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ABP InductionSystems
Sustainable Technology
Middle East Foundry Summit
Dubai, July 20th, 2016
Franz SchröderExecutive Vice President
ABP INDUCTION – HISTORY
• ABP Induction; long tradition within the induction technology sectorASEA, BBC (later ABB).
The employees and the intellectual property of this traditional business areintegrated in ABP Induction, the legal successor of ASEA and BBC
Seite 3
ABP Segments
ABP Segments
ServiceHeaterSteelMelting
Foundries ForgingSteel plant
Heating
Seite 4
ABP Segments
ABP Segments
ServiceHeaterSteelMelting
Foundries ForgingSteel plant
Heating
Agenda
1.Company introduction
2.Foundry equipment
3.Melting of steel scrap in induction furnaces
Induction furnace system in medium frequency technology
1. Introduction
Mains transformer
Power switch
Medium frequency converter
Capacitor bank for compensation
Crucible induction furnace
Induction furnace system
Mains
108 year ABP Inductions furnace tradition
1903: Gysinge Bruk / Sweden:1. Channel furnace with ASEA-power supply went into operation(1,8 t , 300 kW ) with 700 kWh/t
A TRADITION OF INNOVATION
• 112th year anniversary of 1st practically working inductionMelting System (1.8MT/300kW)built by ASEA
• 43rd year automated Pouring Technology introduced duringGIFA 1967 by Brown Boveri
• 44th year developed first solid state power supply in 1968
• Sustainable Technology
• 42 MW 70 t corelessinduction furnace- 2012
The Innovation Continues!
Our strategy:Sustainability and sustainable Technology
Sustainability
E c
o l o
g y
E c
o n
o m
y
S o
c i o
l o
g y
= Ecology, Economy and Sociology in Harmony
Strategy directed into the world market
and into
Focus Ecology as a part of sustainable Technology
� Energy efficiency
Energy efficient products - furnace, power supply, transformer, pumpstand
Energy efficient process - Twin-Power, Energy efficient ladle size, exhaust system worksonly when cover / hood is open, Pouring furnaces instead ofopen ladle
� Reduced CO2 – Emissions
Ecotop hood solution
� Productdesign without usage of environmental critical material
No Asbestos, no Glycol, no PCB
� Recycling, regeneration
chip melting, waste heat utilization
Focus Economy as a part of sustainable Technology
� Long life time - design
The equipment will support 2 generations of foundrymen
Solid stable steel construction, long coil life time
� Reliable technology
maintenance friendly design, low spare part consumption
strong local service network
� Low operational cost
good lining life caused by rigid coil design
low labour cost based on integrated automation
Focus Sociology as a part of sustainable Technology
� Workplace layout in meltshops
Elimination of hazardous work places, automated charging systems
Integrated safety systems
� Continous training to transfer know how
Education of workers
ABP Vision :„People free“ furnace plattform
2015: appr. 450 employees in 11 ABP country organizations
ABP Induction
ABP HQ DORTMUND/GERMANY
Admin Offices
Mech. BldgElect. Bldg
Approx. 200 Employees
Mechanical Factory ( Coil, yokes, assembly )
Focus: High quality made in ABP
Electric shop
Crucible induction furnaces for melting and holding Iron, Steel and Non-Ferrous metals( Aluminum, Copper, Zinc, Magnesium )
Furnace size 0.25 … 0,75 t 1 t … 6t 5t … 60 t 10t .. 70 t
Crucible Type Smart FS FS IFM LFS
Power supply IBGT Thyristor250 kW …4 MW 1 MW … 42 MW Single Power / Twin Power
Products for melt shop systems
medium frequency (MF) Mains/line frequency (LF)
Energy consumption 520 - 580 kWh/t 770 – 1.000 kWh/t
Power density 600 - 1000 kW/t 150 – 300 kW/t
Melt rates 300 % 100 %
Melt conditions Batch type Heel
Flexibility High Low
Changing of alloy Good Bad
Lining live per molten t High Low
5 т12 т
Comparison between LF and MF
MF LF
Melting of chips Low heel High heel
Material density in the furnace High Low
Maintenance Low, no mechanical wear High, mechanical switches
Comparison between MF and LF
12 т5 т
2. MF induction furnace, type IFM/FSDesign features
