Drying and Preheating Systems

What Benefits Does Charge Preheating Offer?

Conveyorized preheating is the introduction of significant heat into furnace charge material prior its to placement into the furnace. Conveyorized charge preheating systems are not just auxiliary pieces of charging equipment. They are a tool capable of providing production advantages as well as economic benefits.

1. Safer Work Environment

Charging wet or oily scrap into a molten metal bath can cause an unwanted water/molten metal interaction. Preheating removes moisture from scrap material prior to furnace charging and helps reduce this danger.

2. Increased Melt Rate

With preheating steel, a large part of the melt energy is introduced into the metal outside of the electric arc furnace. Preheating scrap material to 1200° F can increase induction furnace melt rates by as much as 20%.

3. Reduced Electric Power Consumption

Preheating to 1200° F will reduce power consumed by furnace from between 90 and 100 kWh/ton of metal melted. The basis for reduced electric power consumption is that whenever heat is introduced into the scrap charge, an equal amount of heat input does not have to be supplied by the melting furnace.

4. Reduced Melting Cost

Replacement of between 80 and 100 kWh/ton at the melting furnace with 574 cubic feet of natural gas used by the preheat system to increase scrap temperature to 1200° F offers significant savings per ton of metal melted. Reduced furnace energy requirements and melt times will also reduce refractory wear and electrode consumption.

5. Emissions Control

Furnace charge that is contaminated with oil, rubber, dirt and other unwanted material can cause troublesome pollution and slag buildup. Conveyorized preheat systems produces a high percentage burn off of combustible material within the heat zone. Preheating systems, coupled with proper emission control systems, help to ensure you stay MACT compliant. A high percentage of dirt can also be removed utilizing a perforated secondary dirt removal pan.