07-11-2012, 11:26 AM
REPORT ON INDUCTION FURNACE BY 08DDCS547
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INTRODUCTION
Induction Furnace: It is the most important Unit that helps in melting the iron.
Power Control System: It consists of the sets of practical circuits that is responsible for
the effective power control in order to melt the metal
Water Treatment Unit: Water is an important component in the induction furnace plant.
The main purpose of water is in the regulation of a particular temperature that is it works
as a coolant in the induction furnace plant.
Air Pollution Control Unit: As the name suggest it is required in order to keep the plant
pollution free and thus better efficiency.
Chemical Lab Test: It is done in the chemical lab to test the % of each component present
in the raw material and to decide whether the raw material is applicable for the plant or
not.
Raw Material Control Unit: Consists of experienced labors who purchase raw material
required for the plant
Transportation Unit: Controls the transportation section of the industry.
Induction Furnace
An induction furnace is an electrical furnace in which the heat is applied by induction
heating of a conductive medium (usually a metal) in a crucible placed in a water-cooled
alternating current solenoid coil. The advantage of the induction furnace is a clean,
energy-efficient and well-controllable melting process compared to most other means of
metal melting. Most modern 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 tones
capacity, and are used to melt iron and steel,
copper, aluminum, and precious metals.
The frequency of operation of induction
furnace also varies. Usually it depends on the
material being melted, the capacity of the
furnace and the melting speed required. A high
frequency furnace is usually faster to melt a
charge whereas lower frequencies generate
more turbulence in the metal, reducing the
power that can be applied to the melt.
When the induction furnace operates it emits a
hum or whine (due to magnetostriction), the
pitch of which can be used by operators to
identify whether the furnace is operating
correctly, or at what power level.
Furnace Making
It is done with the help of ramming mass which is a refractory that can withstand high
temperatures. The furnace outer wall is already present and the inner wall of the furnace
is to be constructed.
Furnace inner wall making is done in following ways:
Ramming mass is put at the bottom square of the
container
The cylindrical shaped iron flask (which is thinner than container)is put in the
container
The gap in between the iron flask and the container is filled with the ramming
mass
Now we get a cylindrical shaped hole
The raw material to be melted is put inside it and the induction process is started.
As the induction continues the iron flask, the raw materials gets melted and only
the ramming mass is left with a hole of the flask shape
This furnace obtained is used 10-15 times and after that the refractory material is
broken and the whole steps is repeated again
Magnetic Shielding & Analysis of an Induction Furnace
An induction furnace is an electrical furnace in which the
current is generated within the metal by induction heating
and the heat generated by the electric resistance that melts
the metal. The magnetic iron cores around the coil are
used to protect the coil from being damaged. The
magnetic iron cores also prevent the flux leakage so that
the steel sheet outside the iron cores will not be heated.
The magnetic flux density distribution with and without
the iron core. The flux leakage of the furnace with iron
core is lower than that of the furnace without iron core. So
the steel sheet outside the iron core is protected from
being heated.
The Joule loss of the molten metal with and without iron
core. The Joule loss of the furnace with iron core is about
5% more than that of the furnace without iron core. The
molten metal is heated efficiently with iron core.