Medium

Frequency
Induction Melting
Furnace
The Range of Products and Services:
Induction Melting Furnaces for mini steel plants
Induction Melting / Holding Furnaces for ferrous and
non-ferrous foundries
Electric Arc Furnaces
Electrotherm Refining Furnaces (ERF)
Metal Refining Konverters (MRK)
High Speed Continuous Casting Machines
Coal based Rotary Kiln (Sponge Iron) Plant
Coal based Tunnel Kiln (Sponge Iron) Plant
Gas based HYL DRI Plant up to 200,000 TPA capacity
Turnkey Projects for steel melt shop for producing billets / ingots
Turnkey Projects for Integrated Plant through DRI – SMS route
Plant design and engineering
Plant Automation
Productivity Improvement Equipment (PIE) for improving plant productivity,
end product’s quality and plant efficiency

Our customer gets

vantage
TM

on every Purchase

ETS-05
Solid State Power Supply Unit Performance Enhancing Equipment

DC Choke ET-EH Grabs

Electrotherm’s large iron core DC choke reduces rate of rise of ET-EH Grabs are ideal for handling larger volumes of scrap.
current to dangerous level and allows front-end thyristorized The design of the grab allows a very high gripping force, due to
convertor stop current flow within 6-8 milliseconds. This vertical and large cylinders and the geometry of the claws.
protection is faster than any other circuit breaking device with Specially designed ET-EH Grabs can be mounted on cranes,
minimum risk of fuse blowing and thyristor failures. wheeled loaders and tracked excavators.

The grab's innovative design allows the equipment to

incorporate a very robust mechanism powered by in-
builthydraulic system for grabbing the scrap. These grabs have
DM Water Circulation Unit and Flow Monitoring independent claws, each one set in motion by double acting
System cylinder. This allows the equipment to have a good grip on loose
material & non-symmetrical objects.
Electrotherm uses DM water for cooling of power devices and
copper conductors. Conductivity of DM water is continuously
monitored and power supply unit is tripped in case conductivity
exceeds the set limit. Stainless Steel sacrificial electrodes are
used to prevent electrolysis of copper components. Magnet
float assembly in conjunction with sensitive proximity switches
are used to monitor flow in different paths. The DM water
cooling system with flow monitoring mechanism ensures
enhanced life of water cooled copper conductor and power Lining Vibrator
components.
Electrotherm has introduced customized lining solutions to
Induction Furnaces with its newly developed Lining Vibrator.
Capacitor and Bus Bar Lining Vibrator ensures compact and uniform lining throughout
the furnace which in-turn increases the lining life and hence
Electrotherm’s capacitor bank, mounted on a robust steel productivity and simultaneously also decrease the manpower
structure and fitted with electrolytic grade copper bus tubes and requirement.
flow monitoring switches for failsafe positive interlock in each
capacitor’s water circuit path, facilitates very easy
maintenance and long life of capacitors.

We provide 20% extra capacitors for achieving full power

during entire lining life. We use capacitor connection /
disconnection switches to adjust required KVAR in the circuit.

Pre-fabricated electrolytic grade copper bus bars from Vibratory Feeder

capacitor assembly to water cooled cables are used to
minimize energy loss and installation time. Productivity of a melt shop depends on efficient charging
system. Electrotherm has designed and developed
mechanized charging of sized scrap through vibratory feeders.
Furnace Selector Switches These vibratory feeders are designed to move along their axis
to feed the scrap directly into furnace mouth continuously at the
Electrotherm’s patented, rugged, off - load, double-pole, double desired rate. Vibratory feeder can be refilled in situ while it feeds
break, water cooled furnace isolating switches are known for the furnace.
their reliability. Switches are available in both manual and
mechanized versions from 2KA to 15KA.

