ALU. & ALU. MELTING.
%
AL2O3 59 TO 62
APPROX REQUIRED SIO2 35 TO 62
COMPONENTS IN PERCENTAGE MGO 0 TO 0.5
PRESENT IN LING MAT. FOR. ALU. CAO 0.5
MELTING IN INDUCTION FE2O3 0.8 TO 0.9
FURNACE: MAX. GRAIN SIZE/MM 3 TO 5
BONDING CERAMIC
SERVICE TEMP: 8000C TO 16000C
1. ALUMINIUM SHEET FORMER
FORMER MATERIALS:
2. REMOVABLE M.S. FORMER
RECOMMENEDED CHURING

(STIRRING): BASED ON
H/D RATIO IN INDUCTION 0.035 TO 0.5
MLETING FURNACE FOR ALU.
MELTING
MODERAT CHURNING/STIRING IS ADVICABLE IN ANY CASE, FOR LOW LOSS OF ALUMINUM,
WHILE MELTING IN INDUCTION FURNACE:
oducts
Induction Melting Of Brass
INDUCTION MELTING FURNACE FOR THE MELTING OF BRASS

AVAILABLE CAPACITY:
25 KGS TO 3 TONS
IN KGS:
UNIT CONSUMPTION IN MANGALENZ

INDUCTION MELTING FURNACE
270 KWH/TON TO 310 KWH/TON
@NORMAL CONDITIONS:
OF BRASS MELTING
POURING TEMP FOR BRASS : 1000C TO 11500C
1. ASSORTED SCRAP OF BRASS.
WHICH TYPE OF MAT. CAN MELT IN THE 2. ALLOYING WITH COPPER SCRAP & ZINK.
MAGNALENZ INDUCTION MELTING 3. COPPER INGOT WITH ZINK ALLOYING.
FURNACES: 4. BRASS INGOT.
5. BRASS CHIPS 100%.
1. ACIDIC (SILICA LINING WITH 1% TO 2.5% BORIC
ACID.)
2. NEUTRAL.
RECOMMENEDED LINING FOR BRASS
*SHOULD HAVE EXCELLENT RESISTANCE TO
MELTING :
CHEMICAL, THERMAL AND MECHANICAL DAMAGE,
WITH A LOWER SINTERING TEMP. TO SUIT TO BRASS
MELTING.
%
AL2O3 < 0.2
APPROX REQUIRED COMPONENTS IN SIO2 97
PERCENTAGE CAO < 0.5
PRESENT IN LING MAT. FOR. BRASS FE2O3 < 1.0
MELTING IN INDUCTION FURNACE: MAX. GRAIN SIZE/MM 4
BONDING CERAMIC
FORMER MATERIALS: 1. CASTED BRASS
2. BRASS SHEET FORMER
3. COPPER SHEET FORMER (ADVICABLE)
BRASS: 0.07 TO 0.15
RED BRASS: 0.07 TO 0.15
H/D RATIO IN INDUCTION MLETING
YELLOW BRASS: 0.055 TO 0.15
FURNACE FOR BRASS MELTING
MODERAT CHURNING/STIRING IS ADVICABLE IN ANY CASE, FOR LOW LOSS OF
BRASS, WHILE MELTING IN INDUCTION FURNACE:
Induction Melting Of Copper
INDUCTION MELTING FURNACE FOR THE MELTING OF COPPER

AVAILABLE CAPACITY:
25 KGS TO 3 TONS
IN KGS:
UNIT CONSUMPTION IN
MANGALENZ INDUCTION
MELTING FURNACE @NORMAL 410 KWH/TON TO 450 KWH/TON
CONDITIONS: OF COPPER MELTING
POURING TEMP FOR COPPER : 11000C TO 11500C
1. SCRAP OF COPPER/FLATES/STRIS.
WHICH TYPE OF MAT. CAN MELT
2. COPPER WINDING WIRES.
IN THE MAGNALENZ INDUCTION
3. COPPER CHIPS/SWARFS
MELTING FURNACES:
4. COPPER INGOT WITH ZINK ALLOYING.
1. ACIDIC (SILICA LINING WITH 1% TO 2% BORIC
ACID.)
2. NEUTRAL.
RECOMMENEDED LINING FOR
COPPER MELTING :
WITH A LOWER SINTERING TEMP. TO SUIT TO
COPPER MELTING.
%
AL2O3 < 0.2
APPROX REQUIRED SIO2 97
COMPONENTS IN PERCENTAGE CAO < 0.5
PRESENT IN LING MAT. FOR.
COPPER MELTING IN INDUCTION FE2O3 < 1.0
FURNACE: MAX. GRAIN SIZE/MM 4
BONDING CERAMIC
FORMER MATERIALS: 3. COPPER SHEET FORMER
COPPER 0.15 TO 0.21
H/D RATIO IN INDUCTION
COPPER ALLOYS 0.07 TO 0.125
MLETING FURNACE FOR COPPER
MELTING
COPPER, WHILE MELTING IN INDUCTION FURNACE:
Induction Melting Of Steel
INDUCTION MELTING FURNACE FOR THE MELTING OF STAINLESS STEEL

