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    Technical parameters and process analysis of 0。5 ton melting furnace

    1。1 0。5 ton melting furnace use :

    The 0.5 ton melting furnace is an intermediate frequency coreless induction melting furnace for steel smelting in the foundry .

    0。5 ton melting furnace power 5 00 KW / 1T equipment。

    Basic configuration: two furnace bodies, one set of power supply, one set of compensation capacitors, and two sets of furnaces are operated separately. The tilting method is hydraulically reversed with a remote control box.

    When designing the equipment, the user's on-site working status is considered to be continuous, and the furnace is frequently discharged. The equipment selection of this scheme ensures the user's output index and meets the user's overall requirements for the equipment: the equipment is durable and performance. Stable, safe and reliable.

    1.2 Equipment technical requirements

    Power rating

    500KW

    Power frequency

    1000Hz

    Power line voltage

    3×380V

    Power factor

    The power factor of the furnace under any power operation is not less than 0。95

    Melting rate

    500KW/1T ≥0.65t/h

    Release temperature

    1650 ° C

    Power consumption

    ≤ 580KW.h/t

    Working noise

    <85 decibels

    Melting material:

    Cast steel, cast iron

                 

    1。3  0。5 ton melting furnace smelting description:

    The user's factory uses induction furnace melting, heating, heat preservation, quenching and smelting process.

    1。3。1 Power Supply Selection:

    In general, the smelting speed and the metal to be smelted are determined in advance. The required melting speed determines the required power. Based on experience, the following estimation principles are available.

    The following is the recommended melting furnace rated power configuration (iron and steel)

    Furnace capacity (T)

    Power range (KW)

    0.5-1

    500-750

    2

    1000-1500

    3/4

    1500-2000

    5

    2000-3000

    6

    3000-4000

    8

    4000-5000

    10

    5000-6000

    1.3.2 Selection of transformer:

    Power supply (KW) × 1。25 = transformer (KVA) Note 1。25 is the safety factor;

    1。3。4 Power rectifier design:

    In order to reduce the harmonic pollution generated by the high-power IF power supply to the power grid, our company uses the series inverter technology on the intermediate frequency power supply. Therefore, to ensure that the intermediate frequency power supply operates under high power factor, the generated higher harmonics are within the allowable values of the utility grid harmonics specified in the GB/T14549-93 standard;

    Comparison of characteristics of parallel and series circuits (table)

    Project

    Medium frequency power supply type

    (a) Parallel type

    (b) tandem type

    (c) series and parallel

    Output voltage waveform

    Sine wave

    Rectangular wave

    Sine wave

    Output current waveform

    Rectangular wave

    Sine wave

    Sine wave

    Induction loop fundamental voltage

    Inverter output voltage

    Q× inverter output voltage

    Inverter output voltage

    Induction loop fundamental current

    Q× inverter output current

    Inverter output current

    Q× inverter output current

    DC filter

    Large reactance

    Large capacitance

    Large capacitance

    Anti-parallel diode

    No need to

    use

    use

    Thyristor

    Du/dt

    small

    Big

    small

    Di/dt

    Big

    small

     

    Commutation overlap effect

    Series reactance and distributed inductance cause commutation overlap

    no

     

    Commutation failure protection

    easily

    easily

    easily

    Additional component

    many

    less

    less

    effectiveness

    Low (about 90%)

    Normal (about 95%)

    High (90%)

    Operational stability

    Stable over a wide range

    Stable over a wide range

    Difficult to manufacture below 1000HZ

    energy saving effect

    difference

    excellent

    difference

    Note: The quality factor of the Q-induction loop。

    When designing an intermediate frequency induction furnace, the main circuit of the intermediate frequency power supply adopts a series circuit.

    The main technical parameters:

    A. Comprehensive parameters:

    Equipment form:

    Medium frequency melting furnace

    Equipment use:

    Used to smelt steel

    Rated Capacity:

    1T 0.75T

    Maximum capacity

    2t+10%

    Operating temperature:

    1650 ° C (steel)

    Smelting material:

    steel

    Tilting method:

    Hydraulic control

    Maximum angle of the tilting furnace:

    95 degrees

    Hydraulic medium:

    Machinery oil

    Hydraulic station capacity

    500L

    Working pressure:

    11MPa

    Working noise:

    <85 decibels

    Furnace structure:

    Steel shell

    Way out:

    Side outlet

    Melting rate:

    500KW/2T ≥0.65t/h

    Melting power consumption

    580kW。h/t

    B. Electrical parameters:

    Power supply

    500KW/1T 0。75T

    Number of rectifiers

    6 veins

    Inverter

    SCR series

    Rated frequency

    500Hz

    Line voltage

    3×380

    Transformer primary side line voltage

    10KVA

    Sensor voltage

    1600V

    Start success rate

    100%

    Power factor

    Greater than 0.95

    C。 Closed cooling tower:

    Inlet pressure

    0。2-0。4MPa

    Inlet temperature

    5-35 ° C

    Effluent temperature

    <55°C

    Cooling water flow

    40mm 2  

    Equipment shape

    2300mm*1200mm*2800mm

    Water pump

    5.5KW one use one

     

    Description of the control principle of the 0.5 ton melting furnace :

    Brief description of the operation of 0。5 ton melting furnace :

    Waterway operation:

    a。 Before starting the machine, first check whether the valves of each waterway are open。 Before starting the machine, first turn on the cooling water system。

    b. Open the external circulating water system first, and observe whether the water pressure and temperature meet the requirements;

    c。 Open the inner circulating water system again, and observe whether the water pressure and temperature meet the requirements。 If it does not meet the requirements, adjust it in time;

    d. After all the cooling water is in normal circulation, the electric furnace can be started to smelt;

    Control flow chart for intermediate frequency furnace:

    0.5 ton melting furnace complete equipment range:

    1 equipment range list :

    Serial number

    Device item name

    Specification model

    unit

    Quantity

    Remarks

    1

    Intermediate frequency power supply

    KGPS-500/1

    station

    1

     

     

    2

    Furnace body

    GW-1

    GW-0.5

    station

    2

     

    Leaky furnace alarm

    3

    Hydraulic system

    10Mpa

    set

    2

     

    4

    Model

    1T 0.5T

    only

    1

     

    5mm

    5

    Compensation capacitor cabinet

    KGPS-500/1

     

    set

    2

     

    Includes: channel busbar

    6

    Furnace front console

    LTL-C1

    station

    2

    Includes: three color lights

    7

    Leakage alarm system

    LT-BU-101

    set

    2

    Contains: electrode for furnace body

    8

    Water cooled cable

    SL-500

    set

    2

    A total of 2 400 square

    9

    Pair of flanges, seals, connecting bolts, feet

     

    set

    1

     

    XI. Main components supporting manufacturers and quotations:

    Serial number

    item name

    Place of production

    1

    switch

    Shanghai People's Electric Appliance Factory

    2

    Rectifier thyristor

    Hubei Xiangfan Instrument Component Factory

    3

    Inverter thyristor

    British Sima (domestic package)

    4

    Power meter voltmeter, frequency meter ammeter

    Suzhou Instrument Research Institute

    5

    Capacitor

    Shangyu Capacitor Factory

    6

    main control board

    self made

    7

    Reactor

    self made

    8

    Button, switch, indicator

    Zhengtai

    9

    Wire loop

    Luoyang Copper Material Factory Cold Extrusion Copper Tube T2 Copper

    10

    Yoke (with water cooling)

    Gao Xi silicon steel sheet yoke

     

     


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