In today's world of ever increasing competition mere survival one must continuously find ways and means to reduce costs while simultaneously improving productivity through innovative ideas. This can only be achieved by using latest technologies. "NEW GENERATION HIGH TEMPERATURE ELECTRICAL INSULATION COATING TECHNOLOGY" is one such established and proven technology in use in EAF/LRF & Induction Furnace Steel Melting operations. Through the use of new generation coatings in EAF/LRF operations, POWER & GRAPHITE ELECTRODE consumption can be reduced significantly - Power : 70 kwh/ton & Graphite Electrode : 0.30kg/Ton (approx) and in In Induction furnaces - Power : 45-50 kwh/ton and it is possible to reduce Heat time by >10%.

Power Loss in EAF/LRF /Induction furnace operations is primarily on account of Heat & Magnetic loss. Both losses are significant. They affect performance of furnace operations due to reduction in electrical insulation resistance (IR). Deterioration of IR value of electrical insulation is main cause of POWER LOSS at high temperature (e.g. electrical sparking). New generation coatings do not lose their IR value with rise in temperature, make surface wettable ( molten metal does not stick on coated surface ) and offer protection against attack from molten metal ( e.g. Cooling Panel tubes coated with new generation coating do not rupture easily ). High IR value coating materials do not generate magnetic field (EMF) on Furnace Shell, Furnace Roof, Cooling Panels etc. These Coatings help reduce electrical sparking and rupturing of Cooling Panel tubes. Heat load on the cooling system being maximum and heat loss as high as around 35% coatings help arrest heat / energy loss.

Reduction in POWER LOSS is achieved through high temperature electrical insulation which in turn helps increase furnace input power, reduces frequency of breakdowns resulting in increase in rate of heating and more production ( about 10%) in lesser time period. It also reduces furnace downtime and improves EAF /LRF and Induction Furnace performance. All this translates into lesser Power and Graphite Electrode consumption, increase in production leading to reduction in cost of production and improved profitability and that too without any capital investment. These coatings are easy to apply and 100% safe. Another salient feature of the Coatings is they do not affect quality of molten metal adversