CPT International 04/2016

K MELTING SHOP
Figure 2: SmartReCooler system screen
uations at any time. In energy saving
mode the cooling water pumps
draw very low power, i.e., very little
electricity is consumed. The energy
saving potential depends very much
on the furnace operating regime, i.e.,
on how long the furnaces are run in
holding or cool-down mode or with
reduced power input.
At KSB AG, the leading manufacturer
of pumps and pump systems, this
new technology was used on one of
two identically designed Monomelt
furnaces with independent water recooling
circuits which had been ordered
for the company’s Pegnitz site.
As one furnace plant featured the
smart SRC system while the other
was equipped with traditional water
recooling, the benefits of the new system
could be objectively evaluated.
The furnaces are designed to melt
both cast-iron and steel. Each of
the two plants consists of a 2-tonne
coreless induction furnace with an
IGBT converter rated for 1,500 kW.
The nominal frequency can be set at
500 or 125 Hz. The installations are
equipped with a JOKS melt processor,
a weigh scale, extractor hoods
and a hydraulic power pack.
The water recooling system of
each melting furnace has separate
cooling circuits for the furnace and
the electrical equipment and uses a
glycol-free water-to-air cooler. The
pump rack in the furnace circuit carries
two 7.5 kW pumps operating in
a redundant mode. The cooling cir-
IMERYS
REFRACTORY MINERALS
FOR FOUNDRY APPLICATIONS
INVESTMENT
CASTING
REFRACTORY FLOURS
& STUCCOS
SAND
CASTING
SANDS FOR
CORES & MOULDS
FILLERS FOR
FOUNDRY COATING
PUB IRM FFA EXE OK.indd 1 05/01/2016 11:58:36
18 Casting Plant & Technology 4/2016