Sustainable Technology. ABP Induction Systems. Middle East Foundry Summit Dubai, July 20th, Franz Schröder Executive Vice President

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1 Sustainable Technology ABP Induction Systems ABP Induction Systems GmbH 1 Middle East Foundry Summit Dubai, July 20th, 2016 Franz Schröder Executive Vice President

2 ABP INDUCTION HISTORY ABP Induction; long tradition within the induction technology sector ASEA, BBC (later ABB). The employees and the intellectual property of this traditional business are integrated in ABP Induction, the legal successor of ASEA and BBC

3 ABP Segments ABP Segments Foundries Steel Melting Forging Heater Steel plant Heating Service Seite 3

4 ABP Segments ABP Segments Foundries Steel Melting Forging Heater Steel plant Heating Service Seite 4

5 Agenda 1.Company introduction 2.Foundry equipment 3.Melting of steel scrap in induction furnaces

6 1. Introduction Induction furnace system in medium frequency technology Mains Power switch Mains transformer Medium frequency converter Capacitor bank for compensation Crucible induction furnace Induction furnace system

7 108 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

8 A TRADITION OF INNOVATION 112th year anniversary of 1st practically working induction Melting System (1.8MT/300kW) built by ASEA 43rd year automated Pouring Technology introduced during GIFA 1967 by Brown Boveri 44th year developed first solid state power supply in 1968 Sustainable Technology 42 MW 70 t coreless induction furnace The Innovation Continues!

9 Our strategy: Sustainability and sustainable Technology Sustainability = Ecology, Economy and Sociology in Harmony E c o l o g y E c o n o m y S o c i o l o g y Strategy directed into the world market and into

10 Focus Ecology as a part of sustainable Technology Energy efficiency Energy efficient products Energy efficient process Reduced CO 2 Emissions Ecotop hood solution - furnace, power supply, transformer, pumpstand - Twin-Power, Energy efficient ladle size, exhaust system works only when cover / hood is open, Pouring furnaces instead of open ladle Productdesign without usage of environmental critical material No Asbestos, no Glycol, no PCB Recycling, regeneration chip melting, waste heat utilization

11 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

12 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

13 ABP Vision : People free furnace plattform

14 ABP Induction 2015: appr. 450 employees in 11 ABP country organizations

15 ABP HQ DORTMUND/GERMANY Elect. Bldg Mech. Bldg Admin Offices Approx. 200 Employees

16 Mechanical Factory ( Coil, yokes, assembly ) Focus: High quality made in ABP

17 Electric shop

) Furnace size 0.25 0,75 t 1 t 6t 5t 60 t 10t.

18 Products for melt shop systems Crucible induction furnaces for melting and holding Iron, Steel and Non-Ferrous metals( Aluminum, Copper, Zinc, Magnesium ) Furnace size ,75 t 1 t 6t 5t 60 t 10t.. 70 t Crucible Type Smart FS FS IFM LFS Power supply IBGT Thyristor 250 kw 4 MW 1 MW 42 MW Single Power / Twin Power

19 Comparison between LF and MF medium frequency (MF) Mains/line frequency (LF) Energy consumption kwh/t kwh/t Power density kw/t 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 т 12 т

20 Comparison between MF and LF MF LF Melting of chips Low heel High heel Material density in the furnace High Low Maintenance Low, no mechanical wear High, mechanical switches 5 т 12 т

2. MF induction furnace, type IFM/FS Design

element Fixing coil in axial direction with

21 2. MF induction furnace, type IFM/FS Design 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

22 Your advantages: Better coil protection 2. MF induction furnace ABP coil insulation Better conductivity of evaporation & humidity Easy to handle Mikanit foil Silica cloth Isoplan Segmental insulation Cupper profile Water chamber Liquid metal Refractory Grouting

23 3. Safety: Hedgehog coil Grouting Coil Segments Liquid metal Refractory material Mekanit foil Hedgehog sensor

24 1. Introduction: Available Applications Designed for melting and holding of ferrous and nonferrous metals for FS furnace types Furnace capacity: kg kg (ferrous) Power rating: 250 kw MW

$replaced without removing coil Uniform yoke pressure minimizes refractory stress Fixed$

25 2. MF induction furnace, type IFM: ABP yokes Aluminium yokes: high strength, noise damping high power density application 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

26 1. Introduction: Available Applications Designed for melting and holding of ferrous and nonferrous metals for IFM furnace types Furnace capacity: kg kg (ferrous) Power rating: 3000 kw MW

5. Power supply: two furnaces one power supply Transformer Rectifier for 100 % power ~ - Transformer Smoothing choke ~ - Rectifier for 100 % power Inverter - ~ Smoothing choke Capacitor bank

27 5. Power supply: two furnaces one power supply Transformer Rectifier for 100 % power ~ - Transformer Smoothing choke ~ - Rectifier for 100 % power Inverter - ~ Smoothing choke Capacitor bank Mechanical furnace current switch 0 % 100 % 100 % 0 % Inverter for flexible power distribution Capacitor bank 1 & 2 each for 100 % power Furnaces 1 & 2 Furnaces 1 & 2 Furnace current switches TWIN-POWER

