Electrical Induction Melting Furnace

Electrical induction melting furnace has been widely used in factory production. According to the frequency of the current, the induction melting furnace can be divided into three categories: high-frequency furnace, and power frequency furnace. High-frequency induction furnace is mainly used in the laboratory because of their high current frequency and small crucible capacity. It is mostly used in the production of factories. According to the structure of the intermediate frequency furnaces, they can be divided into intermediate frequency furnaces and cored intermediate frequency furnaces. Considering the current frequency used, it can be divided into intermediate frequency furnaces, power frequency intermediate frequency furnaces, and cored intermediate frequency furnaces. The current frequency used by cored intermediate frequency furnace is power frequency, so it is also called a power frequency cored intermediate frequency furnace.

The electrical Induction melting furnace is used for smelting steel, iron, and non-ferrous metals. The manufacturer of the furnace has serialized the intermediate frequency furnace and can provide complete sets of equipment including a power supply. The parameter table of the intermediate frequency furnace lists the technical parameters of several common intermediate frequency furnaces for smelting steel and iron, which can be used for reference by users. The technical parameters of each manufacturer may be slightly different.

The electrical induction melting furnace with a furnace capacity of less than 250kg has a simple structure and no magnetic conductor. The furnace shell is made of aluminum alloy, which is divided into two halves. The middle is padded with an asbestos cement plate, and is connected to a round aluminum shell with bolts; The induction coil is wound by a rectangular pure copper tube. The brass stud is welded to the coil, and the brass nut is used to connect the coil to the column. There is a certain gap between turns of the coil, and the air is used for turn-to-turn insulation. The outer surface of the coil is coated with moisture-proof paint. The entire induction coil is fixed on the aluminum shell through both ends of the column. The tilting of the furnace is that the motor drives the furnace body to rotate after passing the reducer.

Parameters

Capacity/kg	150	250	500	1000
Current frequency/Hz	1000	1000	1000	1000
Rated power/kW	100	160	250	500
Voltage/V	700	700	700	700
Inductor voltage/V	700	700	1400	1400
Rated temperature/℃	1600	1600	1600	1600
Melting rate/ ( kg/h)	130	200	380	750
Crucible: inner diameter x height/mm	Φ255 x400	Φ300 x500	Φ500 x560	Φ500 x720
Coil: inner diameter X height/mm	Φ400 x 450	Φ450 x 580	Φ560 x650	Φ700 x800
Coil turns/turn	17	15	19	parallel connection12 + 12
Cooling water consumption/ (t/h)	5	7.5	10	18

The main part of the furnace lining is the crucible, which is generally rammed with refractory materials. However, iron crucibles are used when melting aluminum, zinc, and other low melting point alloys, with high melting efficiency and inductor power factor.

The crucible rammed with refractory materials generally adopts acid lining, which is dry rammed after uniformly mixing quartz sand and boric acid. For some special requirements, such as solving the crack problem of complex castings, some factories use an alkaline lining, which generally uses magnesia (Mg>85%), with a refractoriness of about 2000 ℃, which can resist alkaline slag. Slagging materials can be added to the furnace to remove phosphorus and sulfur. In the electrical furnace surface, the refractory cannot contact with the liquid metal and is well sintered, and 2% - 3% water glass is often added.

For medium-frequency furnaces with a capacity of 500kg, the furnace shell is also selected as a steel structure, the coil is surrounded by a magnet, and the tilting of the furnace body is driven by hydraulic pressure.

For electrical induction melting furnace with a furnace capacity of 1T, the furnace shell is generally of steel structure, and there is a magnet around the coil. The furnace body is tilted by hydraulic transmission. There are also medium-frequency furnaces with a furnace capacity of 1000 kg. The furnace shell is made of aluminum alloy. There is no magnetic conductor around the induction coil, but the tilting of the furnace body adopts hydraulic transmission. Compared with the two, under the same conditions of furnace capacity, of course, the medium frequency furnace with steel shell and magnet conductor has a high cost, but its advantage is that the furnace structure is solid, safe, and reliable.

In order to improve the melting rate of the electrical induction melting furnace, some furnace manufacturers have introduced a fast melting furnace, that is, to increase the input power to the inductor, reduce the metal melting time, improve the melting rate of the furnace, but increase the unit power consumption of molten metal.

For the furnace body structure of an induction furnace with a large furnace capacity, the coil pressing device uses a spring to fasten the coil from the top of the coil; The magnetic conductor is installed at the periphery of the coil to prevent magnetic flux leakage, so as to save energy. At the same time, the magnetic conductor supports the coil from the back, enhancing the stability of the coil and resisting the expansion force of the furnace lining; The induction coil is wound with a rectangular pure copper tube; The insulation layer of the coil is insulated with glass tape, and the whole coil is subject to paint dipping and drying treatment; According to the production needs, acid, alkaline and neutral lining materials can be used for dry lining; In case of furnace leakage, the detection device will give an alarm before the liquid metal reaches the coil. The tilting of the furnace body is driven by a hydraulic cylinder.

The electrical induction melting furnace for melting nonferrous metals has the same structure as the medium frequency furnace for melting steel, but its technical parameters are somewhat different, and the materials used for crucibles are different. Crucibles for melting nonferrous metals are made of refractory rammed or graphite crucibles. Crucibles for smelting lead, zinc, magnesium, aluminum, and aluminum alloys are made of cast iron steel plates.

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