AVAILABLE CAPACITY: 25 KGS TO 16 TONS
IN KGS:
UNIT CONSUMPTION IN
MANGALENZ INDUCTION 540 KWH/TON TO 680 KWH/TON
MELTING FURNACE OF MILD S.S. MELTING
@NORMAL CONDITIONS:
*IN ACTUAL RUNING
CONDITION:
POURING TEMP FOR S.S. : 16000C TO 16500C
WHICH TYPE OF MAT. CAN 1. AVAILABLE SCRAP OF ROLLED END
MELT IN THE MAGNALENZ CUTTINGS/STRIPS/SECTION ETC.
INDUCTION MELTING 2. BAILED SCRAP OF STEEL.
FURNACES: 3. STANLESS STEEL TURNING
RECOMMENEDED LINING FOR 1. BASIC RAMMING MASS
S.S. MELTING : *SHOULD HAVE EXCELLENT RESISTANCE TO
WITH A LOWER SINTERING TEMP. TO SUIT TO STEEL
MELTING.
APPROX REQUIRED
COMPONENTS IN AL2O3 10
PERCENTAGE SIO2 1.4
MGO 85
S.S. MELTING IN INDUCTION
FURNACE: CAO 2.2
FE2O3 <0.6
MAX. GRAM SIZ/MM 4
BONDING CERAMIC
MAX. SER.TEMP. 17500C
FORMER MATERIALS: 1. M.S.C.R.C. SHEET/ S.S. SHEET
RECOMMENEDED CHURING 0.07 TO 0.125
MLETING FURNACE FOR S.S.
MELTING
MODERAT CHURNING/STIRING IS ADVICABLE IN ANY CASE, FOR LOW LOSS OF S.S,
WHILE MELTING IN INDUCTION FURNACE:
INDUCTION MELTING FURNACE FOR THE MELTING OF STEEL

AVAILABLE CAPACITY: 25 KGS TO 16 TONS
IN KGS:
UNIT CONSUMPTION IN
MANGALENZ INDUCTION 540 KWH/TON TO 680 KWH/TON
MELTING FURNACE OF MILD STEEL MELTING
@NORMAL CONDITIONS:
*IN ACTUAL RUNING
CONDITION:
POURING TEMP FOR STEEL :
16000C TO 16500C
WHICH TYPE OF MAT. CAN 1. AVAILABLE SCRAP OF ROLLED END
MELT IN THE MAGNALENZ CUTTINGS/STRIPS/SECTION ETC.
INDUCTION MELTING 2. BAILED SCRAP OF STEEL.
FURNACES: 3. SPONGE IRON/PIG IRON.
4. STEEL TURNING.
RECOMMENEDED LINING 1. SILICA RAMING MASS (ACIDIC)
FOR STEEL MELTING : 2. NEUTRAL.
WITH A LOWER SINTERING TEMP. TO SUIT TO STEEL
MELTING.
APPROX REQUIRED ACIDIC ALUMINA
COMPONENTS IN AL2O3 < 0.2 61
PERCENTAGE SIO2 97 36
CAO < 0.5 MGO <0.5
STEEL MELTING IN
INDUCTION FURNACE: FE2O3 < 1.0 <1.0
MAX. GRAIN 4 4
SIZE/MM
BONDING CERAMIC CERAMIC
SERVICE 15500C TO 16000C 16500C
TEMP:

