FS melting systems

FS melting systems

 

MEDIUM FREQUENCY INDUCTION MELTING SYSTEMS

FS SERIES FOR MELTING AND HOLDING OF FERROUS AND NON-FERROUS METALS

 

Medium frequency induction crucible systems are used for melting and holding of ferrous and non-ferrous metals. Melting rate of grey iron in furnaces of this series is within the range from 1,5 t/h to 9,5 t/h.

 

Production program (in reference to grey iron melting) is shown in a table

 

 

FS10

(1t)

FS15

(1,5t)

FS20

(2t)

FS30

(3t)

FS40

(4t)

FS50

(5t)

FS60

(6t)

750 kW

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х

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х

х

х

х

1000 kW

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х

х

х

х

х

х

1500 W

 

х

х

х

х

х

х

2000 kW

 

 

 

х

х

х

х

2500 kW

 

 

 

х

х

х

х

2700 kW

 

 

 

 

х

х

х

3000 kW

 

 

 

 

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х

х

4800 kW

 

 

 

 

 

х

х

 

Induction crucible melting systems consist of following components:

 

  • Induction crucible furnace;
  • Medium frequency power supply;
  • Peripheral equipment (for example, water cooling unit);
  • Hydraulic station and transformer;
  • Control system.

 

The concept of FS series furnace system is your advantage:

 

High level of reliability and operational readiness

Time-proven structural elements such as furnace open design, changeable upper part and supply optimization principle provide high reliability and maximum level of operational readiness.

 

Reduced energy consumption and high economy

Modern semiconductor technologies and optimized furnace design allowed to minimize specific energy consumption.

 

High operational safety

Continuous automatic monitoring of furnace operation provides safety of the melting process.

 

Attractive quality-to-price ratio and long operating life

Usage of ABP standardized modules provides attractive price. Renowned structural strength and reliability of ABP furnace units reduce to a minimum general size of operating costs during their operating life.

 

Ease of installation, operation and maintenance

Furnace design provides the possibility of quick and easy installation as well as ease of operation and monitoring.

 

Time-proven design for a high degree of reliability and availability

 

Induction crucible systems of FS series are designed on the basis of well-proven components of high capacity furnaces of IFM series. Design and molten metal position are of special importance: its location on crucible was defined on the assumption of tasks for mechanical erosion reduction at the bottom part of crucible without sacrificing effective mixing of molten metal.

 

Rectangular copper and coil-in-segment technology, coupled with axial coil fixing, provides high mechanical stability and extends the life-cycle of the coil. Coil segment design promotes “breathing” of the coil and the evaporation of moisture from the refractory during sintering. This makes it possible to apply full power to the coil sooner.

 

Open-cage design permits accessibility and visibility of mechanical parts, designed for easy preventive maintenance.

 

This reduces the down time and increases production. Easy-to-replace furnace head allows easy changing of upper concrete part without inductor disassembling. Higher lining life due to upper cooling coil turns. After its change the immediate start-up is possible without any power losses.

 

Cooling system

 

The induction furnace, capacitor bank and converter are cooled using a common closed loop water system. The special de-ionized water is not required because there are no electrically energized converter parts in contact with the water system.  Equipment of the cooling system consists of pump station, emergency water distribution system, monitoring system and heat exchanger. Pump station is supplied as fabricated assembly. This fact makes system installation easy and fast.

 

                                                                  Power supply

Thyristor or IGBT transistor type converters are used as power supplies for induction melting systems depending on melting metal and required frequency.

Advanced semi-conductor technology and a compact design make the Smart FS power supply best in class. In addition, the Smart FS power supply relies on the same patented maintenance free IGBT technology that are found in ABP’s large drives in which this technology has proven itself for many years.

  • Modular converter – each module consists of a rectifier and an inverter.
  • Modules in an assembly make them fast to replace, giving the furnace higher availability.
  • Small footprint. Compact furnace capacitors and converter modules can be placed in one cabinet.
  • Furnace coil and capacitors are water cooled in one closed-loop circuit.

If several furnaces are to be used this design permits investment in linear plants. This simultaneously increases the availability of the plant. Control of the converter is carried out by a modern, digital control system. The power limits of the whole plant can be controlled by an ABP energy management system.

 

Solutions for improved furnace operation

Installations and converters are controlled with approved Siemens S7 PLC and the melt processor PRODAPT®.

Centralized operator panels allow operators to control the furnace via a touch-panel with user friendly, intelligent screen build-up features. Operator panels offer customers several unique features and allow operators to perform several critical activities such as:

  • Recording of furnace parameters and calculation of the power consumption.
  • Control of the power supply for melting or holding, start-up of the cold furnace, sintering.
  • Recording and display of current operation data and status.
  • Fault monitoring and alarm signaling.
  • User-friendly with large function keys so operators do not need to remove their gloves.
  • Diagnosis

Necessary capacitors and chokes are used in addition to the IGBT transistor type converter or thyristor type converter. 

Both converter types can be used not only in individual furnace supply systems but also in system of parallel supply TWIN-POWER®.

This system allows distributing power of one energy source between two or several furnaces in any ratio. Time losses for secondary operations and for switching now lie in the past.

  • Whilst in one furnace the melting process proceeds, the other furnace can be used for metal holding.
  • Simultaneous melting in two furnaces with power distribution between them in any necessary ratio.
  • Make the refractory backing in one furnace and at the same time make refractory sintering in other one. 
  • Make the refractory material sintering in one furnace simultaneously with melting in the second one.

 

Ease of operation, maintenance and installation

During development of medium frequency induction crucible furnace the emphasis was made on the ease of operation and system maintenance. Personnel training for installation, operation and solving the evolving problems without troubles, which reduces total amount of expenses. Preassembled furnace modules of FS series provide quick and safe installation of equipment on site which also contributes cost saving and quick equipment commissioning.

Maintenance worldwide

Lots of standard components are used for the FS series furnaces which allow us and our clients easily to get necessary spare parts. Usage of standard ABP converters and other components guarantees qualified and quick service. Technical support centers are located in different places all over the world which ensures swift delivery terms of spare parts. Our specialists of expert maintenance and repair are at your service 24 hours a day. Our consultants will help you to optimize your production process, increase your profit and thus contribute return on investment in equipment and technologies. Competence and qualified service are the basic principles of our successful partnership.

 

Our equipment for foundry production

Induction furnaces

  • Inductions crucible furnaces for ferrous and non-ferrous metals.
  • Induction channel furnaces for cast iron, aluminium, copper and zinc.  
  • Pouring systems without pre-heating and with induction pre-heating.
  • Auxiliary equipment: power supplies, cooling systems, locking devices and etc.

 

Control and automatisation

  • Melting process control systems
  • Automatic control system for pouring process OPTIPOUR®

 

Devices and analysis systems

Electric installation

  • Power supplies and energy supply
  • Transformers and converters

 

Consulting, planning and optimization

  • Foundry workshops equipment
  • Production planning

 

Services

  • Project management
  • Installation and commissioning
  • Documentation development and training
  • Maintenance and repair
  • Spare parts supply
  • 24-hour support and emergency help