What are the problems with energy saving in medium frequency induction furnaces?

1. Power supply voltage, transformer loss and impact. Under different power supply voltages, the transformer's own loss is different. Using a reasonable power supply voltage and a corresponding transformer is more conducive to energy saving. The selection of transformers and the matching common sense of medium frequency furnace power are now very familiar to all foundries, so we won't go into details.
2. Energy consumption problems in medium frequency induction furnaces.

A. Selection of different capacities and frequencies.

B. Matching of rated power.

C. The influence of the purity and carrying area of ​​the induction coil and water cable on power consumption.

D. The influence of scale and how to deal with it.

E. The influence of cooling water temperature on power consumption

F. The influence of furnace lining on energy saving.

3. The influence of smelting ingredients, smelting process, smelting time and equipment maintenance on energy saving during the smelting process.

When we adjust all the above items to the best, our electric furnace will produce the most molten iron at the most economical cost for the foundry.

Analysis of losses in various parts of medium frequency induction furnace

1. Manufacturers using medium frequency induction furnaces generally use S7 and S9 energy-saving power transformers, but their voltage is low and not suitable for medium frequency induction furnaces, so they cannot achieve good results.

The unreasonable matching of medium frequency furnaces and transformers often causes unnecessary power loss.

2. The capacity, frequency and rated power of the medium frequency induction furnace selected by steel manufacturers are not suitable, resulting in unnecessary losses.
3. At present, on the one hand, the copper solution cannot meet the needs of consumers, and on the other hand, medium frequency induction furnace manufacturers use low-priced red copper instead of No. 1 electrolytic copper to reduce costs, which increases the resistance of the power supply line and the heat loss accordingly.

This problem involves the purchase of electric furnaces. The same electric furnace has high and low prices. Experts purchase by comprehensive evaluation, and laymen purchase by sellers.

4. The induction coil is the key part of the induction furnace. It is the main body that transfers useful work to the heated or smelted metal charge. Its transfer capacity depends on the magnetic field strength generated by the current passing through the induction coil, that is, the ampere-turns of the inductor. In order to obtain a large heating power, the current flowing through the inductor is very large. Over the years, the medium-frequency induction furnace manufacturers have been using the traditional induction coil and water cable cross-section production mode. The commonly used conductive current density is greater than 25A/mm², and the induction coil and electric cable cross-section are small. Due to the influence of the power factor, after repeated actual measurements, the rated current of the furnace body is 10 times the medium-frequency output current (capacitor full parallel type), and the copper loss is proportional to the square of the current. These ringworms make the induction coil and water cable generate greater heat, and the temperature further rises. A large amount of electrical energy is converted into heat and is wasted by the circulating water, so that the power loss in the inductor can reach 20%-30% of the active power of the medium-frequency induction furnace.
5. The temperature of the cooling circulating water has a certain influence on the resistance of the induction coil. When the water temperature is high, the resistance value of the induction coil increases accordingly, resulting in increased losses and large heat generation. Then the large amount of heat generated raises the water temperature, forming a vicious cycle, which is not conducive to the energy saving of the medium frequency induction furnace.
6. The scale formed in the coil of the medium frequency induction furnace hinders the circulation water circuit, reduces the cooling effect, increases the working temperature of the coil surface, increases the fatal power consumption, and even burns the coil and causes accidents if it causes local overheating. Because the cooling water has a certain potential, the scale inhibition effect of the existing scale inhibitor is not very obvious. As a result, the scale increases, the power loss, and the coil damage accident rate increases.
7. The service life of the lining of the medium frequency induction furnace has an impact on the power consumption of the furnace. The longer the service life of the lining, the less power consumption of the furnace. Therefore, the material selection of the lining and the application of the furnace construction and baking process also have a great impact on energy saving.
8. The quality of the medium frequency induction furnace smelting process is also directly related to the power consumption of the furnace. There is a considerable difference in energy consumption in terms of whether the ingredients are reasonable, the length of smelting time, and whether the smelting is continuous. Improper handling will cause unnecessary power loss.
9. Some factories do not pay enough attention to the maintenance of medium frequency induction furnaces, which makes the lining and power supply system unable to operate normally, resulting in corresponding increase in losses.