FORMER MATERIALS: 1. COLD ROLLED M.S. SHEET
RECOMMENEDED CHURING 0.07 TO 0.128
MLETING FURNACE FOR
STEEL MELTING
STEEL, WHILE MELTING IN INDUCTION FURNACE:
V ery Small C apacity Induction Melting Furnace
VERY SMALL CAPACITY INDUCTION MELTING FURNACE

AVAILABLE CAPACITY: 250 GMS TO 5 KGS
IN KGS:
IN KW: 2 KW TO 5 KW
UNIT CONSUMPTION IN MANGALENZ
INDUCTION MELTING FURNACE BASICALLY SUITABLE FOR PERCIOUS METAL
@NORMAL CONDITIONS: MELTING & TESTING & R & D PURPOSE
POURING TEMP FOR STEEL : 15000C TO 16000C
WHICH TYPE OF MAT. CAN MELT IN VERY SMALL SIZED THINNED & MATERIAL
THE MAGNALENZ INDUCTIONCAN BE MELT OF ANY METAL IN SILICA
MELTING FURNACES: CRUCILBE OR IN CARON CRUCILBE WHICH
ONE IS SUITABLE.
RECOMMENEDED LINING FOR STEEL *SHOULD HAVE EXCELLENT RESISTANCE TO
MELTING : CHEMICAL, THERMAL AND MECHANICAL
DAMAGE, WITH A LOWER SINTERING TEMP.
TO SUIT TO STEEL MELTING. SMALL
CAPACITY METAL CAN BE IN SUITABLE
CRUCIBLE
APPROX REQUIRED COMPONENTS IN
PERCENTAGE
PRESENT IN LING MAT. FOR. STEEL NOT APPLICABLE
MELTING IN INDUCTION FURNACE:
FORMER MATERIALS: NOT APPLICABLE
(STIRRING): BASED ON NOT APLICABLE
H/D RATIO IN INDUCTION MLETING
FURNACE FOR STEEL MELTING
STEEL, WHILE MELTING IN INDUCTION FURNACE:
OPTIMUM UTILIZATION OF THE INDUCTION FURNACE
In view of the higher initial investments, it is externally important to utilize the

induction furnace in a most efficient manner. While determining the efficiency of
the furnace, the metal tapping rate is of greater significance than the melting
rate. The 'metal tapping rate' can be defined as a product of the 'melt rate' and
the 'utilization factor'. It is necessary to operate the furnace in the most
effective way in order to achieve highest utilization factor.
The parameters affecting the utilization factor have been discussed here.
Charging Scrap Quality & Other Raw Materials Quality Parameter:
Correct charge mix plays in important role in deciding the tap to time of the
furnace. Following parameters should be considered while selecting the charge
mix.
The charge should be clean and rust free. The oxidation losses and
the slag generation is substantial in case of rusty scrap.
The charge should be in suitable sizes. The ideal charge is such
that, the whole crucible can be packed without leaving voids. In order to
achieve condition close to this, the charge should be lumpy in form or
should be 'bailed' in suitable sizes.
Most of the time in practice the selection of charge mix is governed by

the prices of the scrap. While selecting the scrap based on economics,
one should also consider the yield of the scrap, power consumption and
the 'tap to tap time'. The selection is done best when the contribution per
ton per hour is considered. It is often found that the cheapest charge mix
need not be the most economical one.
A similar exercise should be made while selecting the other raw

materials.
Metal Charging Parameter:Major improvements can be made in the recovery of the additives,
and the addition times by improving the charging sequence.
As the molten level rises above the power coil, the stirring diminishes. This is more prominent
especially in case of medium frequency furnace. A carbon recovery of 85% to 95% is reported
when the claimed petroleum coke is added along with the charge. The recovery runs down to
75% and below when added above the power coil. The precaluculted additions of the master
alloys thus should be done along with the charge. When the late additions are unavoidable, the
melt level should be kept below the coil level so as to obtain stirring.
Melting Operational Parameter:

Poking of the charge assists in the decent of the semi plastic mass of charge to from a pool in
the bottom of the furnace, thus increasing the melt rate and prevents from bridging. Poking
also prevents from uneven wear of the lining.
In is essential especially when there is no heal of liquid metal in the furnace and when the
opening of the furnace crucible is smaller in diameter. Poking is a peculiar feature of medium
frequency furnace and the furnaces with smaller batch quantities.
Effective poking largely depends upon the skills of the charge men. Poking can effectively be
done with thick MS rods by using the lining top as a fulcrum.
The deslagging should be done as fast as possible. This operation can be done simultaneously
along with the super heating of the metal. Use of proper flux for coagulation of the slag is
recommended. A dish type slag racker can be used for deslagging.
Superheating of the metal should be avoided as it leads to
Lower metallurgical qualities.

