Induction Melting Furnace

Green Furnace

The Green Furnace: Our popular low-frequency model has been further improved upon leading to furnace orders of 19MTPA capacity out of which 6 MTPA are orders of plants using furnaces of other makes. Some of the largest secondary steel manufacturers globally are joining the Green revolution. Below are the reasons why…

Green furnace incorporates the best aspects of parallel as well as series circuits to give the lowest energy consumption and higher productivity
Latest SMD-based inverter with a digital interface
Fibre optics used in inverters & signal boosting in rectifiers

Guaranteed energy consumption of 465 kWh/t using mill heavy/end cutting scrap
Guaranteed 30 kWh/t – 40 kWh/t lower than all other latest furnaces and 60 kWh/t – 75 kWh/t lower than previous generation furnaces
9% – 11% higher productivity compared to other brands
Power factor of 98%
No capacitor switching. Sustained power throughout the heat cycle
High power pickup achieved via voltage boosting
Eight energy consumption and productivity improvement features
State-of-the-art digital system with alarms, remote access, digital parameter displays, data logging, trend analysis, etc.
High power pickup achieved via voltage boosting

	Series Circuit	Parallel Circuit	Green Furnace
Name	Voltage Source Inverter	Current Source Inverter	Voltage-Boosted Current Source Inverter
Power Pickup & melt rate	Good power pickup and high melt rate	Poor power pickup. Low melt rate	High power pickup and best melt rate due to voltage boosting and low-power consumption
Power Factor	96% – 97% (from start)	Max 93% – 94% (from 80% of rated power)	97% – 98% (from 40% of rated power using CPF system)
Capacitor Switching & frequency	Switching is not required. Low frequency maintained throughout the heat cycle	Switching Required. Done via PLC-controlled pneumatics. Medium freq due to the large frequency range	Switching is not required. Low frequency maintained throughout
Energy Consumption	Higher than Green	Higher than Green	Lowest due to 8 Green furnace features
After-sales parts cost	Expensive due to high current carrying devices	Cheaper than a series circuit	Cheaper than a series circuit
Reliability (Shock load and short circuit resilience)	Poor due to the presence of a DC link discharge capacitor	Better due to the presence of heavy current sourcing DC reactor	Better due to the presence of heavy current sourcing DC reactor

Features of Green Furnace & Impact on Performance

Feature No.	Feature	kWh/t Saving	Productivity Improvement
1	Compact Layout & improved copper sections lead to minimal current density and line losses	3-5	1%
2	Nano Cable Design: Lowest cable loss & voltage drop	8-12	1%
3	Power factor of 98% as seen in a series circuit	2-3	2%
4	Strict Harmonics Control	2	0%-1%
5	Low Loss Higher Rated Capacitors	2-3	0%-1%
6	Automatic Voltage Boosting, High Power Pickup, Higher Voltage (4150V up to 8MW/5250V 10MW onwards)	8-10	2%
7	Higher power pickup. Highest Load Factor. Stretching Increased.	10	1%
8	Tight Frequency Range (up to 280 Hz unlike others which go up to 400+ Hz) because of no capacitor switching	25-30	2%
	Total	60-75	10%