Customer from Olbersdorf near Zittau prepares for the future through modernization
ABP Induction’s service portfolio not only includes the planning, development and installation of systems
for foundry operations, but also comprehensive consulting services for repairs and system modernization –
even during the pandemic. ABP customer Olbersdorfer Guß GmbH has chosen to modernize its own system
for this reason and, despite the coronavirus pandemic, has invested in upgrading its own system with the aim
of being better able to address market requirements and respond more flexibly to inquiries. A further key
benefit: After the modernization, the system corresponds to the latest state of the art and thus sustainably
reduces operating, service and maintenance costs.
Consultation regarding the modernization of the existing system near Zittau took place in early November 2020.
Engineering activities started immediately, and delivery of the components is currently scheduled for the beginning
of July 2021. During installation and commissioning, the ABP experts see to it that the customer encounters as little
downtime as possible. Therefore, these steps will mainly take place during the customer’s shutdown period at the
end of July/beginning of August 2021.
A system consisting of two ITMK 6,000 (3 t) induction furnaces with 2,500 kW (250 Hz) and TWIN-POWER® thyristor
converters will be upgraded and modernized. A new transformer, the DICU3 digital inverter control and the PRODAPT®
Enterprise melt processor have been provided for the modernization project. A further element of the modernization is
the conversion to a dual-circuit system with air/water cooler to handle the increase in system output. Olbersdorfer Guss
had previously worked with an evaporative cooling tower. This cooling unit is outdated and, given the new obligations of
the 42nd BImSchV (Federal Immission Control Ordinance) on the prevention of legionella since August 2017 for all
operating companies of evaporative cooling systems, cooling towers and wet separators, has resulted in a tremendous
increase in expenses.
The expansion of the existing furnace system with a third MF crucible furnace type FS 15 (Pmax. 800 kW), connected via a
furnace flow switch tower, is also an important factor for the customer. The customer purchased the furnace in order to be
able to produce smaller batch sizes for special steels. The objective is to achieve greater flexibility for niche products and to
improve the cost-effectiveness of the melting operation. A further key factor was the potential for more cost-effective and
environmentally friendly production.
A major challenge that the ABP engineers faced was the connection of the smaller crucible furnace to the existing converter
power supply, which was oversized for the small furnace. This task was solved by an optimized adaptation of the oscillating
circuit of the new furnace, type FS 15.
Another task: The old, problematic transformer is replaced by a new, more powerful transformer. This also includes the
opportunity to change the voltage level of the supply network. The modernization will increase the output of the furnace
system from the previous 1,900 kW to 2,500 kW.
The example clearly shows: all in all, despite the current pandemic, there are many reasons to invest in system modernization.
Like Olbersdorfer Guß here, customers with the latest technology components from ABP Induction are ideally positioned for
success in the current competitive environment: the PRODAPT® melt processor calculates energy requirements based on
furnace content and automatically controls the energy supply for the melting and holding operation. The DICU3 digital converter
control electronics achieves a technological leap in comparison to its predecessor DICU2, among other things due to the new
processor technology and the potentials resulting from the remote maintenance now possible. The DICU3 is M2M-ready, so that
error analysis can be performed via remote service. This makes customers’ systems Industry 4.0-capable.
Adding intelligent solutions, such as in this case the additional connection of the smaller crucible furnace, with an aim of opening
up further customer and market potential, results in the perfect modernization of an existing system, ensuring reliable and effective
operation for the future.
About ABP Induction
ABP is a leading manufacturer of induction furnaces and systems for inductive melting and holding for the metal and metalworking
industries. ABP is an expert in melting, pouring, holding and heating iron, steel and non-ferrous metals with design, production,
assembly and services for foundries, forges and steelworks. The ABP Induction Group with over 400 employees has companies in
the USA, Mexico, Sweden, Germany, South Africa, Russia, India, Thailand and China. It is represented by service and sales partners
in most of the world’s industrialized countries.
ABP Induction Systems GmbH
Tel: +49 231 997 2633
ABP Induction LLC
1460 Livingston Ave.
North Brunswick, NJ 08902
Telephone: +1 732 – 932 – 6400
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ABP Induction Systems GmbH
Telephone: +49 231 – 997 – 0
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Ryazanski prospect, 75/4
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E-120 / Unit-2, Manjusar GIDC Industrial Area
Opp. Du Pont factory.
Savli – 391775, Vadodara
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No.118, Lane 289 Fulian II Rd.Baoshan
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Priv. La Puerta 2882-4
Parque Ind.La Puerta
Santa Catarina, NL 66350
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77 Heidelberg Rd.City
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1814/17 Fax: +27 11 623 1809
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Spännarhyttans Ind. Område
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80/1 Moo 11, Phaholyothin Road
Tambol Klong Nueng
Amphur Klong Luang
Telephone: +66 25 29 34 57
Fax: +66 25 29 34 84