� Open design
� Easy maintenance
� Better visual control
� Less noise emission
� Exchangeable furnace head
� Upper concrete ring as separate element
� Fixing coil in axial direction with adjustable pressure
� Pouring spout located in tilting axis
� No moving melt stream
2. MF induction furnaceABP coil insulation
� Liquid metal � Refractory � Grouting
� Water chamber
� Isoplan
� Silica cloth
� Cupper profile
� Mikanit foil
� Segmental insulation
� Your advantages:
� Better coil protection
� Better conductivity of evaporation & humidity
� Easy to handle
3. Safety:Hedgehog coil
Coil
Segments
Grouting
Mekanit
foil
Refractory
material
Liquid
metal
Hedgehog
sensor
1. Introduction:Available Applications
Designed for melting and holding of ferrous and nonferrous metals for FS furnace types
Furnace capacity: 1.000 kg – 6.000 kg (ferrous)
Power rating: 250 kW – 4.800 MW
2. MF induction furnace, type IFM:ABP yokes
� Ceramic insulation between coil and yoke
� NO ARCING BETWEEN COIL AND YOKE
� Simple water cooling
� Easy yoke adjustment
� Yokes can be replaced without removing coil
� Uniform yoke pressure minimizes refractory stress
� Fixed in 2 points
Aluminium yokes:
� high strength, noise damping
� high power density application
1. Introduction:Available Applications
� Designed for melting and holding of ferrous and nonferrous metals for IFM furnace types
� Furnace capacity: 8.000 kg – 65.000 kg (ferrous)
� Power rating: 3000 kW – 42.000 MW
5. Power supply:two furnaces – one power supply
-
-
~
~
Furnace current
switches
TWIN-POWER
-~
100 %
100 %
0 %
0 %
Transformer
Rectifier for 100 % power
Smoothing choke
Inverter
Capacitor bank
Mechanical furnacecurrent switch
Furnaces 1 & 2
Transformer
Rectifier for 100 % power
Smoothing choke
Furnaces 1 & 2
Capacitor bank 1 & 2each for 100 % power
Inverter for flexiblepower distribution
Seite 28
PLC Based Melt Processor
Prodapt Advanced
Siemens S7-1500
Data Storage on SD-Card or Fileserver
Crucible wear level diagram
Automatic melting - Cold Start – Sintering - Charge energy mode
Long term trend curves
Seite 29
PC Based Melt Processor
Prodapt Enterprise
In comparison to PLC Based Prodapt Advanced:
Storage in SQL Database
variable dynamic configuration of trend curves
Prodapt Enterprise with openFIS
Robust melt processor in PLC without outage
Long term storage in SQL openFIS Database
Linkage and process improvement auf complete plant
ABP best solution:
Seite 30
ABP-Foundry information system openFIS
open – our understanding
Data exchanged based on well known protocols TCP / IP and OPC-UA
Abstraction of the whole plant by driver model
Partner could integrate their controls with own branding and style
Open software solution for monitoring and controling all plant sections in your foundry
Documentation of your quality within one system for the entire production line
Information is available wherever you are
Power supply: Control unit
Digital Inverter Control Unit
Customer Module
performs all controlling, regulating and protecting functions of the converter
Completely designed in programming technology
System-related data stored as parameters
No hardware to be matched
Internal self-test
Remote diagnosis via Teleservice
� back up control module in case of PRODAPT® failure
� digital read out of:
� Power
� Voltage
� frequency
Exhaust systems: ABP ECOTOP hood
Low height
Two fixing points with furnace platform
INCREASED STABILITYTWO TILTING POINTS FOR SMOOTH TILTINGHigh exhaust capability
No hydraulic cylinders uncovered on platform
NO RISK FOR OPERATORSAVOIDING DAMAGES TO CYLINDERS BY SPLASHESFree platform while forward tilting
Free view and access to the crucible
Easy to operate
4. Exhaust systems:ABP ECOTOP® hood
� Tiltable in two directions
� Forwards for sample taking, temperature measurement and charging
� Backwards for crucible push-out and refilling with liquid iron
4. Exhaust systems:ABP ECOTOP® hood for back-tilting furnace
Telescope system for back-tilting furnaces
Products for melt shop system continued….
