Reducing electricity costs in forging shops by applying induction zone heaters

In response to continually rising electricity prices, production plants featuring electrical systems are relying on intelligent energy management systems (EMS) in order to provide for the temporal levelling of electricity throughput by reducing the power consumption of individual systems, or even switching them off, for limited periods - without any negative side effects on production. In forging operations the induction heaters, as the main consumers of electrical power, should be included in such a management concept, yet this often involves production losses. The use of zone heaters however provides an opportunity to continue the heating process optimally even at a greatly reduced capacity, so that no parts will be heated incorrectly and potentially disrupt production. Ruhrtaler Gesenkschmiede has installed two, from mid 2008 three, induction zone heaters with an overall capacity of 4,500 kW whose operation has facilitated a considerable reduction in the maximum power consumption and therefore also of the electricity costs.