Beruflich Dokumente
Kultur Dokumente
2005)
Abstract
The advancement of any nation technologically has been influenced and elevated
by the extent to which it can usefully harness and convert its mineral resources. The
productions of metal in foundries and in all human lives have also become a general
practice. Different melting techniques are in practice with different energy sources. The
cleanliness and availability of electrical energy sources in Nigeria is of paramount
importance to its use in foundries, hence the need for this design. This paper deals
principally with the mechanical and electrical requirements for induction furnace
production. The mechanical aspect gives consideration to the geometrical components,
cooling system, and the tilting mechanism. The electrical aspect deals with the furnace
power requirement to make it functional. The design was achieved through
consideration of relevant theories and their practical application.
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AU J.T. 9(2): 83-88 (Oct. 2005)
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AU J.T. 9(2): 83-88 (Oct. 2005)
The analysis is based on a 10kg capacity. Heat Energy and Electrical Parameters
The shape of the crucible is cylindrical. The
internal diameter of the crucible and the height The required theoretical heat energy
of melt is determined by the furnace capacity (Ilori 1991), consumed during the first period
(melt volume), with considerations that the of melt is given by:
ratio: Q th = Q m + Q sh + Q s + Q en − Q ex ............ 9
Hm
= (1.6 − 2.0) ........................... 1 where, Qm = amount of heat energy to
Dc
melt 10kg of charge material, J;
where Hm = height of molten metal, m; Qsh = amount of heat energy to
Dc = diameter of crucible, m; superheat the melt to temperature
of superheat, J;
Volume of metal charge is given by: Qs = heat required to melt slag
πd 2 H forming materials, J;
Vm = m m ............................ 2
4 Qen = energy required for
where dm = diameter of molten metal = Dc. endothermic process, J;
Qex = amount of heat energy
The thickness of the refractory lining liberated to the surroundings as a result
(Voskoboinikov, et al. 1985), of the crucible in of exothermic reactions, J.
the middle of the crucible can determine from
the relation Theoretically Qen = Qex.
B r = 0.084 T ........................................ 3 Where
Q th = Q m + Q sh + Q s ........................... 10
where T = furnace capacity in tonnes.
The internal diameter of the inductor can and,
be calculated from the equation: Q m = MC (θ 1 − θ 0 ) + L pt .......... .......... ..11
D in = D c + 2( B r + Bins ) ........................... 4
where Br = thickness of refractory lining, m;
B
where, M = mass of charge, kg;
Bins = thickness of insulation layer. C = specific heat capacity of charge
(Bins is such that 5 ≤ Bins ≤ 6 [mm]). material, (for aluminum, C = 1100J/kg K);
Height of inductor coil is given by: Lpt = amount of heat to accomplish phase
H in = (1.1 − 1.2) H m .................................. 5 transformation, (for pure aluminum Lpt = 0, no
phase transformation);
The height of furnace from bottom of the bath
θ1 = melting temperature of charge, (for
to the pouring spout is:
aluminum θ1 = 660°C);
H f = H m + hs + bt .......... .................... .... 6
θ0 = ambient temperature, 25°C;
where, hs = height of slag formed, m;
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