© A

BP

In

du

ctio

n S

yste

ms G

mb

H 1

ABP InductionSystems

Sustainable Technology

Middle East Foundry Summit

Dubai, July 20th, 2016

Franz SchröderExecutive Vice President

ABP INDUCTION – HISTORY

• ABP Induction; long tradition within the induction technology sectorASEA, BBC (later ABB).

The employees and the intellectual property of this traditional business areintegrated in ABP Induction, the legal successor of ASEA and BBC

Seite 3

ABP Segments

ABP Segments

ServiceHeaterSteelMelting

Foundries ForgingSteel plant

Heating

Seite 4

ABP Segments

ABP Segments

ServiceHeaterSteelMelting

Foundries ForgingSteel plant

Heating

Agenda

1.Company introduction

2.Foundry equipment

3.Melting of steel scrap in induction furnaces

Induction furnace system in medium frequency technology

1. Introduction

Mains transformer

Power switch

Medium frequency converter

Capacitor bank for compensation

Crucible induction furnace

Induction furnace system

Mains

108 year ABP Inductions furnace tradition

1903: Gysinge Bruk / Sweden:1. Channel furnace with ASEA-power supply went into operation(1,8 t , 300 kW ) with 700 kWh/t

A TRADITION OF INNOVATION

• 112th year anniversary of 1st practically working inductionMelting System (1.8MT/300kW)built by ASEA

• 43rd year automated Pouring Technology introduced duringGIFA 1967 by Brown Boveri

• 44th year developed first solid state power supply in 1968

• Sustainable Technology

• 42 MW 70 t corelessinduction furnace- 2012

The Innovation Continues!

Our strategy:Sustainability and sustainable Technology

Sustainability

E c

o l o

g y

E c

o n

o m

y

S o

c i o

l o

g y

= Ecology, Economy and Sociology in Harmony

Strategy directed into the world market

and into

Focus Ecology as a part of sustainable Technology

� Energy efficiency

Energy efficient products - furnace, power supply, transformer, pumpstand

Energy efficient process - Twin-Power, Energy efficient ladle size, exhaust system worksonly when cover / hood is open, Pouring furnaces instead ofopen ladle

� Reduced CO2 – Emissions

Ecotop hood solution

� Productdesign without usage of environmental critical material

No Asbestos, no Glycol, no PCB

� Recycling, regeneration

chip melting, waste heat utilization

Focus Economy as a part of sustainable Technology

� Long life time - design

The equipment will support 2 generations of foundrymen

Solid stable steel construction, long coil life time

� Reliable technology

maintenance friendly design, low spare part consumption

strong local service network

� Low operational cost

good lining life caused by rigid coil design

low labour cost based on integrated automation

Focus Sociology as a part of sustainable Technology

� Workplace layout in meltshops

Elimination of hazardous work places, automated charging systems

Integrated safety systems

� Continous training to transfer know how

Education of workers

ABP Vision :„People free“ furnace plattform

2015: appr. 450 employees in 11 ABP country organizations

ABP Induction

ABP HQ DORTMUND/GERMANY

Admin Offices

Mech. BldgElect. Bldg

Approx. 200 Employees

Mechanical Factory ( Coil, yokes, assembly )

Focus: High quality made in ABP

Electric shop

Crucible induction furnaces for melting and holding Iron, Steel and Non-Ferrous metals( Aluminum, Copper, Zinc, Magnesium )

Furnace size 0.25 … 0,75 t 1 t … 6t 5t … 60 t 10t .. 70 t

Crucible Type Smart FS FS IFM LFS

Power supply IBGT Thyristor250 kW …4 MW 1 MW … 42 MW Single Power / Twin Power

Products for melt shop systems

medium frequency (MF) Mains/line frequency (LF)

