KOSO INDIA PRIVATE

LIMITED
(FOUNDRY DIVISION, COIMBATORE)

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 Training Program
on

Melting Operation

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 Content

 Introduction
 Principles and operation of induction melting
 Melting of steel in induction furnace
 Maintenance and safety aspects in induction
melting

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Introduction
What is Melting ?
The process of a solid becoming a liquid when heat is
applied is called melting. The opposite process, a liquid
becoming a solid is called solidification process.
The equipment's which is used for converting the solid
materials in to liquid metal is called Melting furnace.
A furnace is an equipment to melt the metals for casting or
heat materials to change of shape (Rolling, forging etc.) or
change of properties (heat treatment)
Melting furnaces are employed to overheat solid materials
until they become liquefied. Typically, thermal processing
equipment is utilized to change the internal characteristics
or the surface of materials by elevating their temperature
carefully.
Types and Classification of Different Furnaces:

Based on the method of generating heat, furnaces are broadly

classified into two types ,
1.Combustion type (using fuels)
2.Electric type.

Based on the mode of charging of material furnaces can be

classified as
1.Intermittent or Batch type furnace
2.Continuous Type furnace
Based on mode of waste heat recovery , furnaces are classified
in to two types
1.Recuperative
2.Regenerative furnaces
Electric furnaces are suitable for melting of steel & cast irons
Two types of electric furnace
1. Electric Arc Furnace
2. Electric Induction Furnace
Electric Induction furnaces are suitable for Steel making process
It is suitable for all types of steels including extra low carbon
stainless steels & Non ferrous alloys
The electric induction furnace is a type of melting furnace that
uses electric currents to melt metal. Induction furnaces are ideal
for melting and alloying a wide variety of metals with minimum
melt losses, however, little refining of the metal is possible.
The principle of induction furnace is the Induction Heating
INDUCTION HEATING:

Induction heating is a form of non-contact heating for

conductive materials. The principle of induction heating is
mainly based on two well-known physical phenomena:
1. Electromagnetic induction
2. The Joule effect
ELECTROMAGNETIC INDUCTION
The energy transfer to the object to be heated occurs by means of
electromagnetic induction. Any electrically conductive material placed in
a variable magnetic field is the site of induced electric currents, called
eddy currents, which will eventually lead to joule heating.
JOULE HEATING
Joule heating, also known as ohmic heating and resistive heating, is
the process by which the passage of an electric current through a
conductor releases heat.
The heat produced is proportional to the square of the current multiplied
by the electrical resistance of the wire
KOSO INDIA PRIVATE LIMITED, COIMBATORE

Electric Induction furnace is most popular

melting furnace in foundry operations.
Induction melting furnace offer the following
advantages

 The ability to produce steel of closely controlled

composition.
 The ability to control tapping temperature
precisely.
 A wide range of charge materials can be used.
 Environmental pollution is much reduced.
 The stirring effect of induction power rapidly
incorporates additions.

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 Principle of Induction furnace Melting
Induction furnace works like a transformer, primary is a
coil and secondary is charge. When alternating current is
applied to an induction coil, it produces a magnetic field,
which in turn generates a current flow through the charge
material, heating and finally melting it.

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 Various Parts of Induction Furnace
1. Front inner/outer and rear cover
2. Platform
3. Coil support
4. Copper coil
5. Horizontal and vertical tie rods
6. Emergency tilt lug
7. Refractory bottom blocks
8. Stanchions
9. Stanchions insulation sheet
10. Water cooled lead cover/clamp
plate
11. Pour spout
12. Hydraulic cylinders
13. Rammed lining
14. Pivot bearings
15. Side plate
16. Refractory top blocks

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 Electro Magnetic Stirring
A second magnetic field is created
by the induced current in the
charge. Because these two fields
are always in opposite directions,
they create a mechanical force
that is perpendicular to the lines of
flux and cause metal movement,
or stirring, when the charge is
liquefied. The mechanical force
stays perpendicular to the field
only in the centre of the coil; on
both ends of the coil it changes
direction. The metal is pushed
away from the coil, moves upward
and downward, and flows back

Stirring action
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 Procedures Involving in Melting Operation
Preparation of load

