«Sustainable Induction Technology & Energy Saving» «Sürdürülebilir İndüksyion Teknolojisi & Enerji Tasarrufu» Yılmaz Yıldır (ABP Induction) 2.Oturum: Döküm Teknolojileri Demir - Çelik 2nd Session: Casting Technologies Iron - Steel Oturum Başkanı/Session Chairman: Hüseyin Yumak (Trakya Döküm San. Tic. A.Ş.) Oturumlarda yer alan sunumlar 15 Eylül 2014 Pazartesi tarihinde kongre web sayfasına (kongre.tudoksad.org.tr) yüklenecektir.
17 th International ABP Induction Conference October 1 st 2 nd 2013, Dortmund Sustainable Induction Technology Yilmaz Yildir
1. Sustainable Induction Technology E c o l o g y E c o n o m y S o c i o l o g y Three columns if sustainability Sustainability
Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 4. Sociology 5. Summary 2.1 Reduction of CO2 emissions 2.2 Energy saving 2.2 No environmental critical material 2.3 Recycling
2. Ecology: Specific CO 2 Emissions Including the emission of power plants with today s energy mix gr/t 600 500 400 300 200 100 0 Cupola furnace - cold wind Cupola furnace - hot wind Ind. Furnace LF Ind. furnace MF Rotary furnace Source University of Hannover
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%
2. Ecology: Energy saving coil design expected energy and cost savings: Annual production: 40.000 t Energy consumption (standard coil): 525 kwh/t Coil losses (total): 89 kwh/t Reduction of coil losses: 4,45 kwh/t = 5,0 % Electricity rate (industrial): 8,95 ct / kwh #1 Savings in energy consumption: 40.000 t/year x 4,45 kwh/t = 178.000 kwh/year Savings in costs: 178.000 kwh/year x 8,95 ct/kwh = 15.931 /year #1 Source: Eurostat; Average Electricity Rate Germany 2012
2. Ecology: Energy saving 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
2. Ecology: Energy saving process optimization Simulation of complete liquid metal transport to different sources
2. Ecology: Energy saving process optimization Power, KW / Charge, KG 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 Demo for Lecture_revA 23.09.2013 16:05:19 - Forming facility (6) Charge 500 480 460 440 420 400 380 360 340 320 300 280 260 240 220 200 180 160 140 120 100 80 60 40 20 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 Time, min 180 190 200 210 220 230 240 250 260 270 280 290 300
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.
2. Ecology: Recycling Melting of Returns and Chips using chips from subsequent casting treatments saves resources Waste heat utilization for hall heating and warm water saving energy T 67 C T 40 C Additional heat exchanger T 60 C 30 C T M Customer M Fresh water Storag e Gas or oil burner T Storag e M Cooling tower Shower water Heater Q Pump stand M M
Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 4. Sociology 5. Summary 3.1 Reliable Equipment design 3.2 Reliable Power supply
3. Economy: Furnace design Customers request more and more specific furnace designs for their application: Mechanical design Stirring issues 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)
3. Economy: Power supply constant power supply rel. converter output current I Praxis shows: Furnaces are not always operated at nominal point Power losses, Production losses are the consequence 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 100% 70% 0 Lining wear Built up and/or too low material density in crucible 0 70% 100% rel. converter output voltage U
Leisung KW, Ofeninhalt kg, 3. Economy: Power supply constant power supply Renault power and weight monitoring, 3 furnaces (10 to), one melting, two holding mode, one power supply (8,3 MW) Temperature- Holding furnace 3 Holding furnace 3 measurement furnace 2 Holding furnace 3 00:00:00 00:00:00 8.000 Ofenreise Ofen 2 12000 Weight 10000 00:00:00 00:00:00 6.000 8000 00:00:00 6000 00:00:00 4.000 00:00:00 4000 Power 00:00:00 2.000 2000 00:00:00 00:00:00 1 2 3 4 5 6 7 8 9 101112131415161718192021222324252627282930313233343536373839404142434445 min 0
Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 4. Sociology 5. Summary 4.1 Secured work place ground fault detector 4.2 Secured work place Melt processor
4. Sociology: Ground fault detection Lining Coil grouting Coil Furnace frame Yoke External Ground Fault shorts coil to yoke Transformer External Ground Fault in the power supply ~ - Rectifier for 100 % power Smoothing choke Metal penetration - ~ Inverter Capacitor bank Bottom electrode for grounding Ground detector Insulation / ground monitoring Error message: Ground Fault STOP of Power supply
4. Sociology: Ground fault detection critical situation 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 Ground detector Insulation / ground monitoring Critical Danger Situation, but with no bath electrode, no current flows and there is NO ALARM
4. Sociology: Ground fault detection Improvements / Innovations: automatic activation after bypassing e.g. after sintering of a wet crucible Automatic check of bath grounding Instead of manual check Locating of ground faults Decision-making support for operators for further measurements Hedgehog coil PLC GD ~ - - ~
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
Agenda 1. Sustainable Induction Technology 2. Ecology 3. Economy 4. Sociology 5. Summary
5. 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
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