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Electric Arc Furance Vs Induction Furnace : in steel castings

stanislasdz (Materials) (OP)
18 Nov 07 7:42
Hi,

My questions can seems : a basic question but what are the adavantages and inconvenients bettwen the Eletric Arc Furnace EAF) and the Induction Furnace to produce steel castings parts like :   metallurgical level, quality, costs, environnement..

Any explications or links are welcome.

Stan
arunmrao (Materials)
18 Nov 07 10:37
Stanislasdz,
I know you are good with your casting technology. But please let us know what performance parameter are you looking at for selection of the melting equipment. Also it is generally not recommended to have EAF of capacities less than 10 Tons.

EAF invites the attention to a greater extent of pollution control authorities. But it is the cheapest and most economical way as a variety of scrap can be charged.

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stanislasdz (Materials) (OP)
18 Nov 07 13:41
Hi Arunmrao,

Actually due to the increasing request from our costumers, our company thinks to build a new steel casting foundry for the part between 150 and 2500 Kg....

As this time we develop the parts thinks to EAF. But an overview of the new foundries built this last years show that most of them use Induction furnace !!!

So we study what can bring us the Induction furnaces if use it for the new plant.


I would like have a feedback of your experience Arunmaro on this field.

Thanks

arunmrao (Materials)
18 Nov 07 22:50
I am no spokesperson for Induction melting,but I have spent a major part of my life with Induction furnaces.

Arc furnace provides a simple and effective way of melting various grades of scrap and then going ahead to refine the metal to your specification. It is also useful in making tool steels and alloy steels. This provides a method of utilising low cost scrap,which is available in abundance.The key advantage in EAF melting is that refining is possible and you can also produce low carbon steels.(my experience has been upto 0.08%C).


EAF practice needs experienced melters and operators who are in short supply. Also the cost of graphite electrodes and refractories increase the operational cost. Energy cost formelting compares with Induction furnace.

The cost of EAF may be low compared to Induction furnace, but the cost of electrical transformers,switch gear,cables will be expensive. Additionally you have will have to instal expensive pollution control equipments to meet your local laws.

For the batch type of operations you are envisaging,Induction melting will be desirable. Normally where the liquid metal demand is above 25 tons on a continuous basis, EAF is installed.

The major drawback in Induction melting is the use of clean and segregated scrap,which is expensive and the absence of any refining.

 Installation of the equipment is quick and a low skilled operator can un the furnace. You are able to produce very low carbon (0.03%) grades in induction furnace. Also changing grades of steel can be done on a heat to heat basis.

If you are looking for a 5 ton Induction furnace, India can be your choice as you might be able to get a  sparingly used furnace at less price.

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stanislasdz (Materials) (OP)
24 Nov 07 14:44
Thanks à lot arunmrao :

I have somme questions :

1- Is there any difference in the price of parts produced in EAF or Induction arc furnace ?

2- Is there any difference in the mechanical proprieties of steel casting parts produced by EAF or induction furnace ?

3- Is there any difference on the quality of the parts: inclusions, porosity, hot tearing....between the parts produced in EAF furnace or in induction furnace ?

Thanks in advance !



arunmrao (Materials)
25 Nov 07 2:44
>For hot metal requirements below 10 tph, the medium frequency coreless induction furnace has proven to be the best choice from an operational and economic standpoint.

> Dust generation and collection continue to be two serious problems with electric arc furnaces, and no satisfactory solution appears imminent.

>If the refractory and ladle practice is good, arc furnace metal should also be of better quality .

>Inclusions,dissolved gases etc will be influenced by other parameters too. Cast steel grades prone to form defects caused by nitrogen or hydrogen may pose a problem when melted in induction furnaces.

 >Both types of melting furnace operations benefit from the use of refining operations (secondary metallurgy), particularly with respect to "clean steel" requirements.

> Each melting operation presents its own set of unique requirements, and the optimum practice must be developed on a case-by-case basis; rules-of-thumb are inadequate.

>You may also contact Steel Founder's Society of America for some of the publications.

www.sfsa.org

>If you need an indepth or comprehensive report,you can avail the services of Castings Technology Institute.

http://www.castingstechnology.com/

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