Medium-frequency
coreless induction
furnaces
Al Fe Mg
Cu Sn Steel
Si Zn
…For powerful, flexible
and efficient melting
www.otto-junker.COM
Features and advantages
The technical and economic benefits of OTTO JUNKER
medium-frequency coreless induction furnaces have
led to their increasingly widespread use in the foundry
and semi-finished products industries. Their basic
advantages lie in the direct input of heat into the
metal, as well as in the selectively controlled bath
movement and the metallurgically neutral melting
regime.
Technical features
< Close temperature and process control
< High analysis accuracy and reproducibility
< High melting rates thanks to high power density
< High operating flexibility / easy changeover
between different metal types and grades
Powerful 9,000 kW cast iron melting furnace < Suitability for melting with or without heel
< Ability to handle a broad diversity of charge
materials
< Selective metallurgical melt management
Economic features
< Low energy consumption
< Low melting loss
< High plant availability
< Easy operation and maintenance
< Low building cost thanks to compact design
Furnace platform of an MFT Ge 8,000 / 6,000 kW unit < Minimum erection time due to pre-assembled
equipment modules
< Low labour costs by automated melting operation
OTTO JUNKER equipment is designed and built to
comply with all relevant safety and environmental
codes and regulations.
Medium-frequency coreless induction furnaces have
evolved into the universal metallurgical solution for
melting, holding and pouring a diverse range of
metals.
DUOMELT MFT Ge 12,000 / 9,000 kW installation
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Design and operation
An advanced high-power medium-frequency coreless Coil and coil assembly
furnace system consists of the following components:
< Melting furnace, comprising OTTO JUNKER coils reflect our many years of
Furnace body including coil experience. Each coil is carefully manufactured from
Furnace tilting cradle (optional backward tilting) high-grade materials. Extensive testing ensures
Hydraulic power pack compliance with our exacting quality standards.
Pit guard Our coils are designed and built to provide a high
Operator control desk efficiency, exceptional rigidity and reliable protection
Exhaust hood against voltage flashovers and thermal overloads.
< Electric power supply system, comprising The cooling coil arranged above / below the active
Rectifier transformer coil as well as the yokes surrounding the coil are
Frequency converter dimensioned and built to achieve a substantial
Capacitor rack reduction in magnetic leakage fields which
Power cables thus remain well below acceptable workplace
< Process control system, comprising thresholds.
Weighing system
Operator control cabinet The coil assembly is designed to ensure
JOKS melt processor < Reliable fixing of the coil in place, both radially
Crucible monitoring system and axially
< Auxiliary and ancillary equipment, e.g. < Dependable protection of the coil from mechanical
Water recooling system with damage and metal spatter
air cooler / cooling tower < Easy access to the coil for maintenance and
Dust collection system repairs
Charging equipment < Effective reduction in noise emissions
Charge make-up system < Reliable protection of operators from magnetic field
Crucible ejector system exposure
1 molten metal bath
2 refractory crucible
3 heat insulation layer
4 permanent lining
with embedded OCP
sensor cable*
5 power coil
5a cooling coil
6 furnace top
pouring
6a spout
7 yoke
8 earth rod for earth
leakage monitoring
9 coil cage
* embedded OCP
sensor cable (heavy
duty jacketed glass fibre)
Coil assembly with OCP
Frequency converter system
Parallel oscillating circuit converters of OTTO he rectifier and inverter bridges employ water-cooled
T
JUNKER‘s proprietary design have been purpose- high-power thyristors (SCR).
developed for use in induction melting equipment
and are noted for their safe and reliable performance Apart from this thyristor solution (SCR), OTTO
even in extreme load conditions. The ZEUS digital JUNKER employs innovative transistor technology
converter control unit ensures a maximum power (IGBT) for the inverter section while retaining the
output throughout the entire heat cycle. The system proven parallel oscillating circuit principle for reduced
provides a perfect inverter loads.
