To heat the iron upto 1400 C cupola consumes 55 kg. /ton of fuel against 500 kWH of Induction.
Cupola uses extra 60 kg/ton fuel to super heat the melt 100 C compared to 65 kWH /ton consumption of induction.
Elimination of Pig-iron.
Utilization of low cost borings and turnings gives on effective metal coast saving of 33%
The metal loss is only 1% compared to 5-10 % in cupola. The consumption of refractory is 10 kg/ton in Induction
Heat efficiency of cupola is 10-15% but the over all heat efficiency in Induction is 40-50%.
Sampling, adjustment of temperature, holding of temperature is impossible with cupola.
The composition in cupola alter three times per day. Changes of carbon, silicon in the melt are negligible in Induction for holding for few days.
OVER ARC FURNACE
Cooler, quitter, cleaner and safer working condition, due to elimination of noisy arcs & gaseous product.
Elimination of Electrode consumption (5-15kg./ton).
Shorter melting time, due to no ‘carbon pick-up’ which eliminates the oxidizing operation and result in lower power consumption.
Fast and complete homogenization of alloy due to stirring action.
Lower oxidation loss.
Better power utilization of equipment.
Ability to hold metal temperature for long period of time.
Elimination of stock control equipment when melting clean scrap.
Elimination of sample taking and analysis of each melt, due to more predictable .
SPECIALTY OF MELTING OF IRON
A continuous supply of molten metal.
Excellent temperature control.
Elimination of air pollution problems without costly collection system.
Elimination of sulphur pick-up and silicon loss.
Easier control of carbon content.
Improved machinability.
Higher physical properties in the iron.
More nearly uniform hardness of iron .
Complete homogenous metal because of stirring action.
Increased fluidity that allows lower pouring temperature.
Excellent, reproducible chemistry control.
Ability to hold iron over prolonged periods without discernible change in chemistry.
Melt losses on the order of only 2% for normal gray iron, and even better on Si and alloy iron.
Elimination of effect of humidity variations on iron quality.
Highly automated controls
Elimination of need for highly skilled operator.
Comfortable, clean, cool working conditions.
Reduction of slag disposal problems.
Elimination of coke and limestone storage and handling
Elimination of pig bed because cold ladle metal can be returned for rehashing
Heating of ladles pouring temperature by filling two or three times and returning chilled metal to the furnace
Continuous pouring schedule releasing space required for mold storage.
Simplified charging and reduced labour requirements
Regulation of rates to suit requirements without incurring chemistry and temperature problems.
Ability to melt borings, turnings, and scrap materials with excellent recovery and no charge formality other than the charge opening of the furnace
Accurate and rapid chemistry without intermediate iron. Ability to super heat.
fire hazards is minimum.
The Induction furnace does excellent job in eliminating segregation with no labour.
It is cold top, less oxidation and higher recovery.
Better utilisation of available space.
Used for melting steel & alloys requiring lower carbon than that obtainable in crucible & are furnace.
Induction melting in acids lining of rolling mill scrap yields a steel with all qualities of acids steel which are so valuable for gun & aeroplane and other steel requiring good transverse test.
Heat resisting steel, die & other complex steel , and refractory chromium alloys can be melting in acid or basic linings without substantial alteration of composition.
Manganese steel scrap can be remelted without substantial loss of manganese
