300Kg-30Ton Furnace for Aluminium Metal to Ingots Plant Electric Melting Steel Cast Iron Stove Induction Oven
The medium-frequency furnace is a frequency conversion device that converts three-phase industrial frequency current into single-phase medium-frequency current. It achieves the purpose of heating and melting by inducing eddy currents in metals through electromagnetic fields. It is used for the smelting of black or non-ferrous metals such as steel, copper, aluminum, and alloys; it is mainly applied in the casting and steelmaking industries! We can provide casting manufacturers with complete equipment production lines including melting systems, cooling systems, dust removal systems, automatic batching and feeding systems, and pouring systems. The diversity of products, with various price performances, offers you more choices and more experiences.
Product Advantages:
①High Efficiency: Fast melting, with the shortest single-furnace melting time of less than 40 minutes!
②Energy Saving: Highly competitive energy consumption index (about 510 kWh/ton for cast iron)! About 20% more energy-efficient than ordinary parallel inverter power supplies!
③Quality: Our products have passed ISO international quality management system certification and EU CE safety certificate certification.
④Stable: High-quality component selection ensures the stability of the equipment. The core components of Hengyang electric furnace are carefully selected: using high-quality copper materials, superior insulating materials, and well-known brand thyristors/IGBT modules. Mature circuit design: Optimized resonant circuit and protection logic, resistant to shock and harmonics, suitable for complex grid environment.
⑤Environment protection: Adopt environmental protection dust-removal cover, Comply with the national environmental assessment requirements. Furnace using whirlwind and side suction heat-preservation furnace cover, dust hood (ring) through a certain air absorb dust, waste gas generated in smelting, reach and improve the effect of exhaust emissions, to meet the requirements of environmental impact assessment design.
⑥Safety Protection: Safety is our responsibility. All design of HengYang Electric Furnace is based on the premise of ensuring safety.
⑦Hengyang electric furnace has low maintenance costs - preventing the equipment from becoming "consumables": Hengyang electric furnace integrated modular design: Water-cooled cables, Inductor, power modules, etc. adopt standard interfaces. If any part is faulty, just replace it without the need for an overall factory return. Few and inexpensive wear-prone parts: Reduce the variety of wear-prone parts, all spare parts prices transparent, and reject "Exorbitant profits from after-sales services". Long-life design: Reasonable copper tube wall thickness and insulation treatment to extend the overall lifespan of the machine.
Performance Features:
①High-efficiency, energy-saving series-connected one-to-two or one-to-many (multiple furnaces melting, one furnace holding) power supply design: The series-connected intermediate frequency power supply series enables single-power, dual-power, or multi-power configurations. Among the new type of one-to-two-to-many series-connected intermediate frequency smelting furnaces, it has a function of providing a intermediate frequency power supply to two or more furnaces for simultaneous operation. The total power of the intermediate frequency power supply can be arbitrarily allocated and used among two or more furnaces, achieving the effect of melting one or more furnaces while keeping one furnace in a state of insulation. It can realize the one-time casting of large castings or continuously supply molten iron to the production line.
②Advanced computer melting management system: The on-site melting management computer, digital main control board, PLC, and other equipment form a network system. Through the switch, it can be expanded for office operation and management. Equipped with Ethernet and USB ports and a unique IP address, it allows data collection, transmission, and monitoring of equipment from anywhere in the world, providing remote diagnosis and rapid troubleshooting.
③Fully digital on-site melting control system: Enables automatic temperature control, automatic furnace baking, power distribution display, intelligent melting management, fault information display and storage, and other automated operations.
④Remote operation console: When the medium-frequency power cabinet is placed in the basement, and the remote operation console is placed on the furnace platform, the functions such as starting, stopping and resetting of the medium-frequency power supply can be achieved.The remote operation console is equipped with a large-sized touch screen. The PLC and human-machine interface form a convenient on-site smelting manager. Its functions include: automatic furnace drying, cold furnace startup, fault diagnosis, fault information display and storage, operation information display, system status display, etc.
⑤Fault detection (protection) display screen: Real-time, all-round tracking and protection of operating equipment. When abnormal values such as short circuit of load, overcurrent, overvoltage, insufficient water pressure, or excessive water temperature are detected, they will be promptly fed back to the control system, enabling automatic shutdown protection to prevent potential problems. Additionally, damage to components such as thyristors, compensation capacitors, and voltage transformers will automatically trigger a shutdown and illuminate the corresponding indicator lights.