adjustment for mains
voltage fluctuations and Additional features of the IGBT converter:
changing load conditions. < Outstanding inherent protection against current,
voltage and temperature peaks
< Consistently high power factor (cosine phi)
Characteristic features of the parallel oscillating approaching 1.0 at the converter entry
circuit converter: < Less exacting requirements on cooling water due
< Robust d.c. link circuitry with smoothing reactor for to indirect cooling
high operating reliability
< Small load on the power inverter since it must
handle only the active current (not the furnace
current which is higher by a factor of 5 to 10)
< High electrical efficiency
< Low mains pollution
< 6, 12 or 24-pulse design options
< Easy maintenance and access
Frequency converter system for 12,000 kW IGBT converter for 3,000 kW
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Optimized metallurgical process
management
DUOMELT system
Stepless distribution of frequency converter
output between two furnaces operating in tandem
< Full use of 100 % power rating at all times
< Shorter idle times for higher melting rate
< Simultaneous melting, holding and pouring
< Maximum flexibility
< Electronic control eliminates switching pauses
DUOMELT principle
DUOCONTROL
Computer-controlled switching of power output
between two furnaces operating in tandem
< Shorter idle times for higher melting rate
< Simultaneous melting, holding and pouring
Variable bath movement
< Multi-frequency technology permits changes in
operating frequency in the course of the melting
cycle. For example, an appropriate frequency of
250 Hz is used for melting the charge material
down. For the introduction of carburising agents
and alloying additives, the system is automatically
switched to a lower frequency (e.g., 125 Hz) so as
to increase the bath movement. This shortens the
treatment cycle time significantly.
< Multi-phase stirring technology creates a bath
flow that is adjustable in direction and intensity.
This is achieved with the aid of multiple coil
sections operating on phase-displaced variable
power.
Multi-frequency technology
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JOKS TouchControl
JOKS, the Junker Ofen Kontroll System, optimizes The scope of HMI functions comprises
process control and ensures reliable and dependable XXAutomation
monitoring of your complete melting operation. XXMonitoring
XXRecording
It controls all functions and process sequences
automatically. JOKS handles the exchange of data The system can handle the complete process chain
and information with higher-level control systems, from charge make-up, charging and melting to analysis
records and evaluates the operating data and makes correction and operation of all auxiliary units and
them available via open interfaces. peripheral equipment.
JOKS diagram
Additional software packages available!
< JOKS charge make-up
< JOKS analysis (spectrometer connection)
< JOKS maintenance
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Water recooling system
Our furnace and switchgear cooling circuits are built The water recooling system is operated either in
to ensure an effective heat dissipation for optimum normal mode or – at lower outdoor temperatures – in
reliability of the melting process. a special operating mode in which the entire air cooler
contents is automatically drained into an intermediate
Cooling systems can be alternatively configured with tank which closes the cooling circuit.
a plate heat exchanger for connection to the cooling
tower, a closed cooling tower circuit, or an air cooler. Options:
Customer-specific solutions are likewise feasible. Key advantages of the Frost Proof system:
The latter also include the use of equipment for heat < No risk of equipment freeze-up
recovery. < No need to check glycol concentration or to
monitor additional heating equipment
A prerequisite for the use of air coolers is a reliable < No cost of glycol or heating energy
frost protection capability. OTTO JUNKER‘s Frost < No glycol enters and pollutes the waste water in
Proof* solution has proven its effectiveness on case of emergency water input.
numerous installations and permits trouble-free
operation of air coolers even in winter without any Key advantages of Smart Recooling Control SRC:
additional heating or anti-freeze agents (e.g., glycol). < Converter driven cooling pumps
< Control related to expected furnace power by
* patented JOKS melting processor
< Energy-saving for recooling unit up to 30 %
Water recooling system with air cooler Water recooling system with cooling tower
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The overall plant
11
12
9 4
7
10
8
1 Furnace
2 Exhaust hood
3 Weighing system
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4 Pit guard
5 Hydraulic power pack
6 Control stand with operator desk
7 Frequency converter (DUOMELT)
8 Capacitor rack
9 Transformer
6 10 Water recooling system
2
11 Air cooler
12 Charging machine
13 Dust collection system
5 14 Emergency collecting pit
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9
Exhaust hoods
OTTO JUNKER offers the DUSTCONTROL
extraction hood system in two options: single tilting
axis or double tilting axes. Irrespective of the furnace
position, the DUSTCONTROL hood collects all dusts
and gases released throughout the melting process
and delivers them reliably to the filter system.
