Electric arc VS Induction Furnace
The Difference Between Electric Arc Furnace VS Induction Furnace
The Cost Difference Between Electric Arc Furnace VS Induction Furnace
Compared with the electric arc furnace, the steelmaking cost of the induction furnace is lower, and it is suitable for small and medium-sized enterprises (small workshops)
However, the steel he smelt has many impurities and high carbon content, so the steel smelted is not pure. If the requirements are not high, you can choose induction furnace steelmaking.
The volume of the electric arc furnace is generally more than 3 tons, so only enterprises with a certain scale can use the electric arc furnace, and the steel produced by it is relatively pure.
The difference in Electricity Consumption Between Electric Arc Furnace VS Induction Furnace
The Same Points:
1. Both use electricity;
2. Both have a rectifier circuit
The Difference:
1. The electric arc furnace uses power frequency electricity, while the Induction Furnace uses intermediate frequency electricity.
2. The electric arc furnace can change the material, but the induction melting furnace cannot change the material, that is to say, the electric arc furnace can be smelted, and the intermediate frequency furnace can only be melted;
3. The electric arc furnace is heated by generating an arc through a short circuit, and the intermediate frequency furnace is heated by generating a magnetic field.
4. Compared with the electric arc furnace, the intermediate frequency electric furnace has higher thermal efficiency, so as to achieve high production efficiency, flexible operation, and low energy consumption.
The Difference Between the Features of Induction Furnace and Electric Arc Furnace
Induction Furnace Series Melting Furnace Features:
(1) High melting efficiency, good power-saving effect, compact structure, and strong overload capacity
(2) The temperature around the furnace is low, there is less smoke and dust, and the working environment is good.
(3) The operation process is simple and the smelting operation is reliable.
(4) The metal composition is uniform.
(5) The melting temperature rises quickly, the furnace temperature is easy to control, and the production efficiency is high.
(6) The utilization rate of the furnace is high, and it is convenient to replace the variety.
Electric Arc Furnace Features:
- An electric furnace that smelts ores and metals using the high temperature generated by the electrode arc.
- When the gas discharge forms an arc, the energy is very concentrated, and the arc temperature is above 3000°C. For smelting metals, the electric arc furnace is more flexible than other steelmaking furnaces. It can effectively remove impurities such as sulfur and phosphorus. The furnace temperature is easy to control and the equipment occupies a small area. It is suitable for smelting high-quality alloy steel.
- Electric arc furnaces can be divided into three-phase electric arc furnaces, consumable electric arc furnaces, single-phase electric arc furnaces, and resistance electric arc furnaces according to the arc form. The furnace body of the electric arc steelmaking furnace is composed of a furnace cover, a furnace door, a tapping trough, and a furnace body. The furnace bottom and furnace wall are built with basic refractory materials or acidic refractory materials.
- Electric arc steelmaking furnaces are divided into ordinary-power electric arc furnaces, high-power electric arc furnaces, and ultra-high power electric arc furnaces according to the transformer capacity per ton of furnace capacity.
- Electric arc furnace steelmaking is to input electric energy into the electric arc steelmaking furnace through graphite electrodes and uses the arc generated between the electrode end and the charge as the heat source for steelmaking.
- The electric arc furnace uses electric energy as the heat source, and the atmosphere in the furnace can be adjusted, which is extremely beneficial for smelting steel types that contain more easily oxidizable elements.
- Shortly after the invention of electric arc furnace steelmaking, it was used to smelt alloy steel and has been greatly developed.
The Difference Between Induction Furnace and Electric Arc Furnace Smelting Processing
1. Features in Terms of Refining Ability
Electric arc furnaces are stronger than induction furnaces in terms of phosphorus, sulfur, and deoxidation capabilities. The induction furnace is a cold slag, and the temperature of the slag is maintained by the heat provided by the molten steel. The electric arc furnace is a hot slag, and the slag is heated by an electric arc. The dephosphorization and desulfurization tasks can be completed through the slag, and the diffusion deoxidation can be fully performed through the slag. Therefore, the removal of phosphorus, sulfur and deoxidation ability of an electric arc furnace is better than that of an induction furnace.
The nitrogen content in steel smelted by an electric arc furnace is higher than that of an induction furnace. This is because the nitrogen molecules in the air in the arc high-temperature zone are ionized into atoms and then absorbed by the molten steel. The nitrogen content of the alloy smelted in the induction furnace is lower than that of the electric arc furnace, and the oxygen content is higher than that of the electric arc furnace. The rapid life value of the alloy is higher than that of the electric arc furnace.
2. The Element Yield of Smelting Alloy is High
The yield of alloying elements in an induction furnace is higher than that in electric arc furnace. The volatilization and oxidation loss of elements are large under the high temperature of the arc.
The burning loss rate of alloying elements in an induction furnace is lower than that in electric arc furnaces. In particular, the burning loss rate of alloying elements in the returned material loaded with the furnace is much higher than that of the induction furnace.
During induction furnace smelting, the alloying elements in the returned material can be effectively recovered. During electric arc furnace smelting, the alloy elements in the returned material are first oxidized into the slag, and then reduced back to the molten steel from the slag, and the burning loss rate is obviously increased.
When the return material is smelted, the yield of alloying elements in the induction furnace is significantly higher than that in the electric arc furnace. For example, the yield of molybdenum is 92%-96% in induction furnaces, 85%-90% in electric arc furnaces, 90%-94% in an induction furnace, and 85%-90% in electric arc furnaces. Alloying elements volatilize and lose a lot at the high temperature of the arc, and the induction furnace melts the alloying elements through induction heating with less loss.
3. The Amount of Carbon added to Molten Steel is Low During the Smelting Process
The induction furnace relies on the principle of induction heating to melt the metal charge without carburizing the molten steel. Electric arc furnaces rely on graphite electrodes to heat the charge through an electric arc. After melting, the molten steel will be carburized. Under normal conditions, when smelting high-alloy nickel-chromium steel, the minimum carbon content in electric arc furnace smelting is 0.06%, and it can reach 0.020% in induction furnace smelting. The amount of carbon added in the electric arc furnace smelting process is 0.020%, and that of the induction furnace is 0.010%.
Non-vacuum intermediate frequency induction furnace is suitable for smelting low-carbon high-alloy steel and alloys.
4. Electromagnetic Stirring of Molten Steel Improves the Thermodynamic and Kinetic Conditions of the Steelmaking Process
The movement conditions of the molten steel in the induction furnace are better than those in the electric arc furnace. Electric arc furnaces must install low-frequency electromagnetic stirrers for this reason, and its effect is still not as good as induction furnaces.
The electromagnetic stirring effect in the induction furnace improves the mechanical conditions and promotes the homogenization of the temperature and composition of the molten steel, but excessive stirring will not be conducive to the removal of inclusions and damage to the lining.
5. The Technological Parameters of the Smelting Process are Easy to Control
Induction furnace smelting is more convenient than electric arc furnaces in controlling temperature, refining time, stirring intensity, and maintaining constant temperature, and can be carried out at any time.
The above-mentioned characteristics of the induction furnace play an important role in the smelting of high-alloy steel and alloys. It can produce products independently, and can also form a double-linked process with secondary refining such as electroslag remelting and vacuum self-consumption.
Therefore, non-vacuum intermediate frequency induction furnace smelting has become an important smelting method for the production of high-speed steel, heat-resistant steel, stainless steel, electrothermal alloys, precision alloys, high-temperature alloys, and other special steels and alloys, and has been widely used.
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