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What is Induction Furnaces

An induction furnace is an electrical furnace in which the heat is applied by induction heating of a conductive medium (usually a metal) in a crucible around which water-cooled magnetic coils are wound. Nowadays melting of metals by means of electro magnetic field has become an established technique. Most modern foundries use this type of furnace and now also more iron foundries are replacing cupolas with induction furnaces to melt cast iron, Induction furnace.
Induction Furnace
Capacities range from less than one kilogram to one hundred tones capacity, and are used to melt iron and steel, copper, aluminum, and precious metals. Induction furnaces can be classified according to the operating frequencies

M/s Magnalenz is involving in manufacturing of coreless Medium Frequency Induction Furnaces.

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Furnace Selection

Furnace Selection
The furnace capacity selection is the most common question bothering for the buyer/ prospects. Sometimes it creates confusion, because different manufacturers suggest different combinations.

How should one select the furnace (Kw/KG/Hz) which fitted to one's requirement technically and commercially as well?

So we suggest every one to follow the furnace selection process step by step.

Furnace Selection Process
» Step 1

Which metal or alloy do one's want to melt and at what pouring temperature?

Melt rates or melting speed is different for different metal & alloys at particular applied kw, this is due to difference in specific heat of different metal.

At the same time due to different latent heat of each metal, superheating of each molten metal will be different, so different melt rate at particular applied kW.

For Example :
For Different Metal
At particular kW Furnace Compare Brass & Steel Melting

For Steel Melting
  • 1000 Kgs / Hour @16000C
  • Where as, Brass Melting will be
  • 1900 Kg / Hr @ 11000C
Summary :
So At same kW, different metals, different Melt rate

For super Heating case :
At particular kW for steel melting :
  • At 15000C the melt rate will be 1000 Kgs/ Hour
  • At 16000C the melt rate will be 925 Kgs / Hour
For Same metal, At particular applied kW, Different Pouring Temperature, Different melt rate. Once you configure your requirement i.e. melt rate @ temperature degree centigrade 0C according to step one, Now switch to step 2.

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» Step -2

You must specify the liquid metal requirement in tons or in Kgs, per month with working hours in a day.

A) For Steel Ingot
Suppose you required 1200 Tons / Month of M.S. Steel Ingot @ 16000C what the Furnace size should be?

1st consider working days - 25 days

2nd 1200 Tons / 25 days gives 48 Tons of liquid metal/ Day out of 24 Hrs working.

3rd 48 Tons / 24 Hrs i.e melt rate will be (48/24 = 2) 2 Tons per hour

4th Now consider the unproductive time of cycle, i.e. time for deslagging, charging, sintering, lining etc. so the furnace utilization will be 80 % thus 2 tons / hr divided by 0.8. is 2.0 ÷ 0.8 = 2.5 Tons / Hour should be the required furnace melt rate at 16000C

5th Now refer the furnace specification table. you will find the nearest melt rate can be achieved by 1500 kW / 3 Tons Furnace i.e. 2.6 Tons / Hour Melt rate.

We have considered here 1500kw means 1500 KVA - Exclusive power at the furnace Input. So the Answer is By 1500 KW /3 Ton furnace you can produce 1200 Tons of M.S. Steel Ingots @ 16000C per month.

B) For Castings
Suppose you want to make 300 Tons / Month of finished steel casting, with an average yield of 65% and utilizing of furnace is about to 75%.

Then what should be the furnace capacity? Pls suggest.
So now 300 Tons ÷ yield (0.65)

Gives total monthly molten metal requirement for casting is 465 Tons / month.

Now 465 Tons divided by 25 working days gives 18.6 Tons of molten metal per day of 24 hours working.

18.6 Tons again divided by 24 hours gives required melt rate of molten metal is 775 kgs / Hour. Now considering the utilization of the furnace is 75 %, is due to sintering, lining deslagging , recharging, composition setting etc.

Thus actual molten metal requirement will be 775 ÷ 0.75 i.e. 1033 Kgs/ Hour.

Next step now you refer the table & from the table the nearest suitable furnace, which can give 1033 Kgs/ Hour melt rate is FER 1.

So you should select 600kW & 1 Ton Induction Furnace , which will give you the suitable melt rate.

Another main factor which one foundry men has to be decided is , what should be the batch size ?

The batch size will be depending upon the molten metal weight you required.

For. Example

If you required 600 Kgs, 750 Kgs, 1000 Kgs, metal at a time then you can select 600 kw solid state M.F. Power source with 1000 Kgs crucible or otherwise , if your molten metal requirement is around 500 Kgs or less , then you can select 300 kw x 2 Nos solid state M.F. Power Source with 500 Kgs crucible. Which will cost you more, compare to buy 600 kw one unit.


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» Step 3

Now what should be the right frequency?

Normally frequency selection is not available, and is not an important constraint too. There are many combinations of kw and Kgs available at different frequencies.

Basically frequency is one parameter which affects stirring.

In a core less Induction furnace stirring is produced by magnetic forces acting on a molten metal because of interaction between the coil current and the current flowing in the molten metal bath. The force is the strongest at middle part of the coil so metal is forced at the central side of the bath from where it is resolved to upward and downward. Metal moves up because of upward resolved force. The upward movement of the metal in the center creates meniscus a unique characteristic know as a stirring effect is measured by h/D ratio.

Stirring effect is depending upon the power frequency applied, the induction coil & molten bath as well as density and viscosity & molten metal. The three major variable which Effect stirring are
  • Power
  • Frequency
  • Furnace Size
Stirring can be change with charging any one of the major variable.


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What is effect of stirring?

Inadequate Stirring Cause
  • Insufficient Mixing of Alloys
  • Temperature difference in molten metal bath
  • difficulty to melt light weight scrape
Excessive Stirring Causes
  • Frequent lining erosion
  • Metal oxidized and splashing of metal
  • Lining or slag inclusions in casting found
Once you decide the kW/Kg of the furnace & according to your mixing or alloying requirement, metal properties, operating frequency can be decided




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