innovation for sustainability · È !resume Ý! the developments at abp demonstrate, endurably...

Innovation for Sustainability

1. Sustainable Induction Technology

» Sustainability: Ecology, Economy, Sociology E

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Sustainability

ABP Induction Systems GmbH

Strategy: Leadership in

Sustainable Technology

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Energy savings, safety for operators and the digital foundry world, (Industry 4.0) – State-of-the-art induction furnace technology

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Parts of a MF induction furnace system

» Mechanic:

›  Furnace body, lining material hydraulic and tilting frame

» Electric:

›  Transformer, Converter Capacitor bank, high current connection, Coil

» Control systems:

›  Weighing system, Process-Control

» Auxiliary equipment:

›  Cooling system, charging system, exhaust system

tons

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-

~

~

Transformer

MF-Converter

Capacitor bank

Crucible

furnace

Cooling system electrics

Cooling system furnace

Melt processor

Weighing system

Charging system Exhaust hood

Circuit breaker


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Bottom

electrode

for grounding

Coil

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 4.0

6. Summary Seite 5

2. Ecology: Specific CO2 Emissions

» Specific CO2 Emissions Including the emission of power plants with today’s energy mix

0

100

200

300

400

500

600

Cupola furnace

- cold wind

Cupola furnace

- hot wind

Ind. Furnace

LF

Ind. furnace

MF

Rotary furnace

gr/t

Source University of Hannover

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MF Coreless Induction Furnace System Type IFM, ABP Induction Systems GmbH, GIFA 2011

»  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

2. Ecology: Fume extraction hood, Ecotop

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

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Installation of coil without cooling windings

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» 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): 15,2 ct / kWh #1

Measured7kWh/to=7,86%

›  Savings in energy consumption: 40.000 t/year x 4,45 kWh/t = 178.000 kWh/year

40.000t/yearx7kWh/t=280.000kWh/year

›  Savings in costs: 178.000 kWh/year x 15,2 ct/kWh = 27.056 €/year

280.000kWh/yearx15,2ct/kWh=42.560EURO/year

RSA estimated#2: 280.000 kWh/year x 93,34 cRand/kWh = 261.352 Rand/year

#1 Source: Eurostat; Average Electricity Rate Germany 2014

#2 Source: http://www.eskom.co.za/CustomerCare/TariffsAndCharges/Pages/Tariffs_And_Charges.aspx

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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

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» Simulation of complete liquid metal transport to different sources

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»  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

Charge

Time, min300290280270260250240230220210200190180170160150140130120110100908070605040302010

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Demo for Lecture_revA 23.09.2013 16:05:19 - Forming facility (6)

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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.

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2. Ecology: Recycling

» Chip melting

›  using chips from subsequent casting treatments saves resources

» Waste heat utilization

›  for hall heating and warm water saving energy

Q

�

T

M

T

M

T

T

M

T

Cooling tower

M

M

Gas or oil burner

Storage

Storage

Shower water Heater

Additional heat exchanger

Pump stand

67 °C

40 °C

30 °C

60 °C

Fresh water

Customer

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Agenda


2. Ecology

3. Economy

3.1 Reliable Equipment design

3.2 Reliable Power supply

4. Sociology

5. Industry 4.0

6. Summary

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3. Economy: Furnace design

electromagnetic calculation for an ABP 6t-Ofen (Type FS 60)

» 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

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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

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» Completely designed in digital technology

» High efficiency

3. Economy: Power supply

» Control unit

»  IGBT modules

» Coupling choke

» Capacitors

Power range SCR: 250 kW – 42.000 kW Power range IGBT: 250 kW – 6.000 kW

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3. Economy: Power supply – constant power

Praxis shows:

» Furnaces are not always operated at nominal point à 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

0 70% 100%

0

70%

100%

rel. converter output voltage U

rel. c

on

ve

rte

r o

utp

ut

cu

rre

nt

I

Built up and/or too low material

density in crucible

Lining wear

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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)

Power

Holding furnace 3

Holding furnace 3

Holding furnace 3

Temperature- measurement

furnace 2

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W,

min

Ofenreise Ofen 2

Weight

2.000

4.000

6.000

8.000

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Agenda


2. Ecology

3. Economy

4. Sociology

4.1 Safe work place – ground fault

detector

4.2 Safe work place – Melt processor

5. Industry 4.0

6. Summary

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4. Sociology: Ground fault detection

Rectifier for 100 % power

-

-

~

~ Inverter

Capacitor bank

Transformer

Smoothing choke

Lining

Yoke Coil

Bottom

electrode

for grounding

Insulation / ground

monitoring

Coil grouting

Furnace frame

Ground detector

Metal penetration

Error message: Ground Fault

STOP of Power

supply

External

Ground Fault

shorts coil to

yoke

External Ground Fault in the power

supply

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Rectifier for 100 % power

-

-

~

~ Inverter

Capacitor bank

Transformer

Smoothing choke

Bath electrode

buried in lining

Insulation / ground

monitoring

Ground detector

Metal penetration

Critical Danger Situation, but… with no bath electrode,

no current flows

and there is NO ALARM

Operator has electrocution risk if contacts bath with

conductive tool

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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

-

-

~

~

GD PLC

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n  Hedgehog pin

n  Coil

n  Refractory material n  Liquid metal

n  Penetration of liquid metal

n  Grouting

n  Mecanit

n  Spark

4. Sociology: Hedgehog Coil

» Hedgehog Coil

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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

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Agenda


2. Ecology

3. Economy

4. Sociology

5. Industry 4.0

5.1 Digital foundry world

6. Summary

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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.

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Agenda


2. Ecology

3. Economy

4. Sociology

5. Industry 4.0

6. Summary

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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

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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.

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Thank you for your attention

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Hermann-Josef Kroes Phone: +49 231 997 2475

Cell: +49 172 744 15 30 Email: [email protected]


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.

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Energy consumption for melting iron

»  Enthalpy for melting 1 to of iron at 1.500 °C: 396 kWh/t

0

200

400

600

800

1.000

1.200

Cupola

furnace - cold

wind

Cupola

furnace - hot

wind

Ind. furnace

LF

Ind. furnace

MF

Rotary

furnace

Additions

Material losses

Gas / oel

electrical Engergy

Koke

kWh/t

Source University of Hannover Seite 35

0

100

200

300

400

500

600

Cupola furnace

- cold wind

Cupola furnace

- hot wind

Ind. Furnace

LF

Ind. furnace

MF

Rotary furnace

Energy balance for melting iron

»  Specific CO2 Emission for melting of one ton iron

q  Including the emission of power plans with today's energy mix

gr/t



»  Specific primary energy request for melting one ton iron

q  Using induction furnaces conventional energy (oil, Coke) can be avoid (alternative

energy or atomic engergy)

0

200

400

600

800

1.000

1.200

1.400

1.600

1.800

2.000

Cupola furnace

- cold wind

Cupola furnace

- hot wind

Ind. furnace

LF

Ind. furnace

MF

Rotary furnace

kWh/t



»  Reduktion of CO2 – Emission

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

0%

10%

20%

30%

40%

50%

60%

S weden F innland Austria F ranc e S pa in G ermany G reec e Ita ly P oland G reat-

B rita in

Netherland Malta

2007 2020


innovation for sustainability · È !resume Ý! the developments at abp demonstrate, endurably...

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