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A Brief Profile of Electrotherm (India) Limited
Engineering & Projects Division
Electrotherm (India) Limited,
an ISO 9001:2000 certified,
public limited company, was
founded in 1983 to cater to
the needs of all segments of
steel industry, foundries and
heat treatment industry.
Today, Electrotherm is a well
diversified conglomerate
having businesses in the field
of Engineering & Projects
catering to steel and foundry
industry; transformer
manufacturing; steel making;
ductile iron pipe making;
manufacturing of battery
operated vehicles; renewable energy; transmission line tower; and education.

The Engineering & Projects (E&P) division of Electrotherm is a leading designer and manufacturer of Induction
Melting Furnaces, Electric Arc Furnaces, Metal Refining Konverters (AOD), Ladle Refining Furnaces,
Continuous Casting Machine, Power Distribution and Furnace Transformers and other equipment for Steel
Plants and Foundries, and Induction Heating and Hardening Machines for Heat Treatment Shops. The E&P
division is a customer centric organization, delivering total solutions, and is particularly renowned for providing
end-to-end solutions for steel melt shops, supplying sturdy and highly efficient plant and machinery, and
rendering outstanding pre and post sales services to its customers around the world. Due to high level expertise
and vast experience, Electrotherm (E&P) is the most preferred mini steel plant maker up to 0.5 million ton per
year capacity through various alternative routes. Moreover, Electrotherm (E&P) is the only Indian company
having CE marking for its Induction Furnaces, LRF and MRK, certified by UL Laboratories, USA.

The E&P division of Electrotherm has supplied over 3450

Induction Furnaces for various applications, viz. 550
furnaces for steel billet making plants, 1200 furnaces for
steel ingot making, 1400 furnaces for ferrous and non-
ferrous foundries and around 300 equipment for heat-
treatment applications. It has exported over 550 furnaces
to 38 countries around the world. Besides, it has made
several mini steel plants overseas on turnkey basis in
countries like Turkey, Iran, Iraq, Saudi Arabia, Pakistan,
Bangladesh and some African countries for capacities
ranging from 50,000 TPA to 350,000 TPA.

The Electric Arc Furnaces of Electrotherm are designed

and manufactured under technical collaboration with a
European company. The Gas based Direct Reduced Iron
(DRI) plants up to 0.2 MTPA capacity are manufactured
under strategic alliance with Tenova-Hylsamex, the world's leading designer and manufacturer of Gas based
DRI Plants, wherein the critical parts are supplied directly by Tenova-Hylsamex. Rest of the major machineries,
including Coal based DRI plants and power plant utilizing waste heat generated by rotary Kilns, are designed
and manufactured by in-house expertise and facilities at Electrotherm.

Being a customer centric organization with focus on meeting changing needs of its customers, Electrotherm has
full-fledged Research & Development Centre at its Corporate Office & Works in Ahmedabad with state of the art
manufacturing set up and modern office complex. It also has another R&D centre at Coimbatore supported by
some leading Engineering & Research Institutes for driving technology and product innovation for Power
Electronics.

Front Inner Back Inner

Coreless Induction Melting Furnace Steel Frame Furnace
Cross Section of Steel Frame Furnace From 1 Ton to 50 Ton

Induction Coil
Electrotherm’s induction furnace coil is made of electrolytic
grade extruded copper in rectangular sections having high wall
thickness and integrated passage for water flow. Special ‘Step’
coil is designed for maximum electrical efficiency and
sturdiness. Optimum inter-turn spacing is maintained by FRP
spacers between the turns and FRP flats on coil periphery.
Bottom stainless steel cooling coils maintain uniform
temperature gradient throughout the refractory, prevent over
heating and enhance refractory life. Large magnetic shunts
(Yokes) cover around 70% of coil periphery which minimizes
stray loss and improve efficiency besides providing rigidity to
coil cradle assembly.