Higher oxidation losses.
Excessive lining losses.
Lower utilization factor.
The temperature should be checked on reaching the taping temperature.
Frequent temperature checking should also be avoided as it increases the
consumption of the thermocouple tips and also reduces the utilization
factor. For the given capacity furnace power input required for increasing
a known temperature can be determined. On checking the temperature
once, calculated power can be supplied to the melt and tapped off. This
gives fairly accurate temperature control.
Following are some of the figures of power input for given rise in
temperature.
160 KW
250 Kg
Medium frequency (without lid)
Rate of temperature rise on full load

400C per min 45 Kwh (at 15000C)
Power input required to maintain furnace
Approx time will be taken to achieve will be 58 seconds
Similar observation should be made for individual furnaces as the

operating conditions, such as design, radiation losses etc very. Following
figures indicate the effect of the operating conditions on the power input
figures.
160 Kw-250 Kg
Without lid With lid
Rate of temperature rise on full load 400/ min 460C
Rate of fall of temperature 16.50/ min 80/ min
Furnace Lining Parameter:
Relining the furnace is time consuming and requires as much as time to be given.
Moreover it adds to the cost by way of consumption of costly ramming mass and
sintering power. It is extremely important to achieve high lining life. Lining life as high
as 200 heats of CI per lining can be achieved in medium frequency of 250 kw-550 kgs
capacity furnace.Good quality lining material is one of the most important factors in
obtaining a high lining life. A good lining material should reveal following properties.
 Good strength
 Good refractions
 Resistance to slag penetration.
POWER CONSUMPTION IN INDUCTION FURNACE:
THE FACTORS EFFECT THE POWER CONSUMPTION:
The furnace equipment manufactures only guarantee on the power

consumption per tone and melting rate for the furnace for melting down
or charge under specific conditions, and also the power required for
superheating of molten metal.
In practice in addition to the above additional power and also more time
are required for the following operation, which bring down melting rate
and limit the out-put for the furnace.
Charging time –charging has to be done from time to time
progressively and depends on the charging material also to a large
extent. Solid charges such as blocks and pig iron take considerably less
time than loose material such as steel/C.I. turnings/ borings to melt.
Slagging time- From time to time, as the level of metal builds-up
slag is to be removed, as and when it accumulates, before further
charging to avoid bridging. This time is considerable when light scrap or
turnings and borings are used.
Composition adjustment time- even-though pre calculated charges
are made into the furnace, it is necessary to check the molten metal
composition and make suitable additions for adjustments before pouring.
Foundries having instant analysis facilities such as carbon equivalent
meter or spectrograph can save on this time to a great extant, while
those adopting chemical analysis by normal laboratory methods need
longer time and in the intervening period, the furnace is kept 'on' leading
power to additional power consumption and delays in pouring.
This composition adjustment time can be minimized with tap-and-charge system of furnace
operation, described elsewhere in this paper but is calls for unit metal composition being
used.
Tapping time- This is unavoidable, but can be kept at the barest

minimum practicable by tapping the maximum possible quantity of molten
metal at a time instead of small quantities.
Waiting time- For ensuring the optimal furnace out-put capacity, it
is preferable to keep the moulds waiting for molten metal instead of the
furnace waiting, as this means higher power consumption and reduced
out-put rates.
OTHER FACTORS :( RELATED TO FURNACE/POWER/SCRAP)
In addition to the above, factor which contributes to increased power

consumption is.
Low power factor
Low input voltage
Frequent failure of power supply.
Asbestos thickness and rammed lining thickness, more than
recommended.
Heavily patched/ repaired furnace lining.
Frequent emptying of furnace and cold starts.
Average level of molten metal low in furnace in operation.
The power requirement per tone of molten metal for different
types of charge materials is as follows: (approx)
Solid blocks: 500-550 Units (approx)
Pig iron: 550-600
C.I. scrap: 550-600
C.I. Borings 650-700
Steel scrap: 600-650
Steel Turnings: 650-700
Depends upon cleanness of material. High percentage of mud, etc increases power
consumption.
For various combinations of charge materials intermediate figure are