Energy consumption 520 - 580 kWh/t 770 – 1.000 kWh/t

Power density 600 - 1000 kW/t 150 – 300 kW/t

Melt rates 300 % 100 %

Melt conditions Batch type Heel

Flexibility High Low

Changing of alloy Good Bad

Lining live per molten t High Low

5 т12 т

Comparison between LF and MF

MF LF

Melting of chips Low heel High heel

Material density in the furnace High Low

Maintenance Low, no mechanical wear High, mechanical switches

Comparison between MF and LF

12 т5 т

2. MF induction furnace, type IFM/FSDesign features

� Open design

� Easy maintenance

� Better visual control

� Less noise emission

� Exchangeable furnace head

� Upper concrete ring as separate element

� Fixing coil in axial direction with adjustable pressure

� Pouring spout located in tilting axis

� No moving melt stream

2. MF induction furnaceABP coil insulation

� Liquid metal � Refractory � Grouting

� Water chamber

� Isoplan

� Silica cloth

� Cupper profile

� Mikanit foil

� Segmental insulation

� Your advantages:

� Better coil protection

� Better conductivity of evaporation & humidity

� Easy to handle

3. Safety:Hedgehog coil

Coil

Segments

Grouting

Mekanit

foil

Refractory

material

Liquid

metal

Hedgehog

sensor

1. Introduction:Available Applications

Designed for melting and holding of ferrous and nonferrous metals for FS furnace types

Furnace capacity: 1.000 kg – 6.000 kg (ferrous)

Power rating: 250 kW – 4.800 MW

2. MF induction furnace, type IFM:ABP yokes

� Ceramic insulation between coil and yoke

� NO ARCING BETWEEN COIL AND YOKE

� Simple water cooling

� Easy yoke adjustment

� Yokes can be replaced without removing coil

� Uniform yoke pressure minimizes refractory stress

� Fixed in 2 points

Aluminium yokes:

� high strength, noise damping

� high power density application

1. Introduction:Available Applications

� Designed for melting and holding of ferrous and nonferrous metals for IFM furnace types

� Furnace capacity: 8.000 kg – 65.000 kg (ferrous)

� Power rating: 3000 kW – 42.000 MW

5. Power supply:two furnaces – one power supply

-

-

~

~

Furnace current

switches

TWIN-POWER

-~

100 %

100 %

0 %

0 %

Transformer

Rectifier for 100 % power

Smoothing choke

Inverter

Capacitor bank

Mechanical furnacecurrent switch

Furnaces 1 & 2

Transformer

Rectifier for 100 % power

Smoothing choke

Furnaces 1 & 2

Capacitor bank 1 & 2each for 100 % power

Inverter for flexiblepower distribution

Seite 28

PLC Based Melt Processor

Prodapt Advanced

Siemens S7-1500

Data Storage on SD-Card or Fileserver

Crucible wear level diagram

Automatic melting - Cold Start – Sintering - Charge energy mode

Long term trend curves

Seite 29

PC Based Melt Processor

Prodapt Enterprise

In comparison to PLC Based Prodapt Advanced:

Storage in SQL Database

variable dynamic configuration of trend curves

Prodapt Enterprise with openFIS

Robust melt processor in PLC without outage

Long term storage in SQL openFIS Database

Linkage and process improvement auf complete plant

ABP best solution:

Seite 30

ABP-Foundry information system openFIS

open – our understanding

Data exchanged based on well known protocols TCP / IP and OPC-UA

Abstraction of the whole plant by driver model

Partner could integrate their controls with own branding and style

Open software solution for monitoring and controling all plant sections in your foundry

Documentation of your quality within one system for the entire production line

Information is available wherever you are

Power supply: Control unit

Digital Inverter Control Unit

Customer Module

performs all controlling, regulating and protecting functions of the converter

Completely designed in programming technology

System-related data stored as parameters

No hardware to be matched

Internal self-test

Remote diagnosis via Teleservice

� back up control module in case of PRODAPT® failure

� digital read out of:

� Power

� Voltage

� frequency

Exhaust systems: ABP ECOTOP hood

Low height

Two fixing points with furnace platform

INCREASED STABILITYTWO TILTING POINTS FOR SMOOTH TILTINGHigh exhaust capability

No hydraulic cylinders uncovered on platform

NO RISK FOR OPERATORSAVOIDING DAMAGES TO CYLINDERS BY SPLASHESFree platform while forward tilting

Free view and access to the crucible

Easy to operate

4. Exhaust systems:ABP ECOTOP® hood

� Tiltable in two directions

� Forwards for sample taking, temperature measurement and charging

� Backwards for crucible push-out and refilling with liquid iron

4. Exhaust systems:ABP ECOTOP® hood for back-tilting furnace

Telescope system for back-tilting furnaces

Products for melt shop system continued….

