Factors Affecting Energy Consumption of Intermediate Frequency Furnace

The intermediate frequency furnace has the advantages of high electrical and thermal efficiency, short melting time, power saving, less floor space, lower investment, easy process automation, and production flexibility. Compared with other melting furnaces, such as industrial frequency furnaces, intermediate frequency furnace has lower energy consumption and higher production efficiency. However, the low energy consumption is relative to other equipment. For enterprise production, it is of course to achieve the maximum benefit as the goal and minimize energy consumption. Therefore, it is necessary to increase the production base and reduce the total energy consumption.

To reduce the energy consumption of the intermediate frequency furnace, it is necessary to understand the factors that affect the energy consumption of the intermediate frequency furnace. The main factors affecting the energy consumption of the intermediate frequency furnace are as follows:

1. Power

The power density configuration of the induction furnace. High configuration, fast melting speed and good energy-saving effect. Whether the electric furnace can maintain high power and continuously send power to the furnace will affect the level of energy consumption; the messy arrangement of the power cord of the intermediate frequency furnace will affect the processing capacity of the power supply, resulting in unstable power, low power conversion efficiency, and energy consumption.

2. Melt

The cleanliness of the surface of the charge, if there are 5% impurities, it will consume 5% of the electrical energy to melt these impurities, which will also affect the life of the furnace lining; whether the length of the charge block is appropriate will affect the electric efficiency and melting quality of the electric furnace, generally 200～ 300mm block size is appropriate.

3. Refractory materials

Using a suitable crucible can increase the melting rate. Quartz crucibles are resistant to high temperatures, and when used with intermediate frequency furnaces, the metal materials in the crucible can generate heat by induction heating, which can reduce the consumption of heat transfer.

4. The improper operation causes high energy consumption

The molten metal is overheated, and the furnace is discharged continuously. Not only is it unsafe, but it is also wrong in terms of energy consumption and the melting process. Generally, electric furnace sensors are divided into upper and lower parts. When the molten metal level in the furnace is lower than half of the upper sensor, due to the change of resistance, the upper sensor no longer has induced current to pass, and all are concentrated in the lower sensor, making the lower molten metal overheating, scouring the furnace wall, the life of the furnace lining drops sharply.

Understanding these four major factors that affect the energy consumption of intermediate frequency furnaces and improving them in production can avoid unnecessary consumption, reduce production costs, and improve production efficiency.

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