INDUCTION FURNACE(IF)

Scrap Molten Metal

 INDUCTION FURNACE
The electric induction furnace is a type of melting furnace that uses electric currents to melt
metal. Induction furnaces are ideal for melting and alloying a wide variety of metals with
minimum melt losses, however, little refining of the metal is possible.
PRINCIPLE OF INDUCTION FURNACE
The principle of induction furnace is the Induction heating .
INDUCTION HEATING
Induction heating is a form of non-contact heating for conductive materials.
The principle of induction heating is mainly based on two well-known physical phenomena:
1. Electromagnetic induction
2. The Joule effect
1) ELECTROMAGNETIC INDUCTION
The Coreless furnace is so named because it is an electrical transformer in which the
primary and secondary windings are not coupled using a laminated iron core.
The primary winding of a transformer produces magnetic flux. Flux density varies with the
alternating current passing through the winding. As the current changes in amplitude and
direction, so does the magnetic field in the proximity of the primary coil.
 Induction Furnace

When resistive load is placed within the changing magnetic field, a current is induced in it just
like it would in the secondary winding of a transformer. Induced current passing through the
resistive load produces heat. The metal pieces placed in the furnace become closed-loop
(shorted-turn) secondary windings. The resistance of the metal itself becomes the resistive load.
Each piece of metal and loops formed by pieces of metal in electrical contact with each other are
individual secondary windings. As the metal melts and more is added, the density of the metal
charge increases with an accompanying change in coupling and resistance.

In large furnaces, a Steel Frame is used to provide the required mechanical strength. If the
magnetic flux external to the coil were allowed to pass through the frame, it would be heated by
eddy currents and would eventually melt. A number of magnetic paths of laminated iron (called
shunts) stand vertically in a picket-like fashion around the outside of the coil between the coil
and the steel frame. The magnetic flux path outside of the coil is, therefore, concentrated near
the
outside surface of the coil and is thus prevented from passing through the steel frame.
 Induction Furnace
2) JOULE HEATING
Joule heating, also known as ohmic heating and resistive heating, is the process by which the
passage of an electric current through a conductor releases heat.
The heat produced is proportional to the square of the current multiplied by the electrical
resistance of the wire.

Induction heating relies on the unique characteristics of radio frequency (RF) energy – that
portion of the electromagnetic spectrum below infrared and microwave energy. Since heat is
transferred to the product via electromagnetic waves, the part never comes into direct contact
with any flame, the inductor itself does not get hot and there is no product contamination.
Induction heating is a rapid, clean, non-polluting heating.
The induction coil is cool to the touch; the heat that builds up in the coil is constantly cooled
with circulating water.
 Induction Furnace
FEATURES OF INDUCTION FURNACE
 An electric induction furnace requires an electric coil to produce the charge. This heating
coil is eventually replaced.
 The crucible in which the metal is placed is made of stronger materials that can resist the
required heat, and the electric coil itself cooled by a water system so that it does not overheat
or melt.
 The induction furnace can range in size, from a small furnace used for very precise alloys
only about a kilogram in weight to a much larger furnaces made to mass produce clean metal
for many different applications.
 The advantage of the induction furnace is a clean, energy-efficient and well-controllable
melting process compared to most other means of metal melting.
 Foundries use this type of furnace and now also more iron foundries are replacing cupolas
with induction furnaces to melt cast iron, as the former emit lots of dust and other pollutants.
 Induction furnace capacities range from less than one kilogram to one hundred tonnes
capacity, and are used to melt iron and steel, copper, aluminium, and precious metals.
 The one major drawback to induction furnace usage in a foundry is the lack of refining
capacity; charge materials must be clean of oxidation products and of a known composition,
and some alloying elements may be lost due to oxidation (and must be re-added to the melt).
 Induction Furnace
 There are many different designs for the electric induction
furnace, but they all center around a basic idea.
 The electrical coil is placed around or inside of the crucible,
which holds the metal to be melted. Often this crucible is
divided into two different parts. The lower section holds the
melt in its purest form, the metal as the manufacturers
desire it, while the higher section is used to remove the
slag, or the contaminants that rise to the surface of the melt.
 Crucibles may also be equipped with strong lids to lessen
how much air has access to the melting metal until it is
poured out, making a purer melt.
Fig: Inductor
 Induction Furnace
Mixing of Quartzite Powder
1) At first, the place for mixing the powders has to clean by air
2) 1 kg of boric acid powder has to mix with per 100 kg of quartzite powder by
mixer machine

