Innovation for Sustainability · È !Resume Ý! The developments at ABP demonstrate, endurably...
Transcript of 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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1. Sustainable Induction Technology
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
1. Sustainable Induction Technology
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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
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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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2. Ecology: Energy saving – coil design
Installation of coil without cooling windings
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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): 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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2. Ecology: Process optimization
» Simulation of complete liquid metal transport to different sources
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2. Ecology: Process optimization
» 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
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Cooling tower
M
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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
1. Sustainable Induction Technology
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%
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100%
rel. converter output voltage U
rel. c
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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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Agenda
1. Sustainable Induction Technology
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
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~ 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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4. Sociology: Ground fault detection
Rectifier for 100 % power
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~ 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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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
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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
1. Sustainable Induction Technology
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
1. Sustainable Induction Technology
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]
2. Ecology: Energy saving – coil design
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
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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
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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
Source University of Hannover Seite 36
Energy balance for melting iron
» 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)
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- cold wind
Cupola furnace
- hot wind
Ind. furnace
LF
Ind. furnace
MF
Rotary furnace
kWh/t
Source University of Hannover Seite 37
Energy balance for melting iron
» 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%
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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
Source University of Hannover Seite 38