Figs. 2d-2e. The two batch melting systems achieve similar pour rates as the heel melting systems with significantly lower kW demand.
with a utilization rate of 65%. System 2 also is a mains frequency heel melt- ing system, but it butterflies between two furnaces allowing it to increase utilization and decrease demand. System 3 is a medium frequency heel melting operation. Medium frequency systems allow for smaller capacity furnaces, which reduce holding energy and direct more energy into the melt. System 3 operates at a total kW demand of 4,000. With a melt rate of 8.6 tons per hour, using a power utilization of 75%, it is able to achieve a pour rate of 6.5 tons per hour. The power density is 400 kW per ton, substan- tially higher than Systems 1 and 2. System 4 is a medium frequency
batch melting system. Te inherent efficiencies in batch melting reduces demand while maintaining similar production. Te higher efficiency combined with the higher utilization offered by the multi-output power system reduces demand to 3,000 kW. Medium frequency increases the power density and reduces the size of the furnaces. Tis is a batch butterfly operation, where one furnace is melting while the other is either off or at hold for melt preparation and pouring. Once the first furnace has completed its melt cycle, the melt process begins on the second furnace resulting in a power supply utilization of 95%. Compared to the previous examples, System 4 substantially reduces demand while still maintaining a similar pour rate. System 5 is another medium
frequency batch melting operation, but it features a multi-output system powering three furnaces simultane- ously. Such a system can be used with one furnace melting, the second in melt preparation, and the third furnace pouring. Tis increases the time allowed for pouring and other
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February 2015 MODERN CASTING | 49
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