When SAET EMMEDI has been requested a solution with induction heating for the treatment of two lines for rolling mill bars, our application and material engineers brought out their best capabilities and skills to deal with innovative process developments.

This important project, commissioned to SAET EMMEDI by a first-class and prestigious player in stainless and special steels, consists of ten high-power, in-line converters and an automatic solution for temperature control to heat bars before rolling.

SAET EMMEDI has achieved a very challenging target with the induction system for bars heating, developed starting from the innovative DynaZone technology, which is the modular solution for induction heating lines.

DynaZone is a modular system for variable production rates where the power of each heating section can be tuned and controlled independently, changing the heating profile according to the production needs.
The approach with a modular system for the treatment of long products is so advantageous because of its flexibility, its simplified maintenance, and the possibility to control the temperature of the heating modules independently.
The independent heating modules are composed of a power generator and a set of coils, specifically for this project there are 6 independent high-power modules each connected to 4 inductors with an additional reheating station with 4 modules, with one inductor per module.

The two high-power induction heating lines for rolling mill bars are a good example of how SAET EMMEDI’s R&D Laboratory has expertly used virtual simulation tools to optimize the development of this specific solution for long products.

The analysis made on temperature control has allowed getting different strategies to control the power.
The automatic control mode based on closed-loop temperature measurements and predictive filters is now integrated with our simulation software, the DynaSolver.
Before the process setup, different recipes can be virtually tested to evaluate the effect of process parameters like temperatures, materials, speed, and element size.

Different solutions can be compared to optimize the temperature profile or the energy cost.

The innovative and tailor-made processes based on induction heating make SAET EMMEDI’s R&D, the core that helps our customers achieve, in close synergy, exceptional results for production efficiency improvement, and energy saving.