1. Top-Block Assembly Special Attributes :

2. Heavily extruded rectangular section coil ensures Sturdy design for rugged steel plant application.
highest efficiency, strength and rigidity.
Superior coil winding technique to ensure high
3. Yokes made out of CRGO Steel bolted through M.S. efficiency and uniform lining cooling.
Channel to Support the power coil, guide the stray Top Ring
magnetic flux outside the coil and improve coil power Large magnetic shunts cover around 70% of coil The top refractory blocks are made out of sintered castable
factor periphery which refractory with stainless steel fibre for reinforcement and bolted
4. Bottom cooling coils evenly distribute t e m p e r a t u r e • reduces stray losses with the top ring for easy dismantling of top block without
gradients through out the refractory to prevent • improves efficiency breaking. Blocks can be replaced in parts.
overheating and extend refractory life • prevents over heating of other steel parts
• provides rigidity to coil assembly which supports
5. Bottom Block Assembly. the refractory

6. Lining Failure detection Probe Bottom stainless steel cooling coil distribute
temperature uniformly throughout the refractory to
7. Former prevent overheating and enhances refractory life.

8. Fume Extraction Ring (Optional) Special high voltage insulation to prevent inter-turn
sparking.

Thick farade shield prevents stray losses and directs Bottom Ring
Optional Features : energy in the charge.
The bottom refractory blocks are made out of refractory cement
• Lining push-out arrangement Free board above coil facilitates easy charging and high alumina blocks which give longer life as compared to
• Fume extraction ring without affecting performance. the bottom made out of only castable material.
• Load cell arrangement
• Hydraulically operated lid Easy maintenance and accessibility and minimum
down time.

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SCADA Based Furnace Automation Solid State Power Supply Unit

Electrotherm has acquired word-wide recognition to design, develop and manufacture state-of-the-art
Induction Melting Systems. Electrotherm offers medium frequency solid state power supply units from 3 kW
to 28000 kW catering to the needs of steel industry, foundries and heat-treatment Industry.

Electrotherm’s medium frequency power supply unit consists of 6-pulse / 12-pulse / 24-pulse rectifier, DC
choke, current fed inverter, capacitor bank, furnace selector switches and DM water circulation unit.

Compact and yet spacious layout of converter and inverter assembly facilitates ease of maintenance. 12-
pulse and 24-pulse rectifier reduces total harmonic distortion.

The current fed invertor has the highest efficiency as current through the thyristor is very low. It uses less
variety and numbers of power components ensuring long life of components, easy maintenance and low
down time. The controlled rectifier acts as fast tripping electronic device for maximum safety of high speed
 Supervisory Control and Data Acquisition (SCADA) System for Induction Furnace with
control circuits and facilitates accurate power control at any desired level.
option of interfacing with Central Plant Automation
 Display of important electrical parameters like power, current, voltage, frequency, KVA,
KVAr, power factor, power consumption, etc.
 Display of water circuit parameters like temperature, pressure, flow etc. Special Attributes: Optional
 Display of metal weight and metal temperature
 Display of interlocks and safety, fault diagnosis and alarm generation • Highest efficiency of power supply unit up to 97%. • PLC based control with touch screen MMI.
 Automatic control of KVA demand by intelligent program on instantaneous basis through • Full power from start to end. • Ramp-up and Ramp-down to avoid sudden
• Designed for fastest melting at lowest cost. loading / unloading of power supply unit.
furnace power regulation
• Best quality and liberally rated components. • Auto Sintering.
 Power optimization by automatic connection and disconnection of medium frequency • Energy Optimization.
• Reliable multiple protection.
capacitors depending on load and lining condition • Facility to interface with computer for remote
• Efficient and reliable closed-loop DM water cooling
 Data storage, logging, trending and retrieval of historical data system. monitoring, operation and data logging.
 Remote web access through internet from any location in the world • Earth leakage protection for operator safety.
 Fibre optic network for faster and noise-free communication • Built-in test facility.
• Safe and Convenient layout.
• Operate even under wide voltage fluctuation.
• Power factor up to 0.98.
• Less and easy maintenance.
• Suitable for operation on captive power plant.

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