Key features of the DUSTCONTROL system:
< High collection efficiency thanks to low flow
resistance and favourable exhaust conditions
< Flat design and low space requirements facilitate
ladle handling Workplace dust concentrations and emission levels
< Reduced ambient heat loads in operating areas are kept clearly below applicable legal thresholds.
Features of single tilting axis hood
Optimum extraction during Energy-saving Narrow design for pouring Easy crucible push-out
charging/melting holding into crane ladle without hood removal
Additional features of double tilting axes hood
Operator-friendly Optimum extraction during Easy backfilling Easy crucible push-out
deslagging pouring into forklift ladle without hood removal
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Safety package
Yokes for precision guidance of electromagnetic fields
Optimization of magnetic field by numerical calculation and simulation
< Selective dimensioning and arrangement of yokes and screening elements
Noise protection
Design for reduced noise emissions
< Firmly braced induction coil
< Decoupling and resilient mounting of components
< Installation of noise-absorbing materials
Pit guard*
Automatic furnace pit fencing
< Three-sided guard frame
< Gas pressure springs with protective cylinder for pit guard raising and lowering
Optical coil protection system - OCP*
Temperature measurement between crucible and coil
< Improved protection against operating disruptions, equipment damage and
operator injuries
< Early warning of impending critical temperature conditions
< Very high resolution and temperature accuracy
< Temperature profile logging and visualisation over the entire crucible campaign
< Direct optical temperature measurement not based on electrical circuitry
Earth fault monitoring
Protective system detecting electrical fault voltages
< Contact system with earth rods embedded in the furnace bottom
< Monitors furnace insulation resistance against earth
< Crucible monitoring
Emergency tilting* and emergency water input system
Emergency emptying and emergency cooling in case of power failure
< Emergency emptying options: Hydraulic pump, nitrogen-operated or manual
Emergency power generator, 24 V DC backup
pump
< Emergency water input and drainage by solenoid valve opening when
de-energized
Additional safety features
< Furnace operator control stand*
< Emergency collecting pit*
< Charging machine*
< Exhaust hood*
* quoted as optional safety features
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Furnace sizes and types
Cast iron and steel
Medium-frequency coreless induction furnaces have
evolved into the dominant type of melting furnace in
today‘s foundries, demonstrating their exceptional
metallurgical capabilities thanks to the special
technologies employed. High power densities of up to
1,000 kW per metric tonne of iron ensure high melting
rates from a compact-sized installation. Even high-
performance moulding lines can thus be supplied with
high-grade metal on a continuous basis.
MFT Ge 16,000 / 8,000 kW
Where two furnaces are combined with one common
frequency converter (DUOMELT / DUOCONTROL)
or three furnaces with two converters (TRIOMELT),
a medium-frequency coreless induction furnace can
also serve as a holding furnace.
Photo by: ACTech GmbH
Furnace sizes: MFT furnace type for cast iron and steel
Capacity Power, max. Melting rate, max. Compact MFT Ge 500 / 250 kW system
(kg) (kW) (kg/h)
500 500 950
750 750 1,400
1,000 1,000 1,900
1,500 1,500 2,850
2,000 2,000 4,000
3,000 3,000 6,000
4,000 4,000 8,000
5,000 5,000 10,000
MFT Ge 10,000 / 8,000 kW
6,000 6,000 12,000
8,000 8,000 16,000
10,000 10,000 20,000
12,000 12,000 24,000
16,000 14,000 28,000
18,000 16,000 32,000
25,000 20,000 40,000
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Copper and copper alloys
The specific benefits associated with the inductive
transfer of energy and the metallurgically neutral
process performance are of particular importance in
melting, alloying, refining and pouring as well as in
holding the various copper materials at temperature.
