Induction forging furnaces continue to drive the market in the foundry industry. The design and operation of induction forges continue to improve as smelters look for newer and more cost-effective methods for steel melting.
According to the World Steel Association, global production of steel in 2018 stood at 1.81 billion tonnes. The increase in production was, in part, due to a sharp increase in demand from the building and infrastructure sector. The sector currently consumes about 50% of all the steel produced. As the demand continues to rise, investing in the right induction melting forge gives you a competitive edge through increased efficiency and production rates. Here are five benefits of induction forges over traditional open-hearth furnaces.
The melting point of steel is approximately 1300°C (2500°F). The efficiency of an induction forge closely relates to its power requirements. The high voltage primary coil in induction furnaces produces frequencies of about 50 hertz per second to 10000 hertz per second. This allows the forge to heat up quickly, providing higher thermal efficiency. The increased efficiency in the melting process leads to a higher yield with less burning loss. The furnace mounted materials allow for reduced metal melting time, thus improved steel production.
The financial implication of running your induction melting forge goes hand in hand with energy efficiency. Most industries producing melting furnaces continue to innovate new technology that improves steel smelting. The use of furnaces with the latest technology lowers power consumption, thus saving on production costs. Additionally, automation of the process reduces waste products such as metallic loss to slug common in electrical furnaces.
The principle behind induction melting revolves around the use of a high voltage primary coil to generate an electromagnetic current that heats the metal. The inductor and the molten steel typically repel each other due to charges causing the molten steel at the center to rise. This phenomenon is commonly referred to as electromagnetic stirring. The electromagnetic stir of the molten steel results in uniformity in the chemical composition of the metal product.
The core-type induction furnace reduces the oxidation burn loss of elements in the steel. The low frequencies associated with the induction heating coil reduce the burning rate of the metal elements, thus minimizing oxidation of the molten steel. Besides, no electrodes are used during the smelting process and hence less slug production. It, therefore, reduces the wastes produced by the furnace with less worry on carbon addition by electrodes.
Induction melting foundry have a lesser negative impact on the environment compared to electrical furnaces. The process records reduced emissions of gas, smoke, and dust associated with other types of casting forges. The induction metal furnaces are cleaner with greater control over emissions and their release to the environment. You can focus more on the foundry process with less waste generated. Additionally, the forges are less noisy compared to their open-hearth counterparts.
Induction melting furnaces offer additional benefits over other available melting foundries. Selecting the right forge helps your company enjoy increased production at a lower cost and minimized losses. Take your time to choose the right induction steel furnace that meets your company’s needs.