MEDIUM FREQUENCY INDUCTION FURNACE

There are two general types of Induction furnace commonly used for melting a wide
variety of metals normally cast in the foundry industry. These include the channel and
coreless type furnace.

A standard coreless Induction furnace operates at 50 cycles main frequency. A medium

frequency furnace is one which normally operates at a frequency between 180 to 600
Hz. The depth of penetration of induced current is shallow compared to deep
penetration as in case of 50 Hz Furnace. Shallow depth of penetration surface heating
with a relatively quiet bath. Deep penetration, as produced by the 50 Hz line type
melter, provides for much greater bath agitation and requires a larger load -24 30
inch or larger in order to give the induced currents enough freedom to circulate without
a chucking or cancelling effect and moreover needs a larger plug for starting or heel to
attain full melting rate. Medium frequency melters, on the other hand, has the ability to
heat relatively small scrap sizes on start up and still allow for good heat penetration
and reasonable bath movement. This slow bath movement gives better lining life and
low alloy losses.

In terms of operations the medium frequency furnace has the capability of starting a
cold melt at full power provided the charge is comprised of pieces with a cross section
of 3 to 5 inches or greater and is densely packed thus avoiding starting plug.

The following table shows that a smaller medium frequency furnace can give a higher
melt rate compared to mains frequency furnaces.

Melt Rate Med. Freq. Furnace Size Line Freq. Furnace Size
1.1 Ton/Hr 1 Ton 2 Ton
1.5 Ton/Hr 1.5 Tons 2 - 3 Ton
1.8 Ton/Hr 2 Tons 3 - 5 Tons
2.3 Ton/Hr 3 Tons 6 Tons
3.25 Ton/Hr 3.5 - 5 Tons 7 Tons
4.5 Ton/Hr 5 Tons 10 Tons

From the point of view of the electrical system and maintenance, Medium frequency
furnace has several advantages. Medium frequency is a solid state unit, operates on
three phase 50 Hz power supply. There is no need for phase or line balancing reactor.
Heavy duty transformer is not required. There is no need for tap changes and capacitor
contactors switching. Control consists of off on button and rheostat for power level
selection. The electrical cost of operating medium frequency furnace system is 5% less
than mains frequency coreless furnace because of the flexibility in power control,
melting speed, low thermal losses and lower refractory costs.

With regards to charging, alloying and slagging operations, medium frequency furnace
are operated in the same way as line frequency furnace. Since heel is not required, the
Medium Frequency Furnace can be completely pored off and restarted with solid scrap
at full power allowing the flexibility of producing wide variety of alloys and to meet the
intermittent demand of molten metal in foundry.
Principle of induction heating: Referring to the sketch Fig. 2, it is seen that an induction
coil surrounds the refractory crucible in which the charge is placed. On energizing the
induction coil, an alternating electromagnetic field is created which couples with the
charge. Electric currents are induced in the charge as a result. The circulation of these
Eddy Current causes heating, which raises the temperature of the charge to melting
and super heating levels.

In short, electrical engineers in other fields work hard to keep the eddy current losses
low. The furnace designer on the other hand exploits the eddy current losses for
attaining melting temperature.

In the induction furnace, heat is generated directly in the charge and not transmitted by
radiation / convection from other sources. Hence induction furnaces are capable of
high levels of efficiency.

Effects of Frequency: It was stated that when the metallic charge is subjected to
alternating magnetic field, eddy currents are induced in the charge. The induced
current, however, does not flow uniformly throughout the cross section of the charge.
Substantial portion of the current tends to flow on the outer sections of the charge
causing majority of the heat to be developed in the area. The depth at which the
magnetic field intensity has fallen to e-1 times the value at the surface is called the
depth of penetration. Currents do flow beyond the depth of penetration but at much
reduced or insignificant levels. The depth of penetration is governed by the relation

= K x f), where = depth of penetration, K = constant, = resistivity of the

charge, = magnetic permeability of the charge, f = frequency. (= 1 for non-ferrous
metals and ferrous metals beyond Curie point)

50 Hz 1000 Hz 10 KHz
Copper (in mm) 10 2.27 0.72
Steel (in mm) 80 20.1 6.3
above Curie point

It has been established that the charge diameter has to be about three times or more
the penetration depth to obtain good efficiency. It has also been found that the
favorable ratio of charge height to coil diameter range from 0.9 to 1.2 for typical melting
furnaces. These two considerations would lead us automatically to the minimum
crucible capacities for different frequencies.
Operating frequency: Theoritical smallest possible crucible capacities for steel (metal
within coil level)

50 Hz 600 Kgs.
200 Hz 100 Kgs.
1000 Hz 10 Kgs.
But later we would see that other considerations like stirring influence the choice and in
practice the smallest crucible sizes would in fact be very large.
Charge particle size: while the above mentioned statements considered the charge as
a single homogenous body, practical charge that would be loaded into the furnace
various extensively in size, bulk density and metallic content. The individual piece of
charge loaded into the furnace should be large enough to induce appreciable power
and result in good heating. The recommended charge sizes for different operating
frequencies are given below:
Nominal
Frequency Dia. of Cylindrical Thickness of
Hz Charge (mm) Plate Scrap (mm)
Steel
200 134 89
600 77 51
1000 59 40
3000 35 23
Iron
200 150 100
600 87 58
1000 67 45
3000 39 26
Brass
200 66 44
600 38 25
1000 29 20
3000 17 11

