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In the last class you have learnt about

Electric Arc Heating
Types of Arc Furnaces

Direct

Indirect

Applications of Direct and Indirect Arc Furnaces

Objectives
On completion of this topic you would be able to know
Operation of Induction Heating
Core type and Coreless Induction Heating

Induction Heating
Induction heating is also known as high frequency heating
Induction heating process makes use of currents. induced by
electromagnetic action in the material to be heated
It uses transformer principle
Conversion of electromagnetic energy into heat energy takes
place in the material, it self
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Induction Heating
Heat transfer by high frequency heating is as much as
10,000 W/cm2
The high frequency heating can be applied mainly to two
classes of materials firstly, conducting materials &
secondary insulating materials
Heating of first type of materials is called induction
heating and heating of Second type of materials is
dielectric heating
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Induction furnaces are further classified as

i) Core type induction furnace
ii) Coreless induction furnace

Core Type Induction Heating

Fig.1

9EE605A.17to18

Fig 1 shows a core type

induction surface
The Core type furnace
is essentially a
transformer
Primary side is
connected to supply
Secondary side contains
charge (materials) in
iron core annular hearth

The charge is
magnetically coupled
to the primary by an
iron core

The magnetic coupling

between primary and
secondary is very poor
resulting in high
leakage current and a
low power
factor. For this reason
the furnace is
operated at low
frequencies of the
order of 10Hz or so
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Hence it is called low

frequency furnace i.e.,
10Hz
The low frequency
necessiates an
additional MG set or
frequency converter
To start the furnace
Molten metal is
poured in the annular
hearth before start
10

Otherwise there is no
material and the
secondary side is
open and no current
will be induced
Hence no heating will
take place
This is convenient
where the furnace is
to be used for melting
different types of
charges
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If the current density

exceeds about
5A/mm2 the pinch
effect due to electro
magnetic forces, may
cause a complete
interruption of the
secondary circuit
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Disadvantages

A crucible of inconvenient shape is required

Low power factor due to poor magnetic

A M.G. or frequency converter is required

It is bulky due to the presence of core

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Ajax Wyatt Vertical Core Furnace

Fig.2
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Fig 2 shows Ajax Wyatt

Vertical Core Furnace
It is an improvement
over the core type
induction furnace
The magnetic coupling
in this furnace is better
than core type furnace
Leakage reactance is
comparatively low and
frequency is high, hence
it is high frequency
furnace

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It employs vertical
crucible instead of
horizontal
The system avoids the
pinch effect due to
the weight of the
charge in the main
body of the crucible
The circulation of
Molten metal takes
place round the V
portion by convection
currents
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Inside the furnace is

lined depending upon
the charge
The top of the furnace
is covered with an
insulated cover which
can be removed for
charging
Hydraulic arrangements
are usually made for
tilting the furnace to
remove the molten
metal
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Indirect Core Type Induction Furnace

Fig.3

18

9EE605A.17to18

This type of furnace is

used for heat
treatment of metals
The wall of the
container forms the
secondary winding
Iron core links the
primary as well as
secondary

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Heat produced in the

secondary due to
induced current is
transmitted to the
charge by radiation
A detachable
magnetic circuit made
of a special alloy is
kept inside the
chamber
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The alloy will loose

magnetic properties
at a particular
temperature and are
regained when it cools
down
On reaching the
critical temperature
the reluctance of the
alloy increases and
here by decreasing
induction effect
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Critical temperature
varying 4000c to
10000c can be
employed for heating
different materials

The furnace operates

at a PF of around 0.8

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Coreless Induction Heating

REFRACTORY
CRUCIBLE

PRIMARY
WINDING

CHARGE

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The coreless
induction furnace
operates on the
principle of an electric
transformer
If there is no core, the
flux density will be
low
For compensating the
low flux density, the
primary supply should
have high frequency

9EE605A.17to18

REFRACTORY
CRUCIBLE

PRIMARY
WINDING

CHARGE

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REFRACTORY
CRUCIBLE

The furnace consists

of a refractory or
ceramic crucible
cylindrical in shape
enclosed with in a coil
which forms the
primary of a
transformer
The furnace also may
have a conducting or
non-conducting
container
9EE605A.17to18

PRIMARY
WINDING

CHARGE

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When high frequency

REFRACTORY
CRUCIBLE

of 500 of 1000 Hz
supply is given to
primary windings

PRIMARY
WINDING

The eddy currents are

set up in charge or

CHARGE

container by
transformer action

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There currents heat

the charge to melting
point and they also set
up the electromagnetic
force which produce a
stirring action to the
charge
The furnace becomes
relatively light in
weight and can be
easily tilted for pouring
the metal
9EE605A.17to18

REFRACTORY
CRUCIBLE

PRIMARY
WINDING

CHARGE

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Advantages

High speed of heating

Well suited for intermittent operation

High quality of product

Low operating cost

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Industrial applications
Used in foundries for melting and refining
brass, zinc and other non-ferrous metals
Used for heat treatment of metals

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Industrial applications

These are used for steel production

These are used for melting of non-ferrous metals

like brass , copper, aluminium along with various
alloys of these elements

The production of carbon from ferrous alloys

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Comparison Between High Frequency And

Power Frequency Furnaces
S.
No.
1

High Frequency

Power frequency

Frequency converter is
necessary

Not required.

More energy required i.e, 20%

to 30% for same rating.

Less energy required.

Maintenance cost is more

Less

Less turbulence and stirring

effect

More

Large scrap melts with more

oxidation loss.

Large scrap melts with less

oxidation loss.

No special starting procedure is

required

Special starting procedure is

required.

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Comparison Between High Frequency And Power

Frequency Furnaces
Contd..
7

Low capacity (few kgs. To 15

tons) furnaces are used

Large capacity (above 1

tone)

Initial cost is more

Less cost

High frequency (500 to 1000 Hz) Only 50Hz.

10

Well suited for intermittent

operation of different alloys.

11

Care should be taken against

stray field

12

Overall efficiency is low.

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Well suited for long

production schedules of one
alloy.
Negligible.

Overall efficient is more.

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In this class we have discussed about

Principle and operation of induction heating
Core type induction heating
Core less induction heating

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1.Coreless induction furnace operate on the

principle of
a.
Transformer
b.
Induction motor
c.
Generator
d.
Motor

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Frequently Asked Questions

1) What is induction heating ?
2) Describe briefly with a neat sketch the core type induction
furnace
3) Explain the vertical core type of furnace (Ajax Wyatt
furnace) with a neat diagram
4) Explain the construction and operation of coreless induction
furnace
5) Explain the indirect core type induction furnace with sketch

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THANK YOU

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