High-frequency induction furnace F-MELT100G that achieves energy saving for electric furnaces.
Consolidating energy-saving and power electronics technologies in high-efficiency induction furnaces to contribute to carbon neutrality in industrial furnaces.
In foundries, there is an active movement to promote energy conservation and carbon neutrality. These are important management issues that lead to reduced environmental impact, cost savings, and enhanced corporate value, and it is believed that efforts to address environmental issues will continue across various industries in the future. On the other hand, energy-saving activities at the operational level in foundries have been undertaken for some time. To aim for further energy savings and reductions in CO2 emissions from the current situation, more in-depth initiatives and capital investments, such as restructuring production and business processes, are necessary. When promoting energy conservation and carbon neutrality in foundries, there are methods such as converting the heat source of industrial furnaces and switching to high-efficiency electric furnaces/induction furnaces. This is expected to improve energy unit consumption and reduce CO2 emissions/environmental impact. The product that addresses this challenge is the high-frequency induction furnace F-MELT100G, which consolidates Fuji Electric's energy-saving and power supply technologies. It achieves high efficiency, energy conservation, and safe and secure operations, contributing to energy conservation in foundries and the promotion of carbon neutrality in industrial furnaces.
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basic information
Over 2,500 units of induction furnaces have been introduced. Based on this extensive track record, we have combined our "power electronics technology," "high-voltage insulation technology," and "analysis technology" to create the high-frequency induction furnace F-MELT100G. To address energy conservation, high efficiency, and large capacity needs, the F-MELT100G series is equipped with a high-efficiency furnace body that improves melting unit consumption and a high-voltage IGBT stack. It not only enhances energy efficiency but also evolves reliability and safety, achieving high performance that is unmatched by others. Additionally, by adopting a direct digital control unit equipped with self-check functions and RAS (Reliability, Availability, Serviceability) features, we have made it possible to stabilize equipment operation and reduce the time required to identify causes in the event of a failure. These technologies promote energy savings in electric furnaces, advance carbon neutrality in foundries, and improve productivity and stability.
Applications/Examples of results
■Energy Saving and CO2 Reduction Case Study (Akakane Iron Works Co., Ltd.) Realization of energy saving and CO2 reduction through the transition from cupola to electric furnace/high-frequency induction furnace [Customer Feedback] - "The fact that they have the top market share in the industry and were able to introduce the latest electric furnace was great. It was also good that the supply of maintenance parts is stable. By switching to the electric furnace, we can reduce CO2 emissions and improve quality, which leads to a lower environmental impact and enhanced safety." *Excerpt from customer interview in the introduction case study video [Products and Systems Introduced] - High-frequency induction furnace (F-MELT100G) Furnace monitoring system [Challenges Before Introduction] - Building a manufacturing system aimed at decarbonization and green growth strategy; achieving energy saving and CO2 reduction [Benefits of Introduction] - Reduction of environmental impact, improvement in quality and safety, stabilization of maintenance parts supply
Detailed information
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■Improving melting efficiency with 3D structure and magnetic field analysis technology, achieving energy savings in electric furnaces. In foundries, it is necessary to further promote energy savings and carbon neutrality in response to decarbonization efforts. F-MELT100G is a high-efficiency electric furnace/high-frequency induction furnace. We have consolidated our technologies to reduce the power consumption per unit of output.
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■ Streamlining maintenance work through space-saving design of the panel and reduced coil replacement time. To stabilize factory operations, both preventive and corrective measures, including maintenance activities and reducing downtime during failures, are required for efficiency. The F-MELT100G enables work efficiency through space-saving design of the power panel, reduced coil replacement time, and self-fault diagnosis functions.
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■Real-time understanding of operational status enables preventive maintenance and optimal operation. In recent years, efforts to reduce dependence on individuals through the use of IoT have been progressing. This is due to the anticipated shortage of personnel caused by the retirement of highly skilled engineers. The F-MELT100G adopts IoT and digital technologies, making it possible to visualize operations and streamline and standardize fault diagnosis and deterioration assessment.
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High-frequency induction furnace F-MELT100G that realizes energy saving for electric furnaces.
Examples of energy saving and CO2 reduction through the transition to electric high-frequency induction furnaces.
Increased the batch size of the dissolution furnace and introduced a high-power IGBT power supply.
Survey on Carbon Neutrality in Foundries
Survey on Awareness of IoT and Data Utilization in Foundries
Survey on Energy-Saving Measures in Foundries
Survey on Awareness of Energy-Saving Measures in Factories and Plants
Improving production efficiency and avoiding production stoppage risks with the introduction of IGBT power supply.
Visualization of operations in the new factory using the furnace monitoring system.
Current Status and Challenges of Decarbonization Efforts in Foundries 2025
Company information
Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools
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