GENERAL

Magnalenz Induction Furnaces are designed and produced by studying all available existing Furnaces in the world, adapting all superior features, adding all up to date technologies and combining the necessary needs indicated by foundrymen. For the coming millennium years of 2000 and beyond Magnalenz proudly presents to modern, automated foundries and steel plants the most Economical, the most Reliable, the most Efficient and high Quality Induction Furnace viz. FERmelt.  

Benefits of Medium Frequency Induction Furnace:
• Lower power consumption and enhanced economy
Modern semi-conductor technology and an optimum furnace design minimize the power                              demand and consumption, thus reducing the melting cost.
• High operational safety
Safe melting operations thanks to continuous, automatic furnace monitoring.
• Favorable price/performance ratio and long life cycle
The use of Magnalenz standard modules in the melting plant are responsible for its favorable price. These Magnalenz furnace systems,  are known to be rugged and reliable, minimize total life cycle costs.
• Easy to install, operate and maintain
The advanced furnace design was conceived for quick and easy installation. System operation, monitoring and control are user-friendly and simple.

Higher Yield: The absence of combustion sources reduces oxidation losses that can be significant in production economics.

Faster Startup: Full power from the power supply is available, instantaneously, thus reducing the time to reach working temperature.
 

Flexibility: No molten metal is necessary to start medium frequency coreless induction melting equipment. This facilitates repeated cold starting and frequent alloy changes.

Natural Stirring: Medium frequency units can give a strong stirring action resulting in a homogeneous melt.

Cleaner Melting: No by-products of combustion means a cleaner melting environment and no associated products of combustion pollution control systems.

Compact Installation: High melting rates can be obtained from small furnaces. A coreless furnace capable of melting 2,500 lbs./hr. of aluminum has a crucible measuring 3' in diameter by 6' in depth.

Reduced Refractory: The compact size in relation to melting rate means induction furnaces require much less refractory than fuel-fired units.

Better Working Environment: Induction furnaces are much quieter than gas furnaces, arc furnaces, or cupolas. No combustion gas is present and waste heat is minimized.

Energy Conservation: Overall energy efficiency in induction melting ranges from 55 to 75 percent, and is significantly better than combustion processes.

DESCRIPTION OF MF INSTALLATIONS
Medium frequency Furnaces operate at frequencies ranging from 150 To 10,000 HZ, such furnaces provide the concentration of high power in small volumes with a definitely higher melt rate.

Magnalenz installation consists of:

1. Melting crucible.

2. Solid state power converter.

3. Power factor compensation capacitor bank.

4. Ancillary equipments.

MELTING CRUCIBLES
Structurally it consists of three independent sections:

1. Base frame

2. Tilting Frame

3. Interchangeable inductor comprising the coil made from specially shaped copper section featuring Higher Strength and Higher Conductivity.

The melting basin is inside the inductor with an adequately thick refractory lining in between. The special Trip system for wear on refractory is also provided.

For easy emptying, calm and complete pouring, a special hydraulic system is incorporated.

MF SOLID STATE POWER CONVERTER
Converts the line/mains frequency in to medium frequency required for efficient operation.

Basically it Consists of:

1. Converting A.C. to D.C.

2. Rectifying & Filtering D.C. Current.

3. Converting D.C. to M.F.A.C.

4. Electrical Safety, Protection, Regulation and Control circuits

5. Closed water circuit with water to water heat exchange and deioning with D.M. water.

MF POWER FACTOR COMPENSATION CAPACITOR BANK

A set of water-cooled medium frequency capacitors connected by Electrolytic grade copper busbars, to avoid losses, due to high currents. It is fitted inside panel or outside, specially protected frames, automatically compensates the low power factor to the Furnace.

ANCILLARY EQUIPMENTS
Those Equipments are supplied to specific client’s requirements for a better functionally of the Medium Frequency Furnaces installations:

1. Cooling Tower

2. Step-up & Step-Down Transformers

3. Close loop D.M. Water circulation for crucible

4. Automatic Charging Equipments

5. Energy metering devices

6. Control & Programming of Power absorbed during production cycle

7. E.O.T. Cranes

8. Water softening plant.

SERVICE
24 Hours/365 days a year around service is available.