Electrotherm (India) Limited

Ahmedabad,  Gujarat 
India
http://www.electrotherment.com
  • Booth: 2813


The most preferred Steel Plant maker up to 1 MTPA

Electrotherm (India) was established in1983 for manufacturing Induction Melting Furnaces for steelmaking application  based on openness for ideas, eagerness to innovate, supplemented by in-house research & development and focus on customer-centric product and process development. Electrotherm kept designing and manufacturing larger capacities furnaces, suitable refining equipment like ladle furnaces and metal refining konverters, high speed continuous casting machine and various gadgets for improving productivity and quality of steel produced. It incorporated mechanized charging system and high-end plant automation with SCADA and DCS for reducing dependency on manpower, introduced proper fume capturing and de-dusting system for making steel plant through Induction Furnace route a cleaner affair.

Brands: Electrotherm, Bullet Caster, DiFOC,


 Products

  • Induction Melting Furnace
    Electrotherm E&T provides induction furnace for ferrous metals (iron & steel) that gives you superior performance & minimizes the heat loss during the process. Induction furnaces from 500 Kg to 80 Tons....

  • Electrotherm medium frequency power supplies with power ratings from 5 KW to 36,000 KW and frequency range of 100 Hz to 10,000 Hz have been work horses across the foundries and steel melting plants for their robust design, state of the art technology, efficiency and excellent reliability.

    These power supplies adopt compact design and yet are spacious enough to facilitate easier maintenance. The inverter SCRs are well protected by break-over diodes. The current fed inverter design results in higher inverter efficiency compared to other designs. Less number of power components and component types makes the system very simple. The fast electronic tripping devices protect the system in the event of short circuits. The efficient DC Reactor ensures safety of power components.

    DiFOC

    Latest State-of-the-art Digital Inverter technology through Fibre Optic Communication (DiFOC) systems in power supply units up to 36,000 KW

    • More than 150 efficient customers across the world have already adopted this latest technological innovation for their steelmaking plants
    • Most of the reputed steel makers globally have extended warm welcome to DiFOC® not only for new plants but even for replacing their existing furnaces of other make with DiFOC® based DTi® model
    • Make your melt shop GO DiFOC®  

    Steel Frame Induction Furnace

    • ET Steel frame melting furnaces are available in capacities ranging from 500 Kg to 60 Tons.
    • These furnaces are ruggedly built with heavy structural steel for trouble free operation under harsh melt shop conditions.
    • Thick walled rectangular coil sections are used to minimize coil losses. The higher coil efficiency ensures energy savings and higher productivity.
    • Special coil insulation prevents inter turn sparking.
    • Insulated furnace lid is provided to reduce heat loss through radiation.
    • Fume extraction ring / Fume extraction hood provided to capture smoke and fumes.
    • Coil supports maintain inter turn gap and enhance the rigidity of The coil assembly.
  • Continuous Casting Machine
    Electrotherm took initiative to develop Modular and Compact Billet Casting Technology to meet needs of existing ingot making units willing to migrate to billet making and new mini steel plants....

  • It is suitable for casting heat size as small as 5 ton and modules are available for casting section from 80 mm x 80 mm to 150 mm x 150 mm reduced operating cost and casters that are simple and safer to operate.

    • Complete “Melt to Cast Solutions”
    • Minimum transition time from existing ingot making to billet plant making almost without affecting existing plant productivity
    • The required casting platform size is 6 m x 9 m for single strand and suitable for existing ingot making plants
    • Flexibility of operating each strand independently for optimized caster usage according to availability of molten metal
    • Flexible configuration with possibility of up gradation and expansion by adding modules
  • Ladle Refining Furnace
    Electrotherm Refining Furnace (ERF™) is specially designed metallurgical equipment to de-phosphorize steel besides preforming other processes as done by LRF....

  • ELDFOS™ Process

    Electrotherm Refining Furnace with ELdFOS process is used for the following:

    • De-phosphization of steel by as much as 50 points
    • De-sulphurization of steel by as much as 50 points
    • Removal of metallic inclusions to make clean steel
    • Reduction of gas content by feeding Aluminium / CaSi wire to produce “killed”steel. Oxygen level of 30 ppm can be obtained
    • Homogenization of temperature and composition of  molten steel by gentle stirring
    • Degassing treatment of steel to achieve low gas content (oxygen, nitrogen and hydrogen)
    • Holding of molten steel while sustaining temperature / superheating for sequencing on the CCM

    Special Attributes

    • Specially designed system for removal of slag with phosphorus.
    • Use of Servo  valves and hydraulic cylinders for electrode  regulation provides very precise control ensuring electrode consumption as low as 0.3 -0.4 kg/ ton
    • SCADA based PLC control for electrode regulation system provides impedance control, anti-resonant control, auto deadband adjustment, etc., ensuring precise control of power and virtually constant power from input
    • Reduces flicker and harmonics and improves power factor up to 0.90 even without any compensation
    • Ease in operation due to stationary electrode arms and moving ladle car, which is maintenance free and faster for taking sequence heat.
    • High level automation through PLC. Once the process parameters are set, ERF operates automatically with high level of consistency
    • Rate of superheating after stabilization of temperature in the ladle can be up to 4.50C/min
    • SCADA based controls for gas purging system, with imported flow meter, pressure control valves and flow control valves for Argon purging minimizing the use of argon gas and achieving uniform temperature gradient through molten steel
  • Coal Based Rotary Kiln for Direct Reduced Iron
    Solid state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI)....

  • Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, 500 TPD)

    ince DRI is produced by removing oxygen from iron ore, its structure is just like sponge with a network of connecting pores. These pores results in a large internal surface area which is about 10,000 times greater than the internal surface area of solid iron. Due to this, DRI is also known as Sponge Iron.