Coreless induction furnaces are employed as a
technologically and economically efficient solution in
conjunction with
< Horizontal and vertical continuous casters 50-tonne MFT furnace serving a vertical
continuous caster
< Sand casting and centrifugal casting machines
< Chip recycling equipment
< Remelting and alloying plants
Specific design features of the coreless furnace, such
as the arrangement of pouring and filling systems in
the furnace‘s pivot bearing, are key to the success of
this furnace type for demanding high-grade copper
melting applications.
Furnace sizes: MFT furnace type for copper
Transfer from melting furnace to holding
and pouring unit
Capacity Power, max. Melting rate, max.
(kg) (kW) (kg/h)
600 400 1,000
900 500 1,250
1,200 600 1,500
1,800 900 2,200
2,400 1,200 2,900
3,600 1,400 3,600
4,800 1,600 4,100
6,000 1,800 4,600
Furnace with pouring tube
7,200 2,000 5,100
9,600 2,500 6,400
12,000 3,000 7,700
14,400 3,500 9,000
16,000 4,000 10,300
20,000 5,000 12,800
30,000 6,000 15,400
For chip melting a reduced power density is recommended.
The melting rate for brass 60 is approx. 40 % higher.
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Aluminium
Low melting loss, accurate temperature and process
management plus a variable bath movement control
capability are among the key benefits of medium-
frequency coreless induction furnaces for melting
aluminium and its alloys.
These high-power furnaces are used especially for the
production of high-grade alloys and in chip recycling
applications. MFT Al 1,000 / 750 kW
Fields of application:
< Horizontal and vertical continuous casting
< Sand casting
< Chip and foil recycling
< Remelting and alloying
Furnace sizes: MFT furnace type for aluminium DUOMELT MFT Al 2,800 / 2,000 kW system
Capacity Power, max. Melting rate, max.
(kg) (kW) (kg/h)
200 150 300
300 200 400
400 300 500
600 500 900
700 600 1,100
1,000 900 1,700
1,400 1,000 2,000
1,750 1,400 2,700
Automatic charging of ingots and returns
2,100 1,800 3,500
2,800 2,400 4,700
3,500 2,700 5,300
4,200 3,000 5,900
5,500 3,500 6,900
7,500 4,000 7,800
9,000 4,500 8,800
For chip melting a reduced power density is recommended.
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Special applications
OTTO JUNKER medium-
frequency melting furnaces are
perfectly suited for melting and
holding any type of metal or other
electrically conductive material.
Custom-designed OTTO JUNKER
furnace systems have been used
successfully for the melting of Induction furnace for magnesium
< Magnesium
< Cobalt
< Nickel
< Silicon
< Silver
Further to the above, OTTO
JUNKER also offer the medium- Special crucible for magnesium
frequency coreless induction
furnace as a vacuum furnace. Coreless vacuum induction furnace
Our service portfolio
As your competent partner for all capital investment,
maintenance and upgrading issues relating to
medium-frequency coreless induction furnaces, we
are pleased to provide you with the following services:
< Planning and implementation of complete melt
shop solutions
< Advice on melting plant selection and dimensioning
< Return-on-investment estimates
< Engineering, construction and installation of
furnace systems
< Upgrades and revamping projects
< After-sales service and 24-hour support
< Equipment optimization to reduce energy
consumption and environmental impact
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Illustrations and texts may represent options or extras.
(c) OTTO JUNKER GmbH - 04/2017
Otto Junker gmbh Phone: +49 2473 601-0 | Fax: +49 2473 601-600
Jägerhausstr. 22 E-Mail: [email protected]
52147 Simmerath
Germany www.otto-junker.com
