Channel inductor

If the foundry needs the flexibility of an unheated ladle system, but have high iron temperature control requirements, we can provide a heated ladle solution.
By installing a new ladle body equipped with anchannel inductor, the system can deliver up to 100kW into the iron bath. This will give the foundry the ability to keep the metal at a stable temperature. The electrical efficiency of channel inductor can be up to 90%.
The heated ladle is designed with  back tilt. This ensures a quick and easy way to empty the ladle for metal grade changes. The heated ladle can be powered by a medium frequency or main frequency power supply depending on the applications. Instead of water cooling, air cooling can be used if main frequency system is the choice, this will simplify the system configuraton and further lower the maintenance cost.  

Heated and  Pressurized Pouring Systems - With Channel Inductor.

Advantages:

* Pressurized system, metal level is maintained constant in the pour box to insure a stable metal flow during pouring

* Equipped with medium frequency power supply,  stepless power control

* Temperature can be controlled by superheating molten bath and holding

* Wide capacity range from small to larger as a good metal buffer between melting furnace and molding line

* High electrical efficiency, up tp 90%. Energy saving

* Suitable for long time and continuous production, good for producing single casting with fixed grade. Efficiency is very high and enrgy cost is extremely low

Disadvantages:

* Furnace can not be emptied completely at any time, a heel is always required inside furnace, always power on. The metal grade change is not easy

* Channel inductor is usually located at the furnace bottom or rear side, the inductor circultesand heats  the metal inside channel loop only. The temperature is not uniform through the entire molten bath, especially for in/out siphons which are not exposed to any heating directly. To pour at 1400 deg. C, channel inductor need to heat the metal inside channel loop  up to 1500 deg.C

* Need regularly cleaning and de-slagging channel loop

* In/out sipphons is located at both sides of furance, the molten metal there has the lowest temperature through the entire molten bath. There is a risk for slag build-up in siphons. Maintainance downtime, de-slagging and heawy cleaning in siphons is needed

* For all ductile iron production, downtime of several shifts per week is needed for  maintenance and de-slagging

* Not suitable for ductile iron production

Heated and  Pressurized Pouring Systems - Coreless

Advantages:

* Patented "Apple Core" design, higher electrical efficiency, up to 70% depending on furnace size

* Pressurized system, metal level is maintained constant in the pour box to insure a stable metal flow during pouring

* Equipped with medium frequency power supply,  stepless power control

* Temperature can be controlled by superheating molten bath and holding

* Entire metal area including main bath and in/out siphon is suroundded and heated  by the induction coil, and has uniform temperature. Keep the pouring temperature almost as same as the molten bath inside furnace

* Wide capacity range from small to larger as a good metal buffer between melting furnace and molding line

* Can be totally emtied by back-tilting for easy metal grade change. Cold start is allowed after power off under emergency situation. Complete power off is possible for a long time production stop

* Nodularization fading can be delayed efectively by introducing nitrogen atmosphere protection inside furnace

* The entire molten bath and in/out siphon is heated, less slag build up in siphons and it is easy to clean. Maintainance downtime for de-slagging work is much  less and easier than channel inductor furnaces

* Useable capacity is high. The usable volume is more than 80% of total furnace volume

* Suitable for long time and continuous production, good for producing castings with all sorts of grade including ductile iron

Disadvantages:

* Relatively lower electrical effiency and higher energy cost compared with the system with channel inductor