ABP Induction has recently supplied the largest and most powerful coreless induction furnace in the world rated at 65 000 kgs capacity and powered with a 42 000kW converter.
“Despite the economic woes we have had a very successful period over the last two years. A notable contract was to build ‘the largest induction melting plant in the world’. The project at Taiyuan Iron and Steel Group Ltd. (Tisco), at Taiyuan in China’s Shanxi Province, was completed earlier this year,” said Dr. Wolfgang Andree, President of the ABP Induction Group, which has a centre of excellence in Dortmund, Germany and operations around the globe in Japan, China, Thailand, India, Russia, Sweden, Germany, Brazil, Mexico and USA.
The ABP medium frequency induction melting system consists of two IFM 9 vessels, from ABP’s line of medium-frequency coreless furnaces for melting and holding ferrous or nonferrous metals. The two units installed have capacities of 30 metric tons, powered by 24,000-kW and a 3,000-kW induction power source. In addition, six IFM furnaces were supplied with capacities of 65 metric tons and powered by three 42,000-kW power supplies and three more 1,800-kW sources
“Tisco’s order called for a melt shop capable of producing 180 metric tons per hour of ferrochrome, pouring at a temperature of 1,670°C, to produce stainless steel. The determining factor in the design of this high-volume melt shop was the economic advantage of induction melting over arc melting (which is more common in steelmaking operations), based on significantly lower material losses as a result of the combustion process — specifically, the chromium used to produce stainless alloys.”
“Fifty metric tons from an induction furnace with a tap-to-tap time of 60 minutes is a tremendous achievement, and requires a lot of power,” noted Dr. Andree.
“The furnaces installed include two IFM 9 vessels, from ABP’s line of medium-frequency coreless furnaces for melting and holding ferrous or nonferrous metals. The two units installed have capacities of 30 metric tons, powered by 24,000-kW and a 3,000-kW induction power source. In addition, six IFM furnaces were supplied with capacities of 65 metric tons and powered by three 42,000-kW power supplies and three more 1,800-kW sources.”
“The melt shop design was enhanced by the inclusion of the Ecotop system — a welded steel, refractory-lined furnace hood that attaches to the vessel with a floating system to seal the melt from the atmosphere. A telescoping duct optimises exhaust gas removal.”
A similarly large-scale induction melting installation took place in India.
“Nalwa Steel & Power contacted ABP Induction to build a melt shop capable of producing 700 metric tons/day of direct reduced iron. It is one of the largest DRI operations in India. The plant melts of 85% DRI to a tapping temperature of 1,640°C, and the liquid metal is transferred to 32- and 38-metric ton ladle furnaces for refining, to produce steel.”
“ABP supplied two 30-metric ton capacity IFM furnaces with a 16,000- kW power source based on ABP’s Twin-Power concept: a single power source that distributes the energy supply ‘steplessly’ to two induction furnaces, with no switch time losses or overheating in the melt.”
“The two furnaces have the Ecotop fume-extraction system, as well as an automated slag-skimming capability. Also, ABP provided two ladle refining furnaces, 32 metric tons and 38 metric tons, with an electrical rating of 7.2 MVA.”
“The major deciding factor for the decision in ABP’s favour was its advanced automation, high-energy melt process, ABP’s Ecotop system, and the automated slag remover that reduces the number of operating personal. Thirty metric tons from an induction furnace with a tap-to-tap time of 120 minutes for 85% sponge requires a lot of automation,” Dr. Andree added.
High powered coreless induction furnaces type IFM
ABP Induction medium-frequency coreless induction furnaces Type IFM are utilised for melting and holding ferrous and non-ferrous metals and have a melting capacity of 8 to 65 tons. The furnaces connection capacity is rated at 3 to 42 MW. Coreless induction furnaces of Type IFM are available in various configurations. Type IFM has a high melting rate of up to 52 tons an hour, continuous automatic furnace monitoring and low noise emission.
ABP has recently supplied the most powerful induction furnace in the world for melting steel, with a 65 ton capacity and powered with a 42 000kW converter
When asked about the South African operation Dr. Andree said “Essentially we offer turnkey solutions to industry and our strategic aim for ABP Induction Furnaces, Johannesburg is to operate as a service hub for the whole South African market. Sustainable technology plus sustainable partnership will be the main reasons of our future success.”