Channel induction furnaces for holding Iron and melting and holding Non-Ferrous metals( Aluminum, Copper, Zinc )
Application Holding Iron Melting Al Melting Cu Melting Zn
Furnace size 13 … 135 t 8 t … 70 t 6t … 180 t 10t .. 300 t
Type LFR / IRT RAS RKS RZS
Inductor: 500 kW …3 MW 300 kW ..1,3 MW 200 ..2,5 MW 300 … 800 kW
Pouring systems
Products for pouring systems
Heated and unheated furnaces for automated pouring of iron and copper alloys with Laserpour-Control
Heated P System Unheated P System Open ladle System
Furnace size 2,9 … 25 t 2,4 t … 4,5 t 1 - 3 t
Type Presspour OCC Presspour OCU UPT
Inductor: 130 kW …1000 kW
3.1 PRESSPOUR® OCC:Design Features
Stopper system Level scanning in pour siphon
Pour siphon
Pressurized vessel
Fill siphon
Base frame for long and cross travel
Mould
Channel inductor
3.1 PRESSPOUR® OCC:with crucible inductor
� High flexibility when changing the iron grade
� Holding only by means of gas burner during short standstills
� Possibility of complete emptying
� Easy separation from furnace vessel
� Constant power over the full crucible campaign
Unheated pouring ladleUPT
� High flexibility when changing the iron grade
� Holding only by means of gas burner during short standstills
� Possibility of complete emptying/ No heel
Unheated pouring ladleUPT
Messevideo UPT Castexpo 2016 Ver4.AVI
6. Automatic pouring:OPTIPOUR®
Laser Beam
Measurement range
Pouring stream
� OPTIPOUR® - Laser
� For high speed DISA with very small sprue cup
� OPTIPOUR® - Linelaser
� For small sprue cups
� For high speed DISA with small sprue cups
� OPTIPOUR® - Camera
� For flask lines with large sprue cup
6. Automatic pouring:OPTIPOUR® - Camera
OPTIPOUR® - Camera
Measurement range
Pouring stream
� Measuring and control area is outside of the pouring stream
� Diameter of the sprue cup is 3x diameter of pouring stream
6. Automatic pouring: OPTIPOUR® Visualization
� Furnace visualization
� Electrical system (heated pouring furnace)
� Cooling System
� Pressure delivery system
� Hydraulic system
� Inoculation system
� Positioning
Furnace Control System:Furnace visualization
7. Process control system:PRODAPT-H/P – Inductor charts
2
1
3
4
2
1 3
4
Service
Spare Service Preventive Training Consulting Coil and Retrofitparts on Maintenance furnace
demand repair
for Foundries and Forming plants
Agenda
1.Company introduction
2.Foundry equipment
3.Melting of steel scrap in induction furnaces
EIF vs. EAF
� Restrictions:� Selected scrap� Special lining requirements
� Available units:� MF. furnace from 300 Kg to 65t capacity� Electrical power supply from 250 kW to 42.000 kW per unit
� Advantages IF:� No high demand on el. Net� Possibility of using Generators� Operating and maintenance friendly melting Machine � Lower space requirement� Lower expenditure for environment conformity (dust, noise…)� High metal yield particular for Fe-alloys (Cr, Ni, Mn…etc)� No electrode cost
� Economical production:� Till 500 T t/year economical� Suitable for net reasons until 800 T t/a� High grade steel products