    Sponge Iron is gaining more popularity because of the following reasons…

    • Scrap is getting scarcer by the day
    • Quality and composition variations are compelling
    • Tramp elements coupled with Sulphur and Phosphorus hamper the end product quality of sale-able steel
    • Uniform known composition, size and high bulk density compared to scrap
    • Low Capex and gestation period compared to Gas based DRI plant
    • It can be produced with non-coking coal and poor quality of coal that is available in abundance
    • Capability of forming protective layer of foamy slag in the bath
    • Potential of sensible heat recovery from waste gases
    • Maintenance of Sulphur level in steel by its removal during Sponge iron production**
    • Lower refining requirements of steel produced
    • It allows steelmaking to dilute metallic residuals in scrap

    Main Components of the Rotary Kiln are…

    1. Raw Material Handling & Storage
    2. Rotary Kiln
    3. Rotary Cooler
    4. Magnetic Separators (MS)
    5. Dust Settling Chamber (DSC)
    6. Post Combustion Chamber (PCC)
    7. Product Handling & Storage
    8. Off Gas Handling & Cleaning System
  • Induction Heating & Hardening Equipment
    Heating division of Electrotherm has supplied more than 750 equipment to Forging and heat-treatment industry....

  • The products offered are Ferrous & Non-Ferrous Billet Heating, Extrusion, Rolling, Soldering, Brazing, Heat Treatment including case hardening, Tempering and Annealing, Shrink Fitting, Strip Heating, Tube & wire heating, Continuous Annealing, Stress relieving etc…

    Induction Heating

    Induction heating is a process which is used to bond, harden or soften metals or other conductive materials. For many modern manufacturing processes, induction heating offers an attractive combination of speed, consistency and control.

    Long Bar Heater - Induction Heating Equipment for Various Applications

    Customer Benefit

    • Instant and fast heating.
    • Precise temperature control
    • Eco-friendly heating.
    • Minimize down time.
    • Less rejection of material.
    • Space saving.
    • Minimize scale loss.
    • Process control.
    • Due to uniform heating die life will get increase.
    • Due to automation requirement of man power will be less.
    • Energy saving with greater quality.
    • Maintenance free and easy to Installed.
    • Greater thermal efficiency.

    Applications

    • Automotive
    • Aerospace
    • Industrial
    • Mining
    • Oil and gas
    • Marine
    • Railway
    • Construction
    • Power Generation
    • Agriculture

    Forging & Forming

    Forging and forming process consist of a part that has been previously heated to a temperature at which its resistance to deformation is weak. The forging temperatures of the most commonly used industrial materials are:

    • Steel 1100 to 1250 ºC
    • Brass/Copper 800 to 900 ºC
    • Aluminum 300 to 480 ºC

    HNH Billet Heater - Induction Forging Furnace for Steel, Copper & Aluminum

    After heating up the material, the forming operation is done on different types of machines like mechanical presses, hydraulic presses, hammer, ring rolling etc. Materials used for forging are in shape of rounded bar, square billet.

    The process of forging and forming is a common process in the manufacture of many industrial sectors such as automobile, railway, aerospace, and forging.

    Advantages

    • Labour savings through high degree of automation
    • Small space requirement
    • Eco-friendly and emission-free
    • High operational reliability and availability

    Equipment Rating

    • Power: 50 kW to 1000 kW
    • Frequency: 500 Hz to 100 kHz

    Extrusion

    Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The extrusion process can be done with the material hot or cold. Extrusion may be continuous or semi-continuous. Materials required for this process is mention below

    • Brass/Copper 600 to 1100 ºC
    • Aluminum 350 to 500 ºC

    Advantage

    • lack of oxidation
    • Higher strength
    • Closer tolerances
    • Better surface finish

    Equipment Rating

    • Power: 50 kW to 1000 kW
    • Frequency: 500 Hz to 100 kHz

    Brazing

    Brazing is a process in which two or more materials are joined together by a filler metal that has a lower melting point than the base materials using induction heating. In brazing application joining of two pieces is done by process of using heat and a filler material that melts at a temperature above 427 ºC (800 ºF) and below the melting point of the parts to be brazen.

    The filler metal used in brazing varies depending on the parts being joined. The most preferred alloys are phosphor copper, silver, nickel and cobalt, aluminum, silicon, copper, copper-zinc and magnesium.

    In this process same material or different materials is permanently bond with high strength, simplify mechanical operation and adopt simple production techniques, always compatible with the demands of mass production among others.

    Advantages

    • Improved process efficiency
    • Fast and localized heat
    • Temperature control
    • Creation of clean joint, precise and controllable
    • Clean and technologies
    • The process eliminates the distortion and other undesirable metallurgical changes in different regions of the work pieces

    Application

    • Cookware Bottom Brazing (Sandwich/Capsule Brazing)
    • Rotor Brazing

    Equipment Rating

    • Power: 50 kW to 1000 kW
    • Frequency: 500 Hz to 100 kHz

    In-Line Induction heating system for hot rolling

    See Video1  Video2

    Eletrotherm’s In-Line Induction heating system for hot rolling/ reheating of bars, billets, slabs, plates, and blooms. Our heater provides temperature control and uniform heating from surface to core and head to tail of the product. Our heater is highly efficient and compact; available in frequencies between 50 Hz to 6000 Hz. and power between 500 kW to 10000 kW. Hot rolling is used to form thinner pieces of metal by using heat.

    Inline Induction Heating System for Billet, TMT bar, Angle, Channel, I-beam & Wire Rod

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