Characteristics of the Furnace:
Two kinds of dust removal systems for the medium frequency: Dust Hood and Dust Ring. Dust hood (ring) through a certain fan to absorb dust, waste gas generated in smelting to reach and improve the effect of exhaust emissions and meet the design requirements of government environmental department. User can choose different configuration according to their own need.
Dust Removal Hood: The cyclone dust hood has the excellent dust absorption effect, takes up less space, can be tilted back and forth and any place stops. It is suitable for all automatic feeding and discharging of foundry.
Dust Removal Ring: Side suction type dust removal ring: there is no forward and backward turning mechanism, and the installation is simple. It is suitable for those foundrywho cannot use Dust Removal Hood due to somespecial feeding way of semi-automatic or artificial feeding.
Customizable: Relying on professional customized service capabilities, the solution configuration is flexible and adjustable. The Hengyang electric furnace can match the steel shell/aluminum shell furnace body, thyristor parallel/IGBT series power supply according to the customer's budget and actual working conditions (such as ordinary smelting, precision casting, etc.). Adhering to the principle of practical selection, it avoids waste of resources, optimizes the structure and process while ensuring the lifespan and reliability, and eliminates unnecessary costs. The Hengyang electric furnace only recommends medium-frequency electric furnaces that are suitable for the working conditions, sturdy and durable, stable in performance, and have a high cost-performance ratio to customers. It never blindly promotes or forces the installation of high-end configurations, and truly meets the real production needs of customers.
Product Service: The commitment of Hengyang Electric Furnace is the "Lock Key" project. Not only does it provide high-quality and reliable products, but it also offers free training for customers on the application of medium-frequency furnaces, including process, technology, and operation skills. There is an independent after-sales department that conducts regular tracking services for medium-frequency furnace products, directly solving the actual production problems of users and eliminating their worries.
The medium-frequency furnace is the core equipment of the foundry factory. The stability of the equipment and after-sales service are both indispensable! Hengyang Electric Furnace has been deeply involved in the industry for over twenty years. With rapid after-sales response, it ensures the safety of your production line. One-time investment, long-term return; reasonable early selection and investment, later energy saving + maintenance saving + less downtime, fewer faults, lower maintenance costs, shorter service waiting time. Converted to the per-ton melting cost, Hengyang Electric Furnace is more cost-effective than low-priced generic machines.
The development history and comparison selection of intermediate-frequency power supplies:
①First generation: The KGPS thyristor parallel medium-frequency power supply has been the most widely used throughout the past 20 centuries. It is inexpensive and comes with low-cost accessories. High energy consumption. The electricity consumption per ton of molten steel is approximately 650 degrees. The power is adjusted by regulating the DC voltage. The power factor is low and ≤ 0.90. There is harmonic interference, which has varying degrees of impact on the operation of the reactive power compensation capacitors in the substation.
②Second Generation: The KGCL controllable silicon series medium-frequency power supply is an upgraded version based on the first-generation KGPS parallel medium-frequency furnace. It saves about 15% energy compared to the first-generation KGPS parallel inverter power supply (approximately 510 kWh of electricity consumed per ton of molten iron).
③The third generation: The new energy-saving IGBT module series-connected medium-frequency power supply is a revolutionary and innovative latest energy-saving product, which completely overturns the previous traditional thyristor medium-frequency power supply structure. It adopts IGBT integrated modules (transistors) for frequency modulation and power control, as well as full-wave rectification. It is not affected by the amount of raw materials and the thickness of the furnace lining, and maintains a constant power output throughout the smelting process. The energy-saving IGBT transistor medium-frequency electric furnace can save 15% - 25% energy compared to traditional thyristor medium-frequency power supply (about 480 kWh per ton of molten iron).
The main reasons for energy saving are as follows:
A. The inverter voltage is high and the current is small, resulting in low line losses. This part can save about 15% of energy. The inverter voltage of the energy-saving IGBT medium-frequency power supply is 2800V, while the inverter voltage of the traditional thyristor medium-frequency power supply is only 750V. The current is nearly 4 times smaller, and the line losses have been significantly reduced.
B.The power factor is high, always exceeding 0.98, and the reactive power loss is small. This part is 3% to 5% more energy-efficient than the thyristor medium-frequency power supply. Due to the use of semi-controllable rectification in the energy-saving IGBT transistor medium-frequency power supply, the rectification part does not adjust the conduction angle of the thyristor, so the power factor remains always above 0.98 and there is no power loss.
The IGBT integrated module series intermediate frequency power supply is the most advanced energy-saving intermediate frequency furnace product that our company highly recommends.