Or,
5.5 kg of boron oxide has to mix with per 1000 kg (1 MT) of quartzite powder by
mixer machine
3) The powder tray has to be cleaned properly before keeping the powder
4) The powders can never be kept for 3 to 4 hours before starting the lining
procedure
5) Any type of waste materials/iron particles or contact of water has to be avoided
 Induction Furnace
Criteria of Lining
1) The furnace has to be cooled by cooling fan after its life was expired. Then the
measurement of lining wall has to be taken in presence of Shift In-charge or Team Member.
2) Then the rest of lining wall has to be broken by using pneumatic hammer.
3) The breaking procedure has to be carefully observed to inhibit any type of shock on coil
grout or coil.
4) Similarly, the adjacent slag on side lining or the black portion has to be cleaned/break
properly .
5) The condition of coil grout has to check properly and repair if necessary.
6) All of portion covering the lining area has to be cleaned properly by air.
7) The information of required GLD value (10-15) has to be taken from Shift In-charge or
Team Member.
8) After the confirmation of GLD value lining process can be started. At first, the 18 inches
thick bottom has to be accomplished by quartzite powder. This process has to be done in
three
(03) steps. After completion of each step (6 inch thickness), the forking process has to be
done properly.
9) After completion the forking steps of bottom preparation, the hammering process has to be
continued properly for the required time range.
 Induction Furnace

10) The measurement of selected forma for lining has to be checked properly. Then it has to
be cleaned properly by air.
11) The forma has to be placed properly in the specific position of furnace by proper
measurement by gauge. This process should be done carefully.
12) After the fixation of forma in proper place the side lining has to start and keep continuing
the forking process after 8 inches thickness.
13) After completion of above discussed procedure properly, the Jolter machine has to be
started.
14) After starting the Jolter machine, the proper compaction process at adequate pressure has
to be ensured.
15) The forking process has to be carried on during compaction process by Jolter machine.
16) After accomplishment of compaction process the top side of furnace has to be cleaned
properly by air.
17) The top portion and spout of the furnace has to be prepared by proper mixing ratio of
sodium silicate and quartzite powder in presence of lining technician.
18) The spout has to be dried by firing the waste paper tubes.
 Induction Furnace

ADVANTAGES OF INDUCTION FURNACE:

Induction furnaces offer certain advantages over other furnace systems. They include:
 The absence of combustion sources reduces oxidation losses that can be significant in
production economics.
 Full power from the power supply is available, instantaneously, thus reducing the time to
reach working temperature. Cold charge-to-tap times of one to two hours are common.
 No molten metal is necessary to start medium frequency coreless induction melting
equipment. This facilitates repeated cold starting and frequent alloy changes.
 Medium frequency units can give a strong stirring action resulting in a homogeneous melt.
 No by-products of combustion means a cleaner melting environment and no associated
products of combustion pollution control systems.
 High melting rates can be obtained from small furnaces.
 The compact size in relation to melting rate means induction furnaces require much less
refractory than fuel-fired units
 Induction furnaces are much quieter than gas furnaces, arc furnaces, or cupolas. No
combustion gas is present and waste heat is minimized.
 Overall energy efficiency in induction melting ranges from 55 to 75 percent, and is
significantly better than combustion processes.
 Induction Furnace
DISADVANTAGES OF INDUCTION
FURNACE
 Refining in Induction Furnace is not as
intensive or effective as in Electric Arc
Furnace (EAF).
 Life of Refractory lining is low as compared
to EAF.
 Removal of S & P is limited, so selection of
charges with less impurity is required.
 LADLE REFINING FURNACE(LRF)

Ladle Refining Furnaces are a plant. Ladle Refining is a

proven technology used for
producing alloy- steel,
desulpharizing , de-oxidizing
liquid steel and for improving
the productivity from a steel
post melting treatment that is
after melting in either the
Induction Melting Furnace or
Electric Arc Furnace.
 Objective
LADLE REFINING
FURNACE
Objective of a ladle refining furnace can be
summarized in the following way-

1. Superheat adjustment-Heating of the liquid

steel to a temperature suitable for continuous
casting.