application.
In super heating, generally 50 units per tone of molten metal per 1000C
rise in temperature are observed. Also the melting/super heating power
consumption is higher per ton with smaller furnaces.
FURNACE LINING:
lining & Functions:
Lining is a container formed by ramming a refractory mass mixed with suitable

binder, inside the induction furnace coil, and developing its bond by suitable
means.
To store and hold the metal being melted and superheated.
To physically isolate the metal being melted from other parts of the
furnace, and to avoid electrical contact between the melt and the
induction coil.
PROPERTIES OF A GOOD LINING MATERIAL:
In majority of installations, the melt melted in induction furnace are ferrous,

having the melting point from about 11500 C in case of solf grey-iron to about
15400 C in case of low carbon steel. Alloying elements like manganese,
chromium, nickel, molybdenum, titanium, tungsten, etc and their Ferro-alloys
have high melting points. The normal operating temperature in an induction
furnace is, therefore, from around 1350-14000 C in case of soft-gray iron to as
high as 16500 C in case of low carbon steels, and even higher, up to 17000 C in
certain specialty super alloys containing tungsten. The lining material has to be,
therefore, some form of refractory which can withstand such temperature.
In addition to the refractoriness, the lining material should possess many other
properties to qualify as a good lining material. These are listed below.
It should be capable of holding the liquid metal at its normal
working temperature, and should also be able to withstand occasional
over temperature conditions, without getting fused or losing its hot
strength.
It should be chemically compatible with the metal being melted and
the slag being generated, so that erosion due to reaction with metal
and/or slag is minimum.
It should be able to withstand the stresses developed due to its
own expansion and contraction caused by thermal cycles of furnace
operation.
It should be able to withstand the mechanical forces arising during
metal charging, deslaging and furnace tilting.
It should have low thermal capacity, so that during thermal cycles
of furnace operation, less heat is absorbed by the lining.
It should have low thermal conductivity so as to reduce heat losses
into the induction coil. (However, high thermal conductivity has an
advantage in case of metal penetration through the lining, as the
penetrating metal stream will solidify much before it can reach the coil.)
It should be easily installable and sinter able into a uniform and
high density mass of adequate strength.
After use, it should be easily knocked-out without damaging the
coil.
TYPES OF REFRACTORIES:
In nature there is no such refractory which meets all these properties. From
among the available refractories, three types meet the important properties for
specific applications. These refractories are commonly used to form induction
furnace linings. These are;
Silica (Si02) ------- (acidic)
Alumina (Al2O3) ------- (neutral)
Magnesia (MgO) ------- (basic)
Their typical properties are given in table-1, and expansion characteristics are
given in figure 1.
Silica (Acidic Lining):
The silica lining (Si02) is acidic in nature. It is produced by crushing and grading
of a good quality of quartzite having very high purity (silica content above
99%). It is used in powdered condition. Correct grading is important for uniform
and hard ramming. Typical size grading of silica ramming mass is given in table-
2. Boric acid (or boric oxide) is the most commonly used binder. Pure silica has
a melting point of 17230 C. the rammed lining is sufficiently refractory for use
up to 1550 - 16500 C. Between 6000 C and 16000 C, silica expands very little,
and is superior to both alumina and magnesia to resist thermal shock. Being
available abundantly in nature, cost is very low in comparison to alumina and
magnesia.
Application: It is most widely used in iron-foundries. It is also used in some steel-
melting.
Limitations: It cannot be used for temperature above 16500 C. With

