Electric Furnace Manufacturing Enterprise Application Survey
With the wide application of induction furnaces, the use of induction furnace melting covers almost all metal alloys, melting gray cast iron, alloy cast iron, nodular cast iron accounted for 49%, smelting common cast steel, alloy cast steel accounted for 34%. In particular, in the field of non-ferrous alloy foundry production, although the proportion of induction furnaces in the non-ferrous alloy industry accounts for 15%, due to the adaptability of the furnace structure, smelting temperature, production methods, and metallurgical characteristics, the induction furnace is The application scope of non-ferrous metal casting is narrow, and the actual production is only used to undertake the insulation task. If an induction electric furnace that integrates melting and heat insulation can be designed to achieve continuous supply of non-ferrous metal liquid, it will certainly promote the non-ferrous casting industry. Rapid development will also inevitably create a vast market for induction furnace manufacturers.
In China's production enterprises, induction furnace applications with less than 1 t smelting account for 28%, 18% for 1 to 2t, 22% for 3 to 5t, 14% for 6 to 10t, and 13% for 11 to 20t. 20t or more accounted for 5%. The size of the smelting furnace is mainly determined by factors such as the scale of production, product structure, and company characteristics. It reflects that most SMEs in China account for the majority of the industry, and the degree of industrial concentration is relatively low. It is believed that with the continuous development of the construction of China's foundry industry cluster and the continuous deepening of industrial restructuring, the proportion of large, medium and small-sized manufacturers will tend to be reasonable, and the application of medium and large-scale induction furnaces will increase modestly. However, from a practical point of view, the manufacture and application of small-scale induction furnaces are becoming more and more sophisticated, while medium-to-large-sized induction furnaces cannot fully meet production needs in terms of circuit control systems, cooling systems, and service life, and require equipment manufacturing plants and castings production. Application companies work together to improve the performance of induction furnaces and promote the development of induction melting technology.
Selection of factors affecting the application of induction furnaces Influencing factors for the application of induction furnaces. The influencing factors of the application of induction furnace can be seen that among the five factors that mainly affect the purchase and application of the enterprise, such as energy conservation and environmental protection, melting quality, safety, cost performance, and service life, 26% of them choose energy saving and environmental protection, and choose the quality of smelting. It is 22%, security is 20%, cost-effectiveness is 18%, and service life is 14%. With the continuous improvement of energy-saving and environmental protection requirements, people’s awareness of green environmental protection continues to increase. In addition, the country’s increased supervision over environmental protection indicators has enabled companies to attach importance to energy-saving and environmental-friendly performance indicators when purchasing equipment, and the application of induction furnaces has been adapted. This development needs. However, it should be pointed out that for the induction furnace, environmental protection is unquestionable, but there are different views on energy saving. Because the power used by the induction furnace is secondary energy, the melting process consumes more power and continuous production is more difficult. The power supply situation in different places is also very different, so from the point of view of energy conservation, there is still much room for improvement in its energy-saving technologies.
Industry focus on industrial heating manufacturing technology topics compared to the traditional cupola melting process is quite different, the induction furnace without overheating, carbon increase, increase flow difficulties, post-treatment process is also different, although the industry has long explored the induction melting process, but The quality of smelting molten iron still has problems such as low degree of undercooling, difficult control of nitrogen and oxygen content, and abnormal microstructure of the spheroidal graphite, resulting in unstable quality of smelting molten iron. These problems are particularly prominent in the production of high-end products. In this survey, most of the production line engineers proposed that equipment manufacturers should increase technical support for production and application companies to ensure the quality of smelting. Melting as a high-risk process, companies choose to focus on the safety performance of the electric furnace, the reliability of the alarm system in practical applications is particularly important, whether the company can pay attention to all-position monitoring, these aspects have yet to be improved.
The cost-effectiveness in the primary stage of industrial development is more valued by enterprises. There are tens of thousands of casting enterprises in China, and SMEs are the majority. The pursuit of cost-effectiveness also occupies an important position for a long period of time. However, as the degree of industrial concentration increases, the number of medium- and large-scale enterprises increases. For companies that have financial strength, and considering comprehensive costs such as maintenance, this indicator is continuously weakening. Although in the surveyed performance indicators, the service life is sorted backwards, but the feedback is more problematic, such as less lining usage, the bottleneck of the cooling system application in the northern regions, and the durability of electrical system components. Low-level issues are all left to the electric furnace manufacturing companies to solve the problem.
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