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energy efficient melt shop operation

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6 juergen himmelmann-energy efficient melt shop operation abp

6 juergen himmelmann-energy efficient melt shop operation abp

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  • Die traditionelle Anwendung für LaserPour ® ist die DISAMATIC ® . Der Füllstand im Gießtrichter wird mit einem Laserpunkt in einem kleinen Kanal in dem Gießtrichter gemessen. So wird die Positionierung und die Gießkontrolle gewährleistet. Außerdem wird der Laser für sehr kleine Gießtrichter eingesetzt. Die Kameratechnologie OptiPour ® -S wird an Kastenlinien mit großen Gießtrichtern eingesetzt. Diese Anwendung benötigt in der Regel keine Positionierung. Die LineLaser Technologie misst den Abstand des Gießtrichters, der nicht von dem Gießstrahl verdeckt ist. Das System muß nicht kalibriert werden. Es handelt sich um eine relative Messung. Die Größe des Gießstrahls, Form und Position des Gießtrichters werden erfasst um die Gießeinrichtung schnellstens zu positionieren.
  • Die traditionelle Anwendung für LaserPour ® ist die DISAMATIC ® . Der Füllstand im Gießtrichter wird mit einem Laserpunkt in einem kleinen Kanal in dem Gießtrichter gemessen. So wird die Positionierung und die Gießkontrolle gewährleistet. Außerdem wird der Laser für sehr kleine Gießtrichter eingesetzt. Die Kameratechnologie OptiPour ® -S wird an Kastenlinien mit großen Gießtrichtern eingesetzt. Diese Anwendung benötigt in der Regel keine Positionierung. Die LineLaser Technologie misst den Abstand des Gießtrichters, der nicht von dem Gießstrahl verdeckt ist. Das System muß nicht kalibriert werden. Es handelt sich um eine relative Messung. Die Größe des Gießstrahls, Form und Position des Gießtrichters werden erfasst um die Gießeinrichtung schnellstens zu positionieren.
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    • 1. Agenda  Energy balance for melting iron  Energy balance of a state of the art Induction melting system  State of the are melting system ABP  Energy balance of a melting system  Energy effective melt process  Integration of the melt operation into the total process©ABP Customer day Bangkog, 30.03.2012 1  Automatic pouring system АВР  Pouring via OptiPour®  Energy - Benchmark
    • 2. Energy balance for melting iron  Enthalpy for melting 1to of iron at 1.500 °C: 396 kWh/t kWh/t 1.200 1.000 800 Additions 600 Material losses Gas / oel electrical Engergy 400 Koke©ABP Customer day Bangkog, 30.03.2012 2 200 0 Cupola Cupola Ind. furnace Ind. furnace Rotary furnace - cold furnace - hot LF MF furnace wind wind Source University of Hannover
    • 3. Energy balance for melting iron  Specific CO2 Emission for melting of one ton iron gr/t 600 500 400 300 200 100©ABP Customer day Bangkog, 30.03.2012 3 0 Cupola furnace Cupola furnace Ind. Furnace Ind. furnace Rotary furnace - cold wind - hot wind LF MF  Including the emission of power plans with todays energy mix Source University of Hannover
    • 4. Agenda  Energy balance for melting iron  Energy balance of a state of the art Induction melting system  State of the are melting system ABP  Energy balance of a melting system  Energy effective melt process  Integration of the melt operation into the total process©ABP Customer day Bangkog, 30.03.2012 4  Automatic pouring system АВР  Pouring via OptiPour®  Energy - Benchmark
    • 5. Parts of a MF induction furnace system  Mechanic: Circuit breaker  Furnace body, lining material Transformer hydraulic and tilting frame Cooling system electrics  Electric: ~ -  Transformer, Converter MF- Converter Capacitor bank, high current - connection, Coil ~ Capacitor bank  Control systems:  Weighing system, Process- Exhaust Charging system Control hood  Auxiliary equipment: Crucible©ABP Customer day Bangkog, 30.03.2012 5 furnace Cooling system furnace  Cooling system, charging system, exhaust system Melt processor Weighing tons system
    • 6. Latest ABP melting furnaces Furnace capacity 0,3 … 0,8 t 1t …6t 8 t … 65 t 30 t … 70 t Type Smart FS FS IFM LFS Power supply IGBT MF Thyristor Converter Single Single Twin Power Twin Power Power Power©ABP Customer day Bangkog, 30.03.2012 6 250 kW – 750 kW – 810 kW – 42.000 kW 500 kW 3.500 kW
    • 7. Comparison between LF and MF MF LF Energy consumption 520 - 580 kWh/t 570 – 700 kWh/t Power density 600 - 1000 kW/t 150 – 300 kW/t Melt rates 300 % 100 % Melt conditions Batch type Heel Flexibility High Low Changing of alloy Good Bad©ABP Customer day Bangkog, 30.03.2012 7 Lining live per molten t High Low 12 т 5т