2. Homogenization of chemical composition

and temperature of liquid steel in the ladle.

3. Deoxidation or killing -
Removal of oxygen.

4. Alloy addition to provide bulk

or trim chemical control.
5. Decarburization – Removal of carbon for
meeting the requirement of certain grades of
steel.

6.Desulfurization – Reduction of sulfur

concentrations as low as 0.002%
Also provides de-phosphorization to some extent.

7. Mechanical properties – Improvement in

toughness, ductility, and transverse properties.
LADLE REFINING FURNACE

Steel Reduction of
cleanlines non-metallic
s inclusions

Uniform
distribution of PURGI
temperature and
alloy additives NG

Desulfurizati
on
 LADLE REFINING FURNACE(LRF)

Operation procedure
 Raise and keep molten steel temperature. The molten steel heated by arc to get new thermal
energy. Graphite electrode use for arcing.
 Lime (CaO) , CaF2 addition for slag making.
 Pet coke, Met coke,CaC2, CaSi2-wire, FeMn, SiMn, FeSi etc. are using for chemical
adjustment.
 Average process time (30-40 ) min.
 Average arcing time (20-25) min.
 Temp checking average (2-3) times.
 Average 1st temp. at LRF (1585-1590) degree centigrade.
 Average lifting temperature (1600-1605) degree centigrade.
 Nitrogen/ Argon purging on whole process time for stirring of the molten metal promote
homogenization.(After 20minutes using of Argon should be start in case of purging)
 LADLE REFINING
FURNACE

Desulfurization:

A highly reducing condition is required for an extensive desulfurization.

It is possible to desulfurize aluminium killed steel in the LRF using CaO based
slags to less than 20 ppm Sulfur.
3CaO+2Al+3S=3CaS+Al₂O₃

The slag will absorb sulfur until CaS forms enough to decrease the amount of
dissolved CaO.

Steel deoxidized with Si is difficult to desulfurize because oxygen potential is

significantly higher than it is in case of aluminium killed steel. For these steel
desulfurization is limited to 10-20%.

CaF2 is an excellent desulfurization agent. They decrease oxygen potential and

resulting CaO, which can desulfurize the steel to a great extent.
 Desulfurization can
be very effective by:

1. Increasing stirring
6. Increasing rate. Increased stirring
rate ensures an intimate
Al content. mixing between slag
and metal zone.

5. Higher sulfur
partition co-
efficient,Ls
2. Higher
Ls= temperature.
Sslag/Smetal

4. Decreased 3. Formation
oxygen of foamy basic
potential. reducing slag.
Deoxidation
Refining of hot metal to steel is done under oxidizing atmosphere. During refining oxygen
dissolves in steel. Solubility of oxygen in steel is negligibly small. During solidification of
molten
steel, excess oxygen is rejected by the solidifying steel. This excess oxygen produces
defects like
blow holes and non-metallic oxide inclusion in solidified casting. Defects have considerable
effect on mechanical properties of steel.
Sources of oxygen in steel
 Rust on steel
 Oxygen blowing
 Steelmaking slag
 Atmospheric oxygen dissolved in steel during teeming.
 Oxidizing refractories

At 1600°C solubility of oxygen in liquid steel is 0.23% which decreases to 0.003% in solid
steel
during solidification. According to the degree of deoxidation, carbon steels may be
subdivided
into three groups:
 Killed steel : Oxygen is removed completely. Solidification of such steels
does not give gas porosity (blow holes)
Deoxidizer- AL
 Semi-killed steel: Incompletely deoxidized steels containing some
ammount of oxygen which forms CO during solidification.
Deoxidizer- SiMn
SiMn+Al
SiMn+Ca
 Rimming steel: Partially deoxidized or non deoxidized low carbon steels
evolving sufficient CO during solidification. These steels have good surface finish.
Deoxidizer- SiMn+Ca

Various alloying addition are made to deoxidize the liquid steel before it goes to CCM.
Among
the alloys FeSi and SiMn are mostly used in BSRM Steel Mills Ltd. Nevertheless
depending on the
circumstances FeMn too is used at times.