Operational Condition Monitoring And Optimization Of High-power Induction Furnace

Induction furnace is widely used for smelting copper,steel,aluminum and alloys in industry with advantages of high efficiency,fast heating speed and smelting metal uniformly.Due to the high power required by induction furnace,the energy loss during smelting is huge.Because electrical characteristics(including resonant frequency)of induction furnace body are not fixed,existing energy-saving methods cannot calculate electric energy consumption accurately in real time and provide effective opitimization during smelting.To solve above problem,electrical characteristics equivalent circuit model of high-power medium-frequency induction furnace body is presented in this paper,its operational condition(weight of melted iron and electric energy consumption)is monitored and analyzed during smelting and optimization solutions are presented.Electrical characteristics equivalent circuit model of induction furnace body is presented based on transformer principle and data during smelting.Iron loss resistance is presented in the model,which is assumed to quantify a part of electric energy consumption,to fit the data from simulation and the data during smelting.Using least square estimation algorithm,model parameters can be estimated in real time by recognizing the data during smelting.Operational condition(weight of melted iron and electric energy consumption)of inductionfurnace can be quantified in real time based on electrical characteristics equivalent circuit model and parameter estimation.An online weight method of melted iron is presented in this paper and electric energy consumption of induction furnace body is analyzed.Based on two methods to solve overtopping problem of medium frequency current,energy consumption is calculated online in this paper and the results are compared.In addition,offline energy consumption is calculated based on consumption of furnace lining during smelting and influence of capacitance initial value on energy consumption.Applying the results of online and offline energy consumption calculation to operational optimization,the coordinated optimization problem,initial value problem of capacitance and their optimization solutions are presented in this paper.The equivalent circuit model of induction furnace body is presented to solve the problem thatelectrical characteristics parameters cannot be measured so that the operational condition can be monitored in real time during smelting and operational optimization control of energy consumption is presented.The analysis of energy consumption can provide help for industrial manufacture while the thinking of operational optimization will enlighten energy-saving optimization research of induction furnace.