In practice however users tend to employ lighter scrap than recommended. In such
cases appreciable power can be drawn by the furnace for obtaining a good melt rate,
only after the formation of the liquid pool of molten metal. It is therefore advisable to
reserve good heavy scrap for use at the beginning of the melt and introduce lighter
scrap into the pool of metal already formed. This is especially true for low frequency
furnaces (like 200 Hz) once a substantial bath has formed; charge size is much less
important since most of the heat is induced in the liquid metal.
Stirring: Electromagnetic forces are developed in the molten metal bath as a result of
the circulating current and the magnetic field. These forces cause a stirring action in
the bath as shown in the enclosed fig: 6.
The extent of stirring is expressed as the ratio of the height of meniscus to the
diameter of the crucible. (h/d ratio). A larger ratio indicates a more intense stirring.
Adequate stirring is required for achieving:
1. Uniformity of temperature in the bath.
2. Homogeneity of composition.
3. Distribution of alloying elements.
4. Carburising etc.

Extensive stirring may cause:

1. Excessive refractory wear due to mechanical aberration.
2. Non metallic inclusions in the metals
3. Excessive gas absorption in the melt
4. Spurting of melt, out of the crucible.

Inadequate stirring may cause:

1. Excessive refractory wear due to high temperature at the refractory metal
interface.
2. Non uniformity in temperature and composition.
3. Higher oxidization losses in the initial phase of melting before formation of
molten pool.

What is considered as Adequate stirring for melting different metals is given below
(h/d):
 Grey Iron 0.125 to 0.2
Alloy Iron 0.1 to 0.15
Plain Carbon Steel 0.07 to 0.125
Stainless Steel 0.07 to 0.125
Manganese Steel 0.05 to 0.1
Brass 0.07 to 0.125
Copper Alloys 0.07 to 0.125
Aluminum 0.035 to 0.2
One of the major consideration in selecting the frequency is stirring as will be seen
later.
Furnace Power Factor: With higher frequencies, the furnace power factor tends to be
poorer resulting in higher currents in the leads and bus bars. Overall electrical losses
also tend to increase with higher frequencies.
If other considerations like stirring etc are satisfied, it is not desirable to choose higher
frequencies than essential.
CONSIDERATIONS IN CHOOSING A MEDIUM FREQUENCY CORELESS
INDUCTION FURNACE

The first consideration is the metal to be melted. Coreless furnace are generally
decided to one metal like Iron/ Steel, Aluminum, Brass etc, while it is possible to melt
one metal in a furnace designed for another metal, the optimum design considerations
will be satisfied by the common furnace. Generally two or three furnaces would be
chosen to provide for different metals and to take into account relining or maintenance
needs.

The second consideration is the melting rate and the pouring temperature. The
achievable pouring rate will be lower than the rated melting rate to provider for
charging analysis, additions, de-slagging, pouring etc. Typically for medium frequency
installations, utilization factors of 75 80 % are achievable with good management.
For mains frequency installations, corresponding figure would be 60-65%. (Utilisation
factor is the ratio of realized output to rated output). The desired melting rate of the
equipment can be established by

Desired equipment melt rate = (Pouring rate / Utilisation factor)

If we needs 10 tones in a shift of 8 hours, with an utilisation factor of 75%, the

equipment should at least be rated for an output of 1.67 Ton / Hour.

From the required melting rate and the pouring temperature the KW rating of the
furnace can be established. The following table gives the approximate energy
requirement for a few metals.

Metal Temperature Kwhr / Tonne

Iron 1480 0 C 500
0
Steel 1650 C 570
0
Brass 1175 C 350
Aluminum' 750 0 C 550
To establish the power supply rating in KW, the energy per tones figure has to
multiplied by the melt rate desired of the equipment.

Going back to the above example of 10 T in 8 Hour shift and utilisation of 75% the KW
rating of the power supply would be 1.67 T / Hour x 500 KWh / T = 835 KW, if the metal
to be molten were Iron. The above figures are typical, as the specific energy needed
per tonne of output depends on the furnace size, frequency, type of scrap, size of scrap
etc.

To start with the furnace size can be selected based on a melt cycle ranging between
30 min to 90 min. Although a shorter times can be considered for smaller furnace.

If the melt cycle is too fast, parts of the melt can superheat, giving poor lining life. Also
the high power density required to give fast melt rates can give rise to heating
problems in the furnace body or frame.

The size of the largest casting to be made should also be considered. If for Example,
the largest casting needs 2 tones of molten metal, a 2 tones furnace may be suitable
in terms of volume but need not be the best choice. If the desired melt rate happens to
be high, it would result in short melt cycle. If the desired melt rate is small, the furnace
may turn out to be too large.

Therefore, the furnace size has to be selected based on the large casting that would be
frequently made. If the largest casting is much larger than the average casting and is
only to be made infrequently it would be more practical to give up making this casting
than to install a melting system which is oversized.

Furnace Type: