RGMCET - NANDYAL

Presented by:

R SATISH KUMAR
 RECAP

We have discussed about

• Applications of direct and indirect arc furnaces
 OBJECTIVES

On completion of this topic you would be able to

know

• Operation of Induction Furnace.

 INDUCTION HEATING

• Induction heating is also known a high frequency heating .

• The basic principle involved in this is transformer principle.

•When ac current is passed through primary heating coil, an

electric current is induced in the charge.

•This induced current is dependent on:

 the magnitude of primary current.

The turns ratio.

Co-efficient of magnetic coupling.

• Heat transfer by high frequency heating is as much as
10,000 W/cm2

• Generally this type of heating is used for magnetic elements

because of their high permeability.

•For non magnetic materials the heat generated is due to eddy

current losses where as if it is a magnetic material there will be a
hysteresis losses in addition.

• generally the heat depends on these factors:

•Primary current

•Frequency

•Permeability and resistivity of charge

 Induction furnaces
• Generally there are two types of induction
furnaces :

– Core type or low frequency Induction furnace

– Core less or high frequency induction furnace
 Characteristics of Induction Heating

• Heat is non uniform as the current flows only on

the outer surface of the metal.
• Heat transfer is very quick as the heat is
produced in the metal which is to be heated.
• No mechanical or electrical contact between the
source and the charge i.e, no proper care is
required.
• Temperature attained is very high
CORE TYPE INDUCTION HEATING
• The Core type furnace is essentially a transformer.

• Primary side is connected to supply.

• Secondary side contains charge (materials) in Iron core

annular hearth.

• The charge is magnetically coupled to the primary by an

Iron core.
•The magnetic coupling between primary and secondary is

very poor resulting in high leakage current and a low power

factor. For this reason the furnace is operated at low

frequencies of the order of 10Hz or so.

• Hence it is called low frequencies furnaces i.e., 10Hz.

• The low frequency necessitates an additional MG set or

frequency converter.
• To start the furnace Molten metal is poured in the annular
hearth before start.

• Otherwise there is no material and the secondary side is

open and no current will be induced.

• Hence no heating will take place.

• This is convenient where the furnace is to be used for

melting different types of charges.
AJAX WYATT VERTICAL CORE FURNACE
• It is an improvement over the core type induction furnace

• The magnetic coupling in this furnace is better than core

type furnace.

• Leakage reactance is comparatively low and frequency is

high, hence it is high frequency furnace.

• It employs vertical crucible instead of horizontal.

• The system avoids the pinch effect due to the weight of the
charge in the main body of the crucible
• The circulation of Molten metal takes place round the ‘V’

portion by convection currents.

• Inside the furnace is lined depending upon the charge.

• The top of the furnace is covered with an insulated cover

which can be removed for charging.

• Hydraulic arrangements are usually made for tilting the

furnace to remove the molten metal.

INDIRECT CORE TYPE INDUCTION FURNACE
• This type of furnace is used for heat treatment of metals

• The wall of the container forms the secondary winding.

• Iron core links the primary as well as secondary.

• Heat produced in the secondary due to induced current is

transmitted to the charge by radiation.

• A detachable magnetic circuit made of a special alloy is

kept inside the chamber.

• The alloy will loose to magnetic properties at a particular

temperature and are regained when it cools down.

• On reaching the critical temperature the reluctance of the

alloy increases and here by decreasing induction effect.

• Critical temperature varying 4000c to 10000c can be

employed for heating different materials.

• The furnace operates at a PF of around 0.8

 CORELESS INDUCTION HEATING

Fig.4
We α B2m f2
We = eddy current loss (W)
Bm = Maximum flux density (T)
f = Frequency (Hz).

• The coreless induction furnace operates on the principle of

an electric transformer.
• If there is no core, the flux density will be low.
• For compensating the low flux density, the primary supply
should have high frequency.
•The furnace consists of a refractory or ceramic crucible

cylindrical in shape enclosed with in a coil which forms the

primary of a transformer.

• The furnace also may have a conducting or non-conducting

container.

• The container is made of conducting material it forms the

secondary circuit and the charge can have either conducting

or non-conducting properties.
• When high frequency of 500 of 1000 Hz supply is given to
primary windings

• The eddy currents are set up in charge or container by

transformer action.

• There currents heat the charge to melting point and they

also set up the electromagnetic force which produce a
stirring action to the charge.

• The furnace becomes relatively light in weight and can be

easily tilted for pouring the metal.
 INDUSTRIAL APPLICATIONS

[ Core, Coreless and High frequency furnace ]

• The vertical core type furnaces are widely used in foundries

for melting and refining brass, zinc, tin and nonferrous

metals.

• Coreless furnaces are well suited for intermittent operation.

• And also for High quality of production.

 INDUSTRIAL APPLICATIONS

[ Core, Coreless and High frequency furnace ]

• Molten metal can be held at any desired temperature for an

extended period of time.

• High frequency furnace is used for conducting materials i.e.,

Ferromagnetic and Non-Magnetic.

COMPARISON BETWEEN HIGH FREQUENCY AND POWER
FREQUENCY CORELESS
S. High Frequency Power frequency
No.
1 Frequency converter is Not required.
necessary
2 More energy required i.e, 20% Less energy required.
to 30% for same rating.

3 Maintenance cost is more Less

4 Less turbulence and stirring More
effect
5 Large scrap melts with more Large scrap melts with less
oxidation loss. oxidation loss.

6 No special starting procedure is Special starting procedure is

required required.
 Contd..
7 Low capacity (few kgs. To 15 Large capacity (above 1
tons) furnaces are used tone)

8 Initial cost is more Less cost

9 High frequency (500 to 1000 Hz) Only 50Hz.

10 Well suited for intermittent Well suited for long

operation of different alloys. production schedules of one
alloy.

11 Care should be taken against Negligible.

stray field

12 Overall efficiency is low. Overall efficient is more.

 SUMMARY

We have discussed
• Principle and operation of induction furnace
 QUIZ

1.Coreless induction furnace operate on the principle of

a. Transformer
b. Induction motor
 FREQUENTLY ASKED QUESTIONS

1) What is induction heating

2) Describe briefly with a neat sketch the core type induction
furnace
3) Explain the vertical core type of furnace (Ajax Wyatt
furnace) with a neat diagram
4) Explain the construction and operation of coreless induction
furnace

5) Explain the indirect core type induction furnace with sketch

6) Compare high frequency and power frequency coreless

induction furnace