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71st World Foundry Congress. Bilbao 2014
New induction wireless efficient
manufacturing process for
furnaces
J.L. Villa, C. Cortés, J.F. Sanz, A.
Carrión, M. Ons
CIRCE Foundation, Zaragoza, Spain
71st World Foundry Congress. Bilbao 2014
Demonstration of a new production process able to decrease the
embodied energy of the foundry products by over 25%, reducing
drastically its carbon footprint
“This project has received funding from the European Union’s Seventh Programme for research,
technological development and demonstration under grant agreement Nº 296024”
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71st World Foundry Congress. Bilbao 2014
More flexibility, less emissions and more energy efficiency within the whole plant
“This project has received funding from the European Union’s Seventh Programme for research,
technological development and demonstration under grant agreement Nº 296024”
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71st World Foundry Congress. Bilbao 2014
Sectors tackled: Energy Intensive Industries (
Aluminium, Iron Steel foundry
Most of the energy consumed by these furnaces is used
to heat the raw materials up to the corresponding melting
points (from ~700°C for an aluminium furnace to
~1450°C for Iron furnace and 1650ºC for Steel furnace).
From this energy used during the heating process,
up to 50% is lost via heat transfers and gas waste.
Expected Results and activities
• Recommendations for new processes and equipment
• New integral design of processes, materials and
equipment through simulation
• New detailed concept and methodology for
manufacturing processes in the metallurgical industry
• Three furnaces prototypes to be constructed and
tested i
• Operation guides for the new processes and
equipment
• Definition of new production models
“This project has received funding from the European Union’s Seventh Programme for research,
technological development and demonstration under grant agreement Nº 296024”
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71st World Foundry Congress. Bilbao 2014
IPT SYSTEM OPERATION
 An IPT (Inductive Power Transfer) consist of two coils separated through
the air by a defined distance.
 The system works as a transformer but in this case without iron core
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71st World Foundry Congress. Bilbao 2014
IPT SYSTEM OPERATION
The transferred power depends on:
•
•
•
•
•
M: Mutual inductance coefficient ( geometry, size and section of coils)
ω: Operation frequency. This frequency must ensure that the coils are in
resonance and achieve the highest power transfer with the optimal grid
consumption.
Ip: Primary current. Is set depending the power and the voltage of the grid
RL: Resistance of the furnace.
Qs: Quality factor. Is the increase in power achieved tuning the secondary
coil trough capacitors in both coils
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71st World Foundry Congress. Bilbao 2014
A 100 kW IPT system has been designed to fed an aluminum furnace. The
final design consists of two round coils with a average radius of 250 mm,
separated 30 mm
The theoretical efficiency is around 98 %, but in fact with the system built
and taken into account the power electronic losses, the real efficiency of the
whole system won’t be higher than 85 %
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71st World Foundry Congress. Bilbao 2014
According to the current regulatory framework (ICNIRP-2010), the maximum occupational
public exposure to magnetic fields allowed at the operation frequency (20 kHz) is 100 µT.
Therefore, a shielding for the IPT is mandatory to protect the workers . An aluminum box
keep the magnetic field inside. Figure 3 shows the magnetic field above 100 mT in red
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71st World Foundry Congress. Bilbao 2014
AIR COOLING CONFIGURATIONS
In order to evacuate the thermal load by means of forced convection heat transfer, it is
necessary some perforations in the aluminium box to make possible an air current to cross
the geometry and cool the electric parts inside the box.
The maximum temperature reached in the
centre of the coils is around 70ºC (158 ºF),
lower than the critical point defined at
100ºC (212 ºF) that would induce damage
in the insulation of the coils.
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71st World Foundry Congress. Bilbao 2014
CROSSED FLOW
As a first approach it is also feasible that a forced
air flowing with a speed of more than 7 m/s can
keep the temperature of the ferrite and the
solenoids along the time below required
thresholds
WATER COOLING CONFIGURATIONS
To avoid the deposition of dust inside the boxes,
the space is filled with a solid composite made of a
non-metallic material so that it does not affect the
magnetic field distribution and performance of the
system.
• Using water instead of air allows to greatly
enhance heat transfer at a reasonable cost
• It will be possible to avoid dust deposition on
free surfaces on it.
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71st World Foundry Congress. Bilbao 2014
Thank you for your attention and your comments
Contacts
Dr. Juan Luis Villa: [email protected]
CIRCE Foundation +34 976 762 619
www.fcirce.es
Project NIWE Contacts:
Project Coordinator: Dr. José Carlos García+34 943 10 51 15
[email protected]
Dissemination manager: José Luis Vadillo +34 672 33 40 85
[email protected]