high manganese melt, silica forms low viscosity glass, and
is washed out Very fast. At high temperatures, silica
dissociates into silicon and oxygen, and silicon And oxygen
and silicon level in metal goes up. Si02 + 2C= 2 Si + 2CO
Alumina (neutral lining):
Alumina (Al203) is neutral in nature. Among the three lining materials it has the highest negative
free energy of formation. Hence it is the most stable oxide. Alumina refractories are produced
form bauxite. These are produced to different levels of purity – form 80% Al203. Different
grades are used on the basis of maximum operational temperature during melting.
The commonly used binders are either silica (for use with acidic slags) or magnesia (for use with
basis slag). Additional binders may be added to promote sintering at lower temperature. The
size grading is somewhat coarser to that of silica ramming mass.Advantage: Alumina has high
refractoriness, and is more inert to many metal-slag reactions.
Limitations:Its thermal shock resistance is somewhat poorer to that of silica. It is relatively very
costly.
Magnesia (Basic Lining):
Magnesia (Mg0) is a basic lining. It is made from either naturally

occurring carbonate ore, or is synthetically produced from sea water, It is
graded in size from 0 to 5 mm, but somewhat coarser to silica ramming
mass. Two types of bonds are used- either spinal bond (Mg0.Al203) or
silicate bond (2Mg0.Si02).
Applications: Magnesia linings are widely used in steel melting as well as in
melting of high alloyed irons, for temperature up to 16500 C. Magnesia is
resistant to basic slag and high-manganese melts.
Limitations; Magnesia has very poor resistance to thermal shock, hence it
serves best only with continuous furnace operation.
Different Zones in lining:
During sintering (and also during normal working) the temperature of the lining
varies considerably from its hot inner face to the cold outer face next to the
asbestos sheet. Three different zones are created in the lining.
A sintered zone is formed at the hot face in which due to high
temperature (approx 13000 C), the fusion of boro-silicate glasslike binder
with silica ramming mass is complete. This zone has very low-porosity
and is strong. Its thickness is approximately one-fifth of the lining
thickness.
The next zone, behind the sintered zone, is called a fritted zone, it
is subjected to somewhat lower temperature (900-13000 C), and hence
the bond development is partial. This zone has higher porosity and less
strength, It is about two-fifth of the lining thickness.
The last outermost zone, which is next to the asbestos sheet, does
not attain high temperature, there is no bond formation, and thee
unbounded granular lining remains in its original form. It is highly porous
and has low strength.
In case of any crack in the sintered zone or fritted zone, this outermost zone
prevents metal penetration reaching to power coil by spreading the leaked metal
in all directions.
With increase in the use of the lining, the lining slowly becomes thin, and the
interfaces between these zones move towards the outer coil. Finally the
unbounded zone is completely eliminated. If crack develops in the lining at this
stage, metal can penetrate to power coil.
Diffrent Zone Of Lining
OPERATING PRACTICE FOR LONG LINING LIFE:

Temperature control:
For safe furnace operation and long lining life it is essential that the maximum
temperature is not unduly exceeded beyond the safe temperature. In fact by
paying more attention to metal temperature control by raising it not more than
what is necessary, one can considerably increase the lining life. At low metal
temperature there is a tendency to oxidize silicon form the metal and produce a
highly siliceous slag which may build up on the furnace walls.
Si + 02 = Si02 With increase in metal temperature, silicon oxidation becomes

less and at some temperature the melt remains under equilibrium. At still higher
temperatures, the carbon in the melt reacts with silica lining to reduce it is
silicon and liberates gaseous carbon monoxide.
Si01 +2C = Si + 2 CO
This carbon monoxide can be seen bubbling near furnace walls when metal is
held at high temperature. Slag attack on lining also increases with increases in
temperature.
Thus at higher temperatures the lining is under server attack both form metal as
well as from slag. In addition, the following practices also help increasing the
lining life.
Continuous use of the furnace round the clock gives less thermal
fluctuations and results in long life. Intermittent use results in repeated
and steeper thermal shocks and causes rapid failure or lining.
If a single type of alloy or grade is being repeatedly melted, the
lining life is more. e.g. a furnace melting only unalloyed grey-iron has
longer lining life as compared to a furnace melting various grades of grey
irons, alloy-irons, ni-hard, etc.
Care in charging the furnace to avoid/minimize impact by charging
heavy pieces.
Removal of slag before charging liquid metal from other furnaces,
ladies to the induction furnace to ensure that only clean metal is in
contact with the lining.
Avoid any possibility of bridging of a charge in the furnace. It can
cause excessive wear of bottom lining in case of superheating of the melt
below the bridge.
Do not use heavily rusted scrap. Its use will increase the volume of
slag produced. Slag removal will be difficult and lining life will also be
somewhat reduced.
While using turnings/borings of steel scrap, do ensure that these
are dry and are free from oil or moisture. Otherwise there is a risk of
splashing or explosion, with at times, heavy impact loading on the lining.
During melting and melt-treatment, if any, slag formed should be
removed at regular interval. It will minimize slag/lining reactions or lining
erosion and help in improving lining life.
Various Types Of Lining Wears
LINING REPAIR
During day to day furnace operation the lining is subjected to various kinds of
thermal stresses, mechanical loading and metal-lining reactions. As a result
some minor or major type of lining wear does take place. There are various
methods to repair the lining depending on the size and nature of wear.
Cracking:
Often, small hair-like cracks are seen on the lining surface after it has been
cooled to room temperature. This is natural and need not cause any problem.
On cooling the lining refractory contracts, and when it cannot withstand the
contraction – stresses, it develops small cracks and there by release the
stresses.Tiny cracks o this nature close themselves on reheating of crucible
during next melt. The only care needed is to ensure that in the initial heat after
cold-start the charge should not contain fine metallic particles or borings which
can enter the crack and prevent from self- closing.

