EM stirrers

• Operating principle
• EMS new generation and its advantages
• Effect on production
• Furnaces modernization for the EMS installation
• International supplies

The entire melt volume fast and uniform contactless stirring in the furnace

EM stirrers operating principle is based on the creation of a traveling electromagnetic field that exerts a contactless force on the melt located at a considerable distance. This action causes the melt to enter into intense, controlled motion, enabling various technological processes. This technology has found widespread application in metallurgy for stirring melt in smelting and holding furnaces.

The EM stirring system is a patented high-tech, science-intensive equipment developed to meet individual project requirements and specific features. Each project is unique, in order to develop the optimal proposal, is supported by computer modeling of the technological processes.

EM stirrers new generation

Over the past 7 years, we have completed a significant amount of work on developing EM stirrers new generation with pulsating flow compensation:

• Increased mechanical efficiency due to a relative reduction in the normal component (electromagnetic cushion effect) and heat dissipation power (induction heater effect)
• Spatial and temporal harmonic composition control of the magnetic field to intensify mass transfer in the homogenization phase (soft acceleration) and stimulate dissolution in the loading phase (shaking effect)
• Improved weight and size characteristics due to the magnetic system optimization
• Improving electrical efficiency by optimizing winding configuration
• Increasing reliability and efficiency through the adaptive control system development and the cooling system modernization
• Improving quality through production modernization and switching to modern materials and technologies

The complete transition to channelless electromagnetic stirring based on the use of air-cooled inductors is a logical result of the domestic aluminum industry development in the increasing the reliability direction and smelting and casting production efficiency.

For 40 years, we have been offering equipment with the following comparative advantages:

• The most technologically advanced stirring method on the market today (?)
• No risk of channel clogging. The equipment is completely independent of the furnace load and operating mode.(?)
• Low annual operating costs due to improved energy efficiency (?)
• Increased reliability and equipment safety due to the water cooling elimination (?)
• Less load on the power supply system (?)
• Long service life with minimal maintenance (?)
• A highly qualified team of technical specialists at the Scientific and Production Center of Magnetic Hydrodynamics ensures continuous technology and equipment maintenance at the most modern level, and also ensures fast, safe installation and professional support during its operation.

EM stirrers using impact on production

• The entire melt volume fast and uniform stirring in the furnace
• Increase productivity by 10-20%

  • Melting time reduction due to significant heat exchange improvement  with the loading charge

  • Faster slag removal due to the ability to drain it with the forehearth closed

  • Increased alloying accuracy by reducing overheating and undercooling

  • Improved heat exchange efficiency between the heating system and the melt

  • Reduced time spent on adjusting the the alloy temperature and chemical composition

• Uniform distribution in less than 8 minutes
  • Temperature drop reduction from 100-150°C to 6°C
  • Increased furnace thermal efficiency by improving heat exchange conditions
  • Extended refractory service life by reducing the maximum localized overheating temperature in the melt
  • Increased dissolution rate of alloy components and their subsequent homogenization in the bath
  Slag formation reduction by 2-3 times
  • It is known that the rate of aluminum oxide formation increases sharply at temperatures above 755°C. At 700-750°C, this value is 10-13 mg/cm2/h, and at 770-800°C, it reaches 25-30 mg/cm2/h.
  Energy savings of 5-15%
  • The effect depends on the furnace operating time cycles, the scrap ratio and liquid metal loading, alloy components and adding methods, the pre-chamber time opening for slag removal, alloying materials loading, scrap and fluxes

Furnaces modernization for EM stirrer installation 

One of the requirements for EM stirrer installing in a metallurgical furnace is to ensure the massive ferromagnetic bodies absence between the melt and the inductor. To achieve this, a "non-magnetic socket" is installed in the furnace body, which is made of structural steel, in the area where the inductor is installed.
These works can be performed both during the new furnaces construction and during the existing ones modernization. Furthermore, specialists at the Scientific and Production Center of the Magnetic Hydrodynamics perform design work on the existing stationary and tilting furnaces reconstruction, aimed at ensuring the non-magnetic socket installation for EM stirrer placing, both during major repairs and without furnace shutdown.

• Additional information on cutting in a non-magnetic socket for installing the EM stirrer
• Completed projects for furnaces modernization with non-magnetic socket insertion

International market licensing partner 

Since 2009, we have begun supplying MHD stirring systems abroad through an exclusive partner– ALTEK Europe Ltd under the SiberForce brand. Currently, more than 60 complexes have been implemented at the world's leading aluminum and metallurgical plants (Hydro, Novelis, Sapa, Alcoa, Balco, etc.).