    • 8. Comparison between LF and MF MF LF Melting of chips Low heel High heel Material density in the High Low furnace Maintainance Low, no mechanical High, mechanical switches wear©ABP Customer day Bangkog, 30.03.2012 8 5т 12 т
    • 9. Energy balance of a state of the art induction melting system Energy consumption mains  State of the art technology side 525 kWh/t  Efficiency: 8 kWh/t losses 80% …75 % 517 kWh/t transformer  Development tasks 17 kWh/t losses converter  Reduction of coil losses 500 kWh/t  New lining material 5 kWh/t losses  Reduction of power supply capacitor bank 495 kWh/t losses  Reduction of transformer losses 89 kWh/t electrical losses coil  Aim: 405 kWh/t  Reduction of installation losses 9 kWh/t thermo of 60…90 kWh/t©ABP Customer day Bangkog, 30.03.2012 9 losses  Increasing of efficiency to 87%… 396 kWh/t Enthalpy at 1.500 °C 81 %
    • 10. Energy efficient induction furnaces – Coil losses Coil losses are app. 70 % of the total installation losses  New lining material that covers higher induction power  New coil design  New coil material©ABP Customer day Bangkog, 30.03.2012 10
    • 11. Energy efficient induction furnaces – converter losses  Today‘s converter losses 3….4 % of the installed power©ABP Customer day Bangkog, 30.03.2012 11  New generation of power electronic components (IGBT, IGCT)  Improved control systems
    • 12. ABP power supply: IGBT technology  IGBT = Insulated Gate Bipolar Transistor  Technical features of IGBTs:  Rapid switching  low on- and off switching losses  low conducting losses  Rectifier, filter circuit and inverter in a single module with 250 kW or 750 kW, next generation up to 1.500 kW  Power range: 250 kW – 3.000 kW  Future up to 6.000 kW©ABP Customer day Bangkog, 30.03.2012 12
    • 13. Benefits of IGBT converters  Modular structure  using standardized components  quick and easy maintenance possible  No de-ionizer water required  No elements on potential are in direct contact with the cooling water  Single cooling circuit for the converter and the furnace  Cos φ always as good as > 0,95©ABP Customer day Bangkog, 30.03.2012 13
    • 14. 500 kW converter layout Control unit IGBT modules Coupling choke Capacitors©ABP Customer day Bangkog, 30.03.2012 14 Compact Layout for an easy integration into an existing plant
    • 15. Agenda  Energy balance for melting iron  Energy balance of a state of the art Induction melting system  State of the are melting system ABP  Energy balance of a melting system  Energy effective melt process  Integration of the melt operation into the total process©ABP Customer day Bangkog, 30.03.2012 15  Automatic pouring system АВР  Pouring via OptiPour®  Energy - Benchmark
    • 16. ©ABP Customer day Bangkog, 30.03.2012 16 Energy (in) efficient Melt process
    • 17. Energy efficient Melt (foundry) process  Charge preparation  Charging  Melting  Preparation of the melt  Furnace emptying  Metal transport  Pouring process©ABP Customer day Bangkog, 30.03.2012 17 2 ,0t 1 ,5t
    • 18. Energy efficient Melt process – Charge preparation Big or small charge material  The right mix influences the melt time up to 10 min and more  additional >100 kWh/t shot blasting of returns  If returns are not shot blasted they consist a lot of sand  About 10 % of the returns is sand, that are supplied to the furnace©ABP Customer day Bangkog, 30.03.2012 18  The molten sand creates additional slag  Example: 10 t scrap with 5 t returns and 10 % sand  25 kWh/t additional for melting of the sand
    • 19. Energy efficient Melt process – Charging  Charging when requested  Avoiding bridges!  Process control with melt processors avoids interruptions  Influence of 2 – 4 min interruption©ABP Customer day Bangkog, 30.03.2012 19  Additional 25…50 kWh/t
    • 20. Energy efficient Melt process – Melting  Using the melt processor to get optimal power to the material  Always if possible:  Close cover!  An open cover adds (12 t furnace)  600 kW heat losses  5 min with open cover©ABP Customer day Bangkog, 30.03.2012 20  50 kWh additional losses  Exhaust volume has to be reduced at closed cover
    • 21. Energy efficient Melt process – Preparation of the melt  Time is money!  If possible,use auxiliary equipment  e.g. Slag grapper  Online connection between spectrometer and melt processor  Melt processor calculates automatically the amount©ABP Customer day Bangkog, 30.03.2012 21 of additions  Always if possible:  Close cover!
