New IGBT switchgear system and modern water recooler provide key advantages.
MAFO Systemtechnik AG of Teisendorf had been using two OTTO JUNKER triple-frequency coreless induction furnaces for melting gray iron successfully since the mid-1960s.
In early 2011, the company entered into detailed discussions with OTTO JUNKER experts to review the options for modernizing its furnace technology, and a blueprint was developed jointly. The revamping project has by now been concluded and the upgraded plant is back in fullscale production service.
The upgrade involved the installation of an IGBT switchgear system embodying DUOMELT technology for power supply to the two furnaces having a capacity of 500 and 250 kg, respectively, plus the installation of a glycol-free water recooling system. For plant control purposes, an advanced PLC was fitted and an operating and control cabinet featuring a PC and an integrated monitor.
All other equipment, and especially the coreless induction furnaces, remained unchanged in their entirety.
The advantages obtained by this upgrade can be summarized as follows:
- substantial energy savings of more than 20 %, with corresponding gain in melting capacity
- increased plant reliability and safety in operation
- reduced idling times and infinitely variable power control
Compared with the potential installation of an all-new melting plant, the upgrade involved much lower investment costs and was completed in less time.
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