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Melting Time Prediction Model for Induction Furnace Melting Using Specific Thermal Consumption from Material Charge Approach

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Document pages: 14 pages

Abstract: In this study, the system level evaluation method is used to analyze the operation and process system of induction furnace. The relationship between instantaneous chemical composition of molten pool and energy consumption in steelmaking process is studied in this paper. This is evaluated by numerical simulation to solve the problem of predicting the expected melting time of induction furnace operation. This work provides an insight into the method of reducing energy consumption and estimating the production time of steelmaking using material charge balance. The energy consumption model of molten metal is established by enthalpy calculation and specific charge composition method. The computational simulator engine (castmelt) is also developed in Javalanguage with a MySQL database server for seamless specific charge composition analysis and testing. The model performance was established using real-time production data from a cast iron-based foundry with a 1 and 2-ton induction furnace capacity and a medium carbon-based foundry with a 10- and 15-ton induction furnace capacity. Using parameter fitting techniques on the measured operational data of the induction furnaces at different periods of melting, the results from the model predictions and real-time melting showed good correlation between 81 - 95 . A further analysis that compared the relationship between the mass composition of a current molten bath and melting, time showed that energy consumption can be reduced with effective material balancing and controlled charge. Melting time was obtained as a function of the elemental charge composition of the molten bath in relation to the overall scrap material charge. This validates the approach taken by this research using material charge and thermodynamic of melting to optimize and better control melting operation in foundry and reduce traditional waste during iron and steel making.

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