Innovation for Sustainability

Transcription

1 Innovation for Sustainability

2 1. Sustainable Induction Technology» Sustainability: Ecology, Economy, Sociology Sociology Economy Ecology Sustainability ABP Induction Systems GmbH Strategy: Leadership in Sustainable Technology Seite 2

3 1. Sustainable Induction Technology Energy savings, safety for operators and the digital foundry world, (Industry 4.0) Stateof-the-art induction furnace technology Seite 3

4 1. Sustainable Induction Technology Parts of a MF induction furnace system Circuit breaker Transformer» Mechanic: Furnace body, lining material ~ hydraulic and tilting frame» Electric: Transformer, Converter Cooling system electrics - MF-Converter Capacitor bank, high current connection, Coil - ~ Capacitor bank» Control systems: Weighing system, Process- Charging system Exhaust hood Control» Auxiliary equipment: Cooling system, charging Crucible furnace system, exhaust system Melt processor Weighing system Cooling system furnace Coil tons Bottom electrode for grounding Seite 4

5 Agenda 1. Sustainable Induction Technology 2. Ecology 2.1 Reduction of CO2 emissions comparison of different melting furnaces high efficient ABP ECOTOP hood 2.2 Energy saving new coil for ABP furnaces up to 6 to Process optimization 2.3 No environmental critical material 2.4 Recycling 3. Economy 4. Sociology 5. Industry Summary Seite 5

6 2. Ecology: Specific CO2 Emissions» Specific CO2 Emissions Including the emission of power plants with today s energy mix gr/t Cupola furnace Cupola furnace - cold wind - hot wind Ind. Furnace LF Ind. furnace MF Rotary furnace Source University of Hannover Seite 6

7 2. Ecology: Fume extraction hood, Ecotop»» High efficient hood with integrated furnace cover Tiltable in two directions» Forward for sample taking, temperature measuring and charging» Backward for back charging molten metal and for pushing-out the crucible» Operator friendly free furnace platform MF Coreless Induction Furnace System Type IFM, ABP Induction Systems GmbH, GIFA 2011

8 2. Ecology: Energy saving coil design» Coil losses are approx. 70% of total electrical losses» By substitution of upper and lower cooling windings, losses should be reduced by up to 5%, without negative effect on coil life time Seite 8

9 2. Ecology: Energy saving coil design Installation of coil without cooling windings Seite 9

10 2. Ecology: Energy saving coil design» expected energy and cost savings: Annual production: Energy consumption (standard coil): Coil losses (total): Reduction of coil losses: Electricity rate (industrial): t 525 kwh/t 89 kwh/t 4,45 kwh/t = 5,0 % 15,2 ct / kwh #1 Measured 7 kwh/to = 7,86 % Savings in energy consumption: year t/year x 4,45 kwh/t = kwh/ t/year x 7 kwh/t = kwh/year Savings in costs: year kwh/year x 15,2 ct/kwh = / kwh/year x 15,2 ct/kwh = EURO/year RSA estimated#2: kwh/year x 93,34 crand/kwh = Rand/year #1 Source: Eurostat; Average Electricity Rate Germany 2014 #2 Source: Seite 10

11 2. Ecology: Process optimization» Extension of the ABP simulation tool up to complete process between charging area and liquid metal transport to the molding line» Possible to simulate the process also for complete melt shop including existing furnaces» Realization of bottle necks Seite 11

12 2. Ecology: Process optimization» Simulation of complete liquid metal transport to different sources Seite 12

13 2. Ecology: Process optimization Evaluation of simulation shows potential for improvements, e.g.: Time management (process etc.) Furnace design (content and power) Melt transportation (ladle sizes etc.) Energy savings via high process efficiency Simulation to get high usage of installed power Demo for Lecture_revA :05:19 - Forming facility (6) Charge Power, KW / Charge, KG» Time, min Seite 13

14 2. Ecology: No environmental critical material» Product design without usage of environmental critical material» No usage of environmental critical material NO glycol etc.» No use of health critical material NO asbestos NO PCB etc. Seite 14

15 2. Ecology: Recycling» Chip melting using chips from subsequent casting treatments saves resources Customer Additional heat exchanger» Waste heat utilization for hall heating and T 67 C warm water saving energy Storag e Storag e Shower water T T M Heater 60 C 30 C M Gas or oil burner M T 40 C Fresh water T Cooling tower Q Pump stand M M Seite 15

16 Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 3.1 Reliable Equipment design 3.2 Reliable Power supply 4. Sociology 5. Industry Summary Seite 16

17 3. Economy: Furnace design» Customers request more and more specific furnace designs for their application: Mechanical design Stirring issues Melting High amount of chips Superheating issues Etc.» For furnace designs with max. efficiency, reliability, and mechanical stability, 3D calculations are used by ABP electromagnetic calculation for an ABP 6t-Ofen (Type FS 60) Seite 17

18 3. Economy: Furnace design Advantages in using new tools for the furnace design optimization:» Easier to consider customized desires for the furnace construction such as: Frequency, Bath movement, Power density Lining specification: Wall thickness, -construction etc.» Minimizing mistakes in designing customized furnaces» Increasing the furnace efficiency Seite 18

19 3. Economy: Power supply Power range SCR: 250 kw kw» Completely designed in digital technology» High efficiency Power range IGBT: 250 kw kw» Control unit» IGBT modules» Coupling choke» Capacitors Seite 19

20 3. Economy: Power supply constant power 100% Praxis shows:» Furnaces are not always operated ABP Solution:» ABP converters are designed for 30 % higher power, getting full power also with not optimal filled crucible (= low material density)» High power supply reliability based on overdesigned power parts Lining wear rel. converter output current I at nominal point à Power losses, Production losses are the consequence 70% Built up and/or too low material density in crucible % rel. converter output voltage U 100% Seite 20