    • 22. Energy efficient Melt process – Preparation of the Melt©ABP Customer day Bangkog, 30.03.2012 22
    • 23. Energy efficient Melt process – Preparation of the Melt©ABP Customer day Bangkog, 30.03.2012 23
    • 24. Energy efficient Melt process – Empting of the furnace  Optimize the ladle size to minimize heat losses  No fire work at the furnace during empting!  Optimize the transport ladle (size)©ABP Customer day Bangkog, 30.03.2012 24
    • 25. Energy efficient Melt process – Empting of the furnace Environmental empting of furnace©ABP Customer day Bangkog, 30.03.2012 25
    • 26. Energy efficient Melt process – Results State of the arte Inefficient melt technology process  Charge preparation 10 kWh/t 25 kWh/t  Charging 10 kWh/t 30 kWh/t  Melting 15 kWh/t 70 kWh/t  Preparation of the melt 10 kWh/t 50 kWh/t©ABP Customer day Bangkog, 30.03.2012 26  Empting of the furnace 5 kWh/t 15 kWh/t  Additional process losses 50 kWh/t 190 kWh/t
    • 27. Agenda  Energy balance for melting iron  Energy balance of a state of the art Induction melting system  State of the are melting system ABP  Energy balance of a melting system  Energy effective melt process  Integration of the melt operation into the total process©ABP Customer day Bangkog, 30.03.2012 27  Automatic pouring system АВР  Pouring via OptiPour®  Energy - Benchmark
    • 28. Integration of the melt operation into the total foundry process  Tandem melting plant with variable power distribution©ABP Customer day Bangkog, 30.03.2012 28
    • 29. Pouring with OptiPour®  Regulated pouring  Aim: level of liquid metal in the cup constant during whole pouring time  Changing of pouring conditions in the cup mainly based on opposite pressure inside of the cup  should be reproducible from cup to cup  No big differences for stopper, nozzle and level of liquid bath©ABP Customer day Bangkog, 30.03.2012 29
    • 30. Pouring with OptiPour®  Different systems for automatic pouring  OptiPour® - C (with camera)  Flask lines with big cup diameters  OptiPour® - L (with laser)  High speed molding lines with extreme small cup diameter and measure nose for the laser©ABP Customer day Bangkog, 30.03.2012 30  OptiPour® - LL (with Line-Laser)  High speed molding lines with extreme small cup diameter
    • 31. Agenda  Energy bilanz for melting iron  Energy balance of a state of the art Induction melting system  State of the are melting system ABP  Energy balance of a melting system  Energy effective melt process  Integration of the melt operation into the total process©ABP Customer day Bangkog, 30.03.2012 31  Automatic pouring system АВР  Pouring via OptiPour®  Energy - Benchmark
    • 32. Energy – Benchmark, foundries Theoretically Equipment losses Energy consumption Process losses Integration losses©ABP Customer day Bangkog, 30.03.2012 32  Aim: specific energy consumption < 580 kWh/t
    • 33. Energy – Benchmark, foundries kWh/t 1.200 1.000 800 Melting - Pouring Process 600 Equipment Specific Enthalpie©ABP Customer day Bangkog, 30.03.2012 33 400 200 0 State of the art Future destroyer Old fashioned
    • 34. ©ABP Customer day Bangkog, 30.03.2012 34 attention… Thank you for your
    • 35. ©ABP Customer day Bangkog, 30.03.2012 35 Contact: ABP Induction Systems GmbH Kanalstraße 25 44147 Dortmund Jürgen Himmelmann Phone.: 02 31 / 997 – 28 88 Fax: 02 31 / 997 – 24 67 Mail: juergen.himmelmann@abpinduction.com

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