Optimization of energy efficiency of induction melting furnaces as a factor in sustainable development of mining areas

Introduction. Sustainable development of mining areas requires the integration of environmental and economic aspects. A key focus is improving the energy efficiency of energy-intensive processes, such as zinc smelting in induction furnaces. Research objective. To conduct a systems analysis of the induction furnace fleet to develop measures to optimize their energy efficiency and reduce the negative impact on the power grid. Objective and methods. The study involved five induction furnaces (models IC-20, IC-30, and IC-40) at an existing production facility. The methodology included a comparative analysis of the furnaces’ technical parameters, electrical calculations, and instrumental monitoring of power quality using an Energotester device for analyzing harmonic distortion with and without static capacitor banks (SCB). Results and discussion. Significant heterogeneity was identified within the fleet: the IC-40 furnace has the highest specific energy efficiency (3.12 t/h per 100 kVA), outperforming other models by a factor of 3–5. It was found that the BSC effectively compensates reactive power and suppresses higher harmonics (from the 7th), but causes resonant amplification of the 3rd and 5th harmonics, requiring adjustments to the compensation device settings. Conclusion. The possibility of significantly increasing energy efficiency by redistributing the melting load to the most efficient equipment and optimizing reactive power compensation systems has been demonstrated. Prospects for further research include developing detailed furnace operating maps, modeling and adjusting filter-compensating devices to suppress resonant harmonics, and assessing the economic and environmental impact of the proposed measures

AC power · Efficient energy use · Harmonics · Induction furnace · Induction heating · Smelting · Sustainable development · Induction Heating and Inverter Technology · Industrial Engineering and Technologies · Stonefly species taxonomy and ecology