Computer simulation of the thermal regime of double-loop channel induction furnaces

Double-channel induction furnaces are used extensively in many processing industries due, mainly, to their relatively low operating costs. However, thermal stresses in the refractory lining caused by high temperatures during the loading cycle can cause erosion of the lining and premature inductor failure. Prevention of premature failure by close monitoring of the thermal regime of the inductor is very important to operators and relatively simple and reliable tools need to be developed to this end. The present work is related to the development of such a tool using a thermal modelling software and unidirectional axial channel flow speeds of the melt that are estimated from analysis based on the first-law of thermodynamics. This analysis reduces the cost, complications and uncertainties associated with coupled multiple field analysis approach. The results of the analysis show reasonable correlation with reported flow data and a comprehensive set of scenarios can be devised on the basis of the developed approach to simulate start-up, transient operation and steady state operation of double-channel induction furnaces.