Transfer the load

from scrap yard to melting platform

Dump the load into

working furnace

Switched on the furnace and raise the power

14 A
 A

Meltdown

Deslagging

By
Furnace Tilting

By
Slag 30 Powder

Bath Chemistry Analysis

Adjusting Chemistry
according to specification

15 B
 B

Ensuring The Tapping

Temperature

Use Preheated Ladle with

Red-hot condition

Deoxidation
Tapping Liquid steel dissolves oxygen; as the steel cools, the
dissolved oxygen combines with carbon in the steel
forming carbon monoxide:
De oxidant [C] + [O] = CO (g)
Addition If allowed to occur during solidification this would cause
gas porosity in the castings.
The deoxidation reactions due to addition of FeAl,
Pouring Operation FeSiCa, and FeSiZr, described below,
[Al] + [O2]  (Al2O3)
[Si] + [O2]  (SiO2)
[Ca] + [O2]  (CaO)
16 [Zr] + [O2]  (ZrO2)
Charging Sequence and quality of raw materials for make quality final melt
Charging Sequence
The initial charge (scrap) should be 15-20 % of the total charge.
After addition of scrap add weighed colour coded returns.
Follow the same sequence up to 75 % of the total melt.
Based of spectro analysis, ferro alloys and returns will be added to
meet aimed chemical composition.

Raw materials Quality

The scraps are should be free from oil and rust, because rusted scrap
contains FeO on the surfaces, will raise dissolved oxygen content in melt.
Oily scraps contain hydrocarbon, this will also will rise dissolved gas
content in liquid metal.

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KOSO INDIA PRIVATE LIMITED, COIMBATORE
Preventive measures for Furnace lining life Enhancement
Superheating of melt should be avoided to minimize lining erosion , which will
happen because of stirring action at high temperature.
Use proper charging material and different size of charge material to eliminate
bridging formation in furnace.
Avoid liquid metal holding in furnace at switched off condition , which will lead GLD
trip and skull formation.
Charge scrap and returns with proper sequence for gradual melting and avoid
super heating.
Heavy weight returns will be loaded smoothly without hitting furnace wall ,
otherwise lining will get damaged.
The furnace life will enhance by “Patching” process. After some pre determined
heats the furnace lining should be patched with mixer of sodium silicate/water
and ramming mass, which will improve the overall furnace lining life.

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KOSO INDIA PRIVATE LIMITED, COIMBATORE

The Ground Leak Detector (GLD)

The GLD used for detect and indicate a leak condition between the
furnace coil and the metal charge with in the furnace .
In induction furnace the coils turns are highly insulated. Therefore, any DC
voltage applied could cause some small current called leakage current
between the coil and the melted bath.
The leakage current will shown in the DC ammeter.

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 If liquid metal penetrating the refractory lining, the leakage current will
detect. Usually the leakage current value is extremely small. If the
condition is severe. The GLD will shutdown the power to the coil.

GLD antenna Assembly

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 Check List for Daily Preventive Maintenance

DAILY PREVENTIVE MAINTENANCE CHECK LIST

INDUCTION FURNACE
DATE:
REMA
FURNACE'S A B C D RKs
FURNACE IDENTIFICATION:

CHECK GLD FUNCTION (+ VE & - VE)

GLD VALUE (Limit allowed, single digit in mA)
CHECK GLD TEST & RESET CONDITION
CHECK GLD ANTENNA WIRE
BUSBAR TO FURNACE- LOOK FOR SIGN OF SEVERE DISCOLOURATION
CLEANLINES AT FURANCE-DONOT ALLOW SLAGS TO TOUCH FURNCES LEADS
CHECK GENERAL CLEANLINES AT CABIN EXIT
CHECK FOR AND CORRECT INTERNAL WATER LEAKAGE
CHECK FOR AND CORRECT EXTERNAL WATER LEAKAGE
CHECK WATER LEVEL IN ALL TANKS
REMOVE SCARP UNDER THE FURANCE AND KEEP THE WORKING AREA CLEAN
CHECK HYDRAULIC OIL LEVEL IN THE TANK
CHECK CRUCIBLE TILTING OPERATION

MAINTENANCE
MELTING

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 Safe working procedures in induction melting

Make sure that the safety PPEs are wore before starting work .
PPEs in this area are helmet, respirator, gloves, shield and shoes.
Ensure the furnace area is clean before starting melting process to avoid
electric shock and equipment's damage.
Check the condition of hydraulic tilting system.
Check whether the GLD wire is properly connected to the lining.
Ensure the under ground of the furnace free from water and oil.
The induction furnace should be switched off while de-slagging, sampling
and measuring temperature.

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 Important Aspects in Melting Operation
Effect of Superheat:
Pro long holding time in the furnace or operated under
higher power rate condition will leads liquid metal get super heated.
Liquid steel have higher affinity of gases at higher temperatures.
Gas absorption will be more at super heated condition.
Chances of Porosity and blowhole formation will more in this condition.

Blowhole

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KOSO INDIA PRIVATE LIMITED, COIMBATORE

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