21 3. Economy: Power supply constant power» Renault power and weight monitoring, 3 furnaces (10 to), one melting, two holding mode, one power supply (8,3 MW) Holding furnace 3 Holding furnace 3 Temperaturemeasurement furnace 2 Holding furnace 3 Ofenreise Ofen 2 0:00: Weight 0:00: Leisung KW, :00: :00: :00: :00: Ofeninhalt kg, 0:00:00 Power 0:00: :00:00 0:00: min Seite 21

22 Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 4. Sociology 4.1 Safe work place ground fault detector 4.2 Safe work place Melt processor 5. Industry Summary Seite 22

23 4. Sociology: Ground fault detection Lining Coil grouting Furnace frame Coil Yoke External Ground Fault in the power supply External Ground Fault shorts coil to yoke Transformer ~ - Rectifier for 100 % power Smoothing choke Metal penetration - Inverter ~ Capacitor bank Error message: Ground Fault STOP of Power supply Bottom electrode for grounding Insulation / ground monitoring Ground detector Seite 23

24 4. Sociology: Ground fault detection Operator has electrocution risk if contacts bath with conductive tool Transformer ~ - Rectifier for 100 % power Smoothing choke Metal penetration - Inverter ~ Capacitor bank Bath electrode buried in lining Insulation / ground monitoring Ground detector Critical Danger Situation, but with no bath electrode, no current flows and there is NO ALARM Seite 24

25 4. Sociology: Ground fault detection Improvements / Innovations: automatic activation after bypassing ~ Automatic check of bath grounding e.g. after sintering of a wet crucible - Instead of manual check Locating of ground faults Decision-making support for operators for further measurements PLC GD Seite 25 - ~

26 4. Sociology: Hedgehog Coil» Hedgehog Coil Mecanit n n n n n Liquid metal n Hedgehog pin n Spark n Coil Grouting Penetration of liquid metal Refractory material Seite 26

27 4. Sociology: Melt processor» Operation of melt processor systems Save energy Secure melt quality Support operators Reduce off-times» Fully-fledged PLC based melt processors For reduction of PC based breakdowns / errors For enhancing workplace security via continuous monitoring of melting process Seite 27

28 Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 4. Sociology 5. Industry Digital foundry world 6. Summary Seite 28

29 5. Industry 4.0» ABP open FIS (Foundry Information System) Digital foundry world Server for data collection Common Interfaces for communication s between different installations (eg. melting furnaces, holding furnaces, pouring station etc.) Customized software for process optimization Process description with action list (if this à than ) Considering Priorities Etc. ABP equipment's are already developed to communicate with each other Open FIS, prepared to add e.g. moulding lines, exhaust system etc. Seite 29

30 Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 4. Sociology 5. Industry Summary Seite 30

31 6. Summary Sustainable Induction Technology»Ecology Reduction of CO2 emissions using induction furnaces as a melting aggregat Energy saving based on new coil design and process optimization No environmental critical material use such as PCB, Asbestos etc. Recycling by melting of chips»economy Reliable Equipment design using 3D simulation tools Reliable Power supply with constant power supply even under not optimal conditions»sociology Secured work place ground fault detector protects the operator Secured work place Melt processor on SPS base Seite 31

32 6. Summary Sustainable Induction Technology»Industry 4.0 The digital foundry world for process optimization and safety production»resume The developments at ABP demonstrate, endurably which improve the environment and provide longevity for our succeeding generations, focussing on the safety of every single operator, with the emphasis on production optimization, to be profitable in the future. Seite 32

33 Thank you for your attention Hermann-Josef Kroes Phone: Cell: Seite 33

34 2. Ecology: Energy saving coil design Results on the first tests: Slight cracking formation in some stones, which substitutes the upper cooling winding Solution: usage of joint sealer with higher elasticity Results on energy saving were not reproducible enough for a final statement Variations during comparison attempts in: Interruptions of melting process Charging with different scrap densities and composition Etc. On all energy saving processes on the coil design the mechanical stability the safety features (open coil design that water can evaporate) has to be considered. All actions don t have to lead to a weaker furnace construction. Seite 34

35 Energy consumption for melting iron» Enthalpy for melting 1 to of iron at C: 396 kwh/t kwh/t Additions Material losses Gas / oel 400 electrical Engergy Koke Cupola Cupola furnace - cold furnace - hot wind wind Ind. furnace LF Ind. furnace MF Rotary furnace Seite 35 Source University of Hannover

36 Energy balance for melting iron» Specific CO2 Emission for melting of one ton iron gr/t Cupola furnace Cupola furnace - cold wind - hot wind Ind. Furnace LF Ind. furnace MF Rotary furnace q Including the emission of power plans with today's energy mix Source University of Hannover Seite 36

37 Energy balance for melting iron» Specific primary energy request for melting one ton iron kwh/t Cupola furnace Cupola furnace - cold wind - hot wind Ind. furnace LF Ind. furnace MF Rotary furnace q Using induction furnaces conventional energy (oil, Coke) can be avoid (alternative energy or atomic engergy) Source University of Hannover Seite 37

38 Energy balance for melting iron» Reduktion of CO2 Emission % 50% 40% 30% 20% 10% 0% S weden F innland Austria F ranc e S pain G ermany G reec e Italy P oland G reat- Netherland B ritain Malta q Development of the regenerated energy production of the total energy request in Europe from 2007 to 2020 (2020: Tendency) q The development of energy production green energy : ð Using induction furnaces, saving raw material ð Using induction furnaces, reduces CO2 Emission Source University of Hannover Seite 38