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How to reduce the power consumption of intermediate frequency induction furnace?

Author:admin      Time:2018-10-30 15:32
The main factors affecting the power consumption of medium frequency furnace include smelting equipment, burden, smelting operation, production organization, utilization ratio of molten steel (iron), etc. Through effective control and improvement of these factors, the power consumption per ton of castings is reduced from 1 900 to 1 400 degrees and remarkable results are achieved.

Strengthen the management of smelting equipment, standardize the operation process requirements such as furnace building, baking, sintering, smelting and maintenance system of medium frequency power, effectively increase furnace life, ensure the normal operation of medium frequency power, thereby reducing smelting power consumption.

The composition of castings is mainly analyzed and adjusted by direct reading spectrometer, and the control requirements are strict. Because of the variety and material of the product, it often appears that different grades and different kinds of materials are mixed together, which makes the content of one or several elements exceed the standard and needs to be adjusted in front of the furnace. Even a large amount of liquid steel (iron) needs to be poured out, which not only causes the waste of materials, but also increases the energy consumption of smelting. In addition, the cleanliness of the burden and the size of the furnace will also affect the smelting efficiency of the intermediate frequency furnace.

Strengthen the inspection and control of the quality of raw materials into the factory, clearly indicate their composition; Strengthen the management and monitoring of the returned burden in the foundry workshop, clearly identify the material, stack the burden into the frame, according to the material classification, special frame, timely reuse, avoid mixing. Furnace charge with unclear composition is used after chemical analysis beforehand. In addition, the management of pouring ladle should be strengthened to ensure that similar materials are used in the same pouring ladle, and special ladle is used to avoid different kinds of materials sticking together when sticking. By strengthening burden management, reduce component deviation.The scrap of steel (iron) has caused the increase of smelting power consumption.

Correct charging operation, charging mode and reasonable temperature control are not only directly related to the safe use of the furnace, but also greatly affect the smelting efficiency and power consumption.
 
When the furnace is empty, small pieces of material are added at the bottom of the crucible to make it close, shorten the time of molten steel (iron) melting, increase bulk material in the middle, fill small pieces of material in the gap, and refractory and large pieces of burden are installed as close as possible to the crucible wall. When charging, one-time charging should be avoided as far as possible, even exceeding the furnace mouth to reduce the melting rate, or cause "rack material"; during the smelting process, the melting situation in the furnace should be often observed, the furnace charge should be filled in time before the complete melting, found rack material in time to poke, to prevent the following steel (molten iron) temperature rising sharply caused by the furnace or through.

Due to the variety of product structure, including single small-batch production, but also a large-scale production; both simple and complex parts; both weight less than 1 kg of small pieces, but also more than 5 tons of large pieces. And the product material is more diverse, generally divided into high chromium cast iron, medium and low alloy cast steel, high manganese steel, heat-resistant and corrosion-resistant steel four categories, each category includes a number of specific materials. In the production arrangement, considering the delivery time and the convenience of organizing production, we should arrange the products with similar material as far as possible. After pouring, the remaining dozens of kilograms of molten steel (iron) in each furnace can be obviously shortened the melting time, the composition control can be easily guaranteed, the analysis and adjustment time before the furnace can be shortened, and the simple parts and complex parts, large pieces and small pieces can be staggered together. Matching, strengthen the coordination between the various processes, and conduct a strict smelting time assessment, to avoid waiting for casting smelting conditions.
 
 
The utilization rate of steel (iron) is referred to the ratio of the actual application of molten steel to iron castings. Therefore, it is necessary to carefully calculate the yield of the casting process and pay attention to the use of insulating risers; carefully calculate the amount of molten steel (iron) required before the start-up to reduce the waste caused by excessive melting of molten steel (iron); strengthen the ladle management, strictly bake the ladle before pouring, and pay attention to the coordination and stability of the operation process during the discharge and pouring. In addition, casting scrap is one of the most sensitive and prominent factors affecting the utilization rate of molten steel (iron), resulting in the increase of smelting power consumption in intermediate frequency furnace and the cost of casting auxiliary materials. Strengthening quality management and control, reducing the scrap rate is one of the keys to reducing the power consumption in casting smelting.