QUICK SINTER


INTRODUCTION

Mobirise

Fig. 1: Induction Furnace Cross-Section

Sintering Process

Sintering is a process in which loose aggregate/granule material is subjected to high temperature and/or pressure to form a solid mass/piece.

Sintering in Induction Furnace

A former (hollow metal cylinder with open top and closed bottom, fig. 2) is placed inside the furnace (fig. 3). Lining material/ramming mass is filled in the space between induction coil and former (fig. 4). The former is then filled with starter blocks/scrap of clean metal. It is heated inductively and the power is varied, while adding clean scrap as necessary to follow the temperature gradient according to the furnace size and lining binder type (see table).

Mobirise

Table 1: Heating rate for Calderys Silicamix Ramming Mass

Development of Quick Sinter

Proof of Concept

A 12 KW heater for a 300 KG furnace with single zone control.
Temperature control through bottom thermocouple.

On-site Testing of MVP

35 KW heater for 1.5 Ton furnace with 2-zone control .

75 KW, 8 Ton heater with 3 zones.

90 KW, 10 Ton heater with strip type element (single zone).

30 KW, 25 Ton heater for coil coat drying application (2 zones)

90 KW SCR based power supply with water cooling

40 KW SCR based power supply with forced air cooling

30 KW Contactor based power supply

Quick Sinter

An Innovative Way for Induction Furnace Sintering

Production demands and electrical costs are two of the major problems faced by foundries and steel plants. These two problems can be directly linked with the sintering process of induction furnace alongside other problems such as inconsistent lining performance and lining life, poor plant load and workforce utilization, etc.
Quick Sinter a unique, fully automated solid-state heater can effectively tackle all such problems. Moreover, all the benefits of the Quick Sinter can be further extended when used during Cold Starting of a furnace, Patching/Re-lining of a furnace and Coil Coat Drying.

Ways in which Quick Sinter can Benefit You

Less Energy Consumption
Reduced electrical costs as Quick Sinter consume at least 70-80% less unit as compared to regular Sintering heat.
More Production Output 
As independent power supply is used, full power of the induction PSU can be given to the other furnace during the sintering process. Thus, production is neither stopped nor slowed down.
Uniform Sintering
The heater is divided into 1/2/3 zones as per the furnace size and are independent of each other, giving uniform temperature from top to bottom. This ensures uniform sintering throughout the furnace.
Fully Automatic
Each zone has its own set of thermocouples, profile controller and power circuit and can be controlled individually. This eliminates the need of labour for manually varying the power as well as for the charging of the scrap.
No Need of Auxiliary Equipment
More units saving is realised as auxiliary pumps are not required. Furnace cooling can be effectively done through over head tank or small water pump.
Safety is Priority
The Quick Sinter provides protection against short circuit fault along with earth leakage and open load detection. This ensures upmost safety of the personnel as well as of the equipment.
Optimum Plant Load Factor
As independent PSU is used, full power of the induction PSU can be utilized during sintering cycle, thus ensuring optimum utilization of the plant load.
Cold Starting of the Furnace
All the benefits of the Quick Sinter can further be realized when it is used during the Cold Starting of the Furnace.
Patching/Re-lining of the Furnace
Quick Sinter can be of further benefit by using it during the patching or re-lining of the furnace.

Case Study of 1.5 Ton Furnace:

Below is the comparison between different parameters for conventional sintering process and the Quick-Sinter.

Mobirise

Assuming the cost of electricity as Rs. 7/unit and for labour as Rs. 50/man-hour following points are concluded.

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Total savings per sintering cycle = Rs. 5,844
Also, extra 8 hours of production is realized during the sintering cycle.