28 PLC Based Melt Processor Prodapt Advanced Siemens S Data Storage on SD-Card or Fileserver Crucible wear level diagram Automatic melting - Cold Start Sintering - Charge energy mode Long term trend curves Seite 28

solution: Prodapt Enterprise with openfis Robust melt processor in PLC without outage

29 PC Based Melt Processor Prodapt Enterprise In comparison to PLC Based Prodapt Advanced: Storage in SQL Database variable dynamic configuration of trend curves ABP best solution: 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 Seite 29

branding and style Open software solution for monitoring and controling all plant sections in your foundry

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 Seite 30

System-related data stored as parameters No hardware to be matched Internal self-test Remote diagnosis

31 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 STABILITY TWO TILTING POINTS FOR SMOOTH TILTING High exhaust capability No hydraulic

32 Exhaust systems: ABP ECOTOP hood Low height Two fixing points with furnace platform INCREASED STABILITY TWO TILTING POINTS FOR SMOOTH TILTING High exhaust capability No hydraulic cylinders uncovered on platform NO RISK FOR OPERATORS AVOIDING DAMAGES TO CYLINDERS BY SPLASHES Free platform while forward tilting Free view and access to the crucible Easy to operate

33 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

34 4. Exhaust systems: ABP ECOTOP hood for back-tilting furnace Telescope system for back-tilting furnaces

Products for melt shop system continued.

and melting and holding Non-Ferrous metals(

Holding Iron Melting Al Melting Cu Melting

35 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 t 8 t 70 t 6t 180 t 10t t Type LFR / IRT RAS RKS RZS Inductor: 500 kw 3 MW 300 kw..1,3 MW ,5 MW kw

36 Pouring systems

System Furnace size 2,9 25 t 2,4 t 4,5 t 1-3 t

37 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

38 3.1 PRESSPOUR OCC: Design Features Stopper system Level scanning in pour siphon Pressurized vessel Fill siphon Mould Pour siphon Base frame for long and cross travel Channel inductor

39 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

40 Unheated pouring ladle UPT High flexibility when changing the iron grade Holding only by means of gas burner during short standstills Possibility of complete emptying/ No heel

41 Unheated pouring ladle UPT Messevideo UPT Castexpo 2016 Ver4.AVI

42 6. Automatic pouring: OPTIPOUR OPTIPOUR - Camera For flask lines with large sprue cup Pouring stream OPTIPOUR - Laser For high speed DISA with very small sprue cup Laser Beam Measurement range OPTIPOUR - Linelaser For small sprue cups For high speed DISA with small sprue cups

43 6. Automatic pouring: OPTIPOUR - Camera OPTIPOUR - Camera Pouring stream Measurement range Measuring and control area is outside of the pouring stream Diameter of the sprue cup is 3x diameter of pouring stream

44 6. Automatic pouring: OPTIPOUR Visualization Furnace visualization Electrical system (heated pouring furnace) Cooling System Pressure delivery system Hydraulic system Inoculation system Positioning

45 Furnace Control System: Furnace visualization

46 7. Process control system: PRODAPT-H/P Inductor charts

47 Service Spare Service Preventive Training Consulting Coil and Retrofit parts on Maintenance furnace demand repair for Foundries and Forming plants

48 Agenda 1.Company introduction 2.Foundry equipment 3.Melting of steel scrap in induction furnaces

49 EIF vs. EAF 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 Available units: MF. furnace from 300 Kg to 65t capacity Electrical power supply from 250 kw to kw per unit Restrictions: Selected scrap Special lining requirements

50 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

51 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

52 General set up of an IF System:

53 Tisco North ( 6x 65t; 3x 42MW)

54 ABP IF System: 65t Furnace Capacity

55 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 t/a via ONE IF-system is possible

56 IF Lines: Low Carbon Steel Charging Induction Furnace OEM / KSA t/a of Billet 4 x 25t IF crucibles 2 x 14 MW Crane Car Steel plant INDIA t/a of Billet 2 x 30t IF crucibles 1 x 16 MW Caste r LR F

IF Lines: Low Carbon Steel Charging Induction Furnace OEM / Africa 300.

57 IF Lines: Low Carbon Steel Charging Induction Furnace OEM / Africa t/a of Billet 3 x 25t IF crucibles 2 x 14 MW Crane Car Caste r LR F OBS

58 IF Lines: Low Carbon Steel Charging Induction Furnace EAF Crane Car Steel plant in KSA t/a of Billet 2 x 24t IF crucibles 1 x 16 MW 80t EAF Caste r LR F

59 IF Lines: Steel Alloying Charging Induction Furnace Stainless steel plant India t/a Stainless Steel Product 3 x 25t IF crucibles 3 x 18 MW Crane Car Caste r AOD LR F

60 Stainless Steel plant / INDIA Melt shop Layout 3 x 25t IF 3 x 18 MW SP 3 x 25t IF 3 x 18 MW SP

61 IF Lines: Steel Alloying Charging Induction Furnace EAF / BF Crane Car 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 t/a Caste r AOD LR F

Advantages of induction furnaces Modest requirements regarding utility supply (electricity) Low investment and operating cost Easy to operate and

62 Advantages of induction furnaces 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

63 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

65 THANK YOU FOR YOUR KIND ATTENTION!

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