In induction heating, the energy is introduced directly into the workpiece by the electromagnetic field of an induction coil. Compared with alternative heating methods, the process enables very high energy densities and can thus achieve good efficiency due to low radiation losses.
When green electricity is used, the process is virtually C02-neutral. This means that conventional heating processes for melting (coke, gas) and also for forming (gas) can be replaced in a largely C02-neutral manner. Of particular interest for existing heating lines with gas furnaces is the fact that a step-by-step conversion with complementary addition of an induction heater leads to an equivalent C02 reduction and thus to the achievement of the interim C02 reduction targets set for 2030.
The level of savings depends on the C02 footprint of the current heating process and the availability of green energy for induction heating. A paper on the topic will be presented in Düsseldorf at the GIFA Forum on Monday, 12/06/2013 at 15:30, entitled 'Conversion of a smelting operation from cupola furnace to modern induction furnace technology'.
The article describes the replacement of a cupola furnace operated with coke. As a result, emissions of 890 kg CO2/t of cast iron prior to 2009 were reduced to 512 kg CO2/t of cast iron (Scope 1 and Scope 2). By purchasing green electricity this year, the CO2 footprint will be reduced to 61kg CO2/t of castings. This represents a C02 saving of more than 93%.
In addition, digital solutions from ABP offer a wide range of options for highly efficient operation of melting furnaces, including remote monitoring and maintenance, data analysis, intelligent calculations, and predictive maintenance capabilities.
With digital sensors, control systems and AI, operating conditions such as temperature, amperage and frequency can be monitored and adjusted in real time. Automated data analysis can identify patterns and trends that indicate potential problems or point to opportunities to optimize efficiency and quality. Intelligent calculations can be used to test different requirements and incorporate optimal solutions into product developments even before they are implemented in the melting and casting process. Predictive maintenance helps to anticipate and plan maintenance work in order to reduce expensive downtime.