Channel induction furnaces for holding Iron and melting and holding Non-Ferrous metals( Aluminum, Copper, Zinc )

Application Holding Iron Melting Al Melting Cu Melting Zn

Furnace size 13 … 135 t 8 t … 70 t 6t … 180 t 10t .. 300 t

Type LFR / IRT RAS RKS RZS

Inductor: 500 kW …3 MW 300 kW ..1,3 MW 200 ..2,5 MW 300 … 800 kW

Pouring systems

Products for pouring systems

Heated and unheated furnaces for automated pouring of iron and copper alloys with Laserpour-Control

Heated P System Unheated P System Open ladle System

Furnace size 2,9 … 25 t 2,4 t … 4,5 t 1 - 3 t

Type Presspour OCC Presspour OCU UPT

Inductor: 130 kW …1000 kW

3.1 PRESSPOUR® OCC:Design Features

Stopper system Level scanning in pour siphon

Pour siphon

Pressurized vessel

Fill siphon

Base frame for long and cross travel

Mould

Channel inductor

3.1 PRESSPOUR® OCC:with crucible inductor

� High flexibility when changing the iron grade

� Holding only by means of gas burner during short standstills

� Possibility of complete emptying

� Easy separation from furnace vessel

� Constant power over the full crucible campaign

Unheated pouring ladleUPT

� High flexibility when changing the iron grade

� Holding only by means of gas burner during short standstills

� Possibility of complete emptying/ No heel

Unheated pouring ladleUPT

Messevideo UPT Castexpo 2016 Ver4.AVI

6. Automatic pouring:OPTIPOUR®

Laser Beam

Measurement range

Pouring stream

� OPTIPOUR® - Laser

� For high speed DISA with very small sprue cup

� OPTIPOUR® - Linelaser

� For small sprue cups

� For high speed DISA with small sprue cups

� OPTIPOUR® - Camera

� For flask lines with large sprue cup

6. Automatic pouring:OPTIPOUR® - Camera

OPTIPOUR® - Camera

Measurement range

Pouring stream

� Measuring and control area is outside of the pouring stream

� Diameter of the sprue cup is 3x diameter of pouring stream

6. Automatic pouring: OPTIPOUR® Visualization

� Furnace visualization

� Electrical system (heated pouring furnace)

� Cooling System

� Pressure delivery system

� Hydraulic system

� Inoculation system

� Positioning

Furnace Control System:Furnace visualization

7. Process control system:PRODAPT-H/P – Inductor charts

2

1

3

4

2

1 3

4

Service

Spare Service Preventive Training Consulting Coil and Retrofitparts on Maintenance furnace

demand repair

for Foundries and Forming plants

Agenda

1.Company introduction

2.Foundry equipment

3.Melting of steel scrap in induction furnaces

EIF vs. EAF

� Restrictions:� Selected scrap� Special lining requirements

� Available units:� MF. furnace from 300 Kg to 65t capacity� Electrical power supply from 250 kW to 42.000 kW per unit

� Advantages IF:� No high demand on el. Net� Possibility of using Generators� Operating and maintenance friendly melting Machine � Lower space requirement� Lower expenditure for environment conformity (dust, noise…)� High metal yield particular for Fe-alloys (Cr, Ni, Mn…etc)� No electrode cost

� Economical production:� Till 500 T t/year economical� Suitable for net reasons until 800 T t/a� High grade steel products