Magnalenz Induction Furnace

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Magnalenz Induction Furnace

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Magnalenz Induction Furnace

Benefits of Medium Frequency Induction Furnace:

Higher Yield: The absence of combustion sources reduces oxidation losses

Faster Startup: Full power from the power supply is available,

Flexibility: No molten metal is necessary to start medium frequency

Cleaner Melting: No by-products of combustion means a cleaner melting

Compact Installation: High melting rates can be obtained from small

Reduced Refractory: The compact size in relation to melting rate means

Better Working Environment: Induction furnaces are much quieter than

Energy Conservation: Overall energy efficiency in induction melting

The Magnalenz Difference

Magnalenz Induction Furnace for Metals

Magnalenz Products Range

Magnalenz installation consists of:

The melting basin is inside the inductor with an adequately thick

MF Solid State Power Converter V i e w

Basically it Consists of:

MF Power Factor Compensation Capacitor Bank

Basically it Consists of:

 Control Circuits Safety

Thyristor Controlled Rectifier

Safety Margin In Power

Reduced Melting Cost With Constant Power

Safety And Protection System

For Different Metal

So At same kW, different metals, different Melt rate

( A ) For Steel Ingot

B) For Castings (Step -2)

WHAT IS EFFECT OF STIRRING

INADEQUATE STIRRING CAUSE

1. Insufficient Mixing of Alloys

EXCESSIVE STIRRING CAUSES

1. Frequent lining erosion

Role of Frequency in Melting

HOW TO CALCULATE THE FURNACE.EFFICIENCY

55% TO 65% (MAX) OVERALL ENERGY EFFICIENT FURNACES ARE AVAILABLE.

LOSSES IN INDUCTION FURNACE

In foundry the tool or unit of efficiency measurement is kwh/ton.

2. Furnace down time:

Basic lining is better conductor of heat compared to acidic lining

INDUCTION MELTING FURNACE FOR THE MELTING OF ALUMINUM

Induction Melting Of Brass

INDUCTION MELTING FURNACE FOR THE MELTING OF BRASS

Induction Melting Of Copper

INDUCTION MELTING FURNACE FOR THE MELTING OF COPPER

Induction Melting Of Steel

INDUCTION MELTING FURNACE FOR THE MELTING OF STAINLESS STEEL

INDUCTION MELTING FURNACE FOR THE MELTING OF STEEL

V ery Small C apacity Induction Melting Furnace

VERY SMALL CAPACITY INDUCTION MELTING FURNACE

OPTIMUM UTILIZATION OF THE INDUCTION FURNACE

In view of the higher initial investments, it is externally important to utilize the

Charging Scrap Quality & Other Raw Materials Quality Parameter:

Most of the time in practice the selection of charge mix is governed by

A similar exercise should be made while selecting the other raw

Melting Operational Parameter:

Superheating of the metal should be avoided as it leads to

Lower metallurgical qualities.

Rate of temperature rise on full load

Approx time will be taken to achieve will be 58 seconds

Similar observation should be made for individual furnaces as the

Furnace Lining Parameter:

POWER CONSUMPTION IN INDUCTION FURNACE: