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Though induction furnaces are being used since a long time, the production of mild steel by the
induction furnace (IF) is relatively a very recent phenomenon. Induction furnaces work on the
principle of electromagnetic induction which was discovered by Michael Faraday.
History
In 1870 De Ferranti started experiments in Europe on induction furnaces. The first induction
furnace for melting metals was patented by Edward Allen Colby in 1900. The first steel made in
an induction furnace in United States was in 1907 in a Colby furnace near Philadelphia. First 3
phase furnace was built in Germany in 1906 by Rochling- Rodenhauser.
In India the use of induction furnaces started in mid sixties. Imported medium frequency
induction furnaces were used from mid seventies. Early eighties to mid nineties sudden growth
has taken place. During this period indigenous manufacture of the induction furnaces also
started. Initially induction furnaces were used for melting stainless steel scrap but these furnaces
are used for mild steel production from mid eighties.
There are mainly two types of the induction furnaces. They are given below.
i) Induction channel furnace In this furnace induction heating takes place in the channel which
is a small and narrow area at the bottom of the main bath. The channel passes through a steel
core and the coil assembly. Such type of furnaces are not been used for the steel making.
ii) Induction crucible furnace- This type of the furnace is also called coreless induction furnace.
It is a refractory lined vessel (Crucible). Its other main components are power supply unit
consisting of transformer, inverter and capacitor bank, the charging arrangement, the cooling
system for the power supply and furnace coil, process control system and the fume extraction
equipment. These furnaces two separate electrical systems; one for the cooling system, furnace
tilting and instrumentation and second for the induction coil power. The power for the induction
coil is fed from a 3-phase, high voltage, high amperage electrical line. Schematic of this furnace
is shown in Fig. 1
A large tonnage of mild steel is made through IF route in India. While producing this steel, the
chemistry of end product is controlled. The chemical analysis of all the input materials is done to
have a decision on the charge mix. After completing 50% charging of the input materials, a bath
sample is analyzed for chemical composition. Based on the chemical analysis of the bath sample
at this stage calculations are made for further additions of the metallics. If the bath sample at this
stage shows high percentage of carbon, sulphur and phosphorus then the sponge iron content of
the charge is increased. Final bath sample is taken when 80% melting is completed. Based on the
analysis of this sample there is another adjustment in the charge. The lower content of carbon in
the sample is corrected by increasing the quantity of pig iron/charge iron in the charge. Silicon
and manganese in the metal is oxidized by the iron oxide of the sponge iron. Sulphur and
phosphorus is also diluted by the sponge iron. Because of use of sponge iron the trace elements
in the steel made in the IF remains under control.
Comparison with Electric Arc Furnace steel making process
The comparison of the operating parameters of induction furnace with those of electric arc
furnace is given in Table 1.
Table 1 Comparison of operating parameters with Electric Arc Furnace (EAF)
Sl. No.
1
2
3
4
5
6
7
8
Subject
Electrical Energy
Refractory
Electrodes
Oxygen
Flux
Dust generation
Noise level
Slag generation
Unit
kWh/t
Kg/t
Kg/t
N Cum/t
Kg/t
Kg/t
dB(A)
Kg/t
EAF
490-510
4.1 -4.2
2.4-2.6
15-25
25-28
6-12
95-120
65-72
IF
540-550
3.4-3.6
Nil
Nil
Nil
1-2
82-86
11-15
The induction furnace has the following technical advantages over electric arc furnace.
i) Low requirement on the electric grid
ii) Relatively cleaner process and lesser environ related expenditure.
iii) Higher yields
iv) Lower consumption of Ferro-alloys
v) No cost on electrodes
vi) Lesser capital expenditure
vii) Lower space requirement
viii) Induction furnace is suitable for charging addition agents any time due to the charateristics
of the bath agitation.
ix) Has low load and no flicker disturbance
x) Automated application in a simple way
The disadvantages are
i) The requirement of minimal wall thickness of the refractory lining is having risk of crack
formation resulting in stoppage of operations.
ii) Induction furnaces puts more stringent requirement on the quality of scrap
iii) Decarburizing, desulphurizing and dephosphorizing is restricted due to refractory wear.
iv) The non metallic component of the charge materials is to be kept under control so that
volume of the slag remains under limit and does not have adverse effect on the lining.
v) Compared to EAFs, Induction furnaces of very high capacities are not presently available