EIF vs. EAF: 1t LM Costs for 25t

IF EAF IF – EAF

Raw Material Price 313,00 310,00 3,00

Power 18,70 16,10 2,60

Refractory 6,00 1,60 4,40

Electrode 0,00 9,70 -9,70

Fluxes 0,00 4,70 -4,70

Oxygen 0,00 2,30 -2,30

Other gases 0,07 0,11 -0,04

Temp. Measuring 0,07 0,03 0,04

Samples 0,08 0,03 0,05

Alloy materials 5,50 13,40 -7,90

Total effect 343,42 357,97 14,55

� Saving of approx.14 $ for every IF ton produced� Consumption statistic for EIF & EAF in US $ / Feb. 2012

EIF vs. EAF: 1t LM Costs for 25t

IF EAF IF – EAF

Raw Material Price 313,00 310,00 3,00

Power 18,70 16,10 2,60

Refractory 6,00 1,60 4,40

Electrode 0,00 9,70 -9,70

Fluxes 0,00 4,70 -4,70

Oxygen 0,00 2,30 -2,30

Other gases 0,07 0,11 -0,04

Temp. Measuring 0,07 0,03 0,04

Samples 0,08 0,03 0,05

Alloy materials 5,50 13,40 -7,90

Total effect 343,42 357,97 14,55

� Saving of approx.14 $ for every IF ton produced� Consumption statistic for EIF & EAF in US $ / Feb. 2012

General set up of an IF System:

Tisco North ( 6x 65t; 3x 42MW)

ABP IF System:

65t Furnace Capacity

ABP Power supply:

POWER SUPPLY UP TO 42 MW

With the latest development in the IF technology and the references already realized a yearly production up to 450.000 t/a via ONE IF-system is possible

IF Lines: Low Carbon Steel

Induction Furnace

Charging

CarCrane

LRF

Caster

⇒ OEM / KSA

� 300.000 t/a of Billet

� 4 x 25t IF crucibles

� 2 x 14 MW

⇒ Steel plant INDIA

� 120.000 t/a of Billet

� 2 x 30t IF crucibles

� 1 x 16 MW

IF Lines: Low Carbon Steel

Induction Furnace

Charging

CarCrane

LRF

Caster

OBS

⇒ OEM / Africa

� 300.000 t/a of Billet

� 3 x 25t IF crucibles

� 2 x 14 MW

IF Lines: Low Carbon Steel

Induction Furnace

Charging

LRF

Caster

CarCrane

EAF

⇒ Steel plant in KSA

� 150.000 t/a of Billet

� 2 x 24t IF crucibles

� 1 x 16 MW

� 80t EAF

IF Lines: Steel Alloying

Induction Furnace

Charging

CarCrane

LRF

Caster

AOD

⇒ Stainless steel plant India

� 300.000 t/a

� Stainless Steel Product

� 3 x 25t IF crucibles

� 3 x 18 MW

Stainless Steel plant / INDIA – Melt shop Layout

3 x 25t IF 3 x 18 MW SP

3 x 25t IF3 x 18 MW SP

IF Lines: Steel Alloying

Induction Furnace

Charging

CarCrane

LRF

Caster

AOD

EAF / BF

⇒ Ferro Alloy Plant CHINA

� BF + 30t IF

� 2 x 30t IF crucibles

� 1 x 25 MW

⇒ Ferro Alloy Plant CHINA

� BF & EAF 160t

� 6 x 65t IF crucibles

� 3 x 42 MW

⇒ ca. 1.000.000 t/a

� Modest requirements regarding utility supply (electricity)� Low investment and operating cost� Easy to operate and maintenance friendly� Small space requirements� High metal yield particular for ferro alloys (Cr, Mn, Mb)� No electrode cost� Short return of investment

Advantages of induction furnaces

Long standing customer relationships

� Long standing customer relationship with several large & medium foundries ( GM, DC, Volvo, Ford, Toyota, Hyundai, Honda, Nissan, ThyssenKrupp, Hitachi) all over the world with experienced key account managers

� Strong local service in all key markets we serve

THANK YOU FOR YOUR KIND ATTENTION !