EIF vs. EAF: 1t LM Costs for 25t
IF EAF IF – EAF
Raw Material Price 313,00 310,00 3,00
Power 18,70 16,10 2,60
Refractory 6,00 1,60 4,40
Electrode 0,00 9,70 -9,70
Fluxes 0,00 4,70 -4,70
Oxygen 0,00 2,30 -2,30
Other gases 0,07 0,11 -0,04
Temp. Measuring 0,07 0,03 0,04
Samples 0,08 0,03 0,05
Alloy materials 5,50 13,40 -7,90
Total effect 343,42 357,97 14,55
� Saving of approx.14 $ for every IF ton produced� Consumption statistic for EIF & EAF in US $ / Feb. 2012
EIF vs. EAF: 1t LM Costs for 25t
IF EAF IF – EAF
Raw Material Price 313,00 310,00 3,00
Power 18,70 16,10 2,60
Refractory 6,00 1,60 4,40
Electrode 0,00 9,70 -9,70
Fluxes 0,00 4,70 -4,70
Oxygen 0,00 2,30 -2,30
Other gases 0,07 0,11 -0,04
Temp. Measuring 0,07 0,03 0,04
Samples 0,08 0,03 0,05
Alloy materials 5,50 13,40 -7,90
Total effect 343,42 357,97 14,55
� Saving of approx.14 $ for every IF ton produced� Consumption statistic for EIF & EAF in US $ / Feb. 2012
General set up of an IF System:
Tisco North ( 6x 65t; 3x 42MW)
ABP IF System:
65t Furnace Capacity
ABP Power supply:
POWER SUPPLY UP TO 42 MW
With the latest development in the IF technology and the references already realized a yearly production up to 450.000 t/a via ONE IF-system is possible
IF Lines: Low Carbon Steel
Induction Furnace
Charging
CarCrane
LRF
Caster
⇒ OEM / KSA
� 300.000 t/a of Billet
� 4 x 25t IF crucibles
� 2 x 14 MW
⇒ Steel plant INDIA
� 120.000 t/a of Billet
� 2 x 30t IF crucibles
� 1 x 16 MW
IF Lines: Low Carbon Steel
Induction Furnace
Charging
CarCrane
LRF
Caster
OBS
⇒ OEM / Africa
� 300.000 t/a of Billet
� 3 x 25t IF crucibles
� 2 x 14 MW
IF Lines: Low Carbon Steel
Induction Furnace
Charging
LRF
Caster
CarCrane
EAF
⇒ Steel plant in KSA
� 150.000 t/a of Billet
� 2 x 24t IF crucibles
� 1 x 16 MW
� 80t EAF
IF Lines: Steel Alloying
Induction Furnace
Charging
CarCrane
LRF
Caster
AOD
⇒ Stainless steel plant India
� 300.000 t/a
� Stainless Steel Product
� 3 x 25t IF crucibles
� 3 x 18 MW
Stainless Steel plant / INDIA – Melt shop Layout
3 x 25t IF 3 x 18 MW SP
3 x 25t IF3 x 18 MW SP
IF Lines: Steel Alloying
Induction Furnace
Charging
CarCrane
LRF
Caster
AOD
EAF / BF
⇒ Ferro Alloy Plant CHINA
� BF + 30t IF
� 2 x 30t IF crucibles
� 1 x 25 MW
⇒ Ferro Alloy Plant CHINA
� BF & EAF 160t
� 6 x 65t IF crucibles
� 3 x 42 MW
⇒ ca. 1.000.000 t/a
� Modest requirements regarding utility supply (electricity)� Low investment and operating cost� Easy to operate and maintenance friendly� Small space requirements� High metal yield particular for ferro alloys (Cr, Mn, Mb)� No electrode cost� Short return of investment
Advantages of induction furnaces
Long standing customer relationships
� Long standing customer relationship with several large & medium foundries ( GM, DC, Volvo, Ford, Toyota, Hyundai, Honda, Nissan, ThyssenKrupp, Hitachi) all over the world with experienced key account managers
� Strong local service in all key markets we serve
THANK YOU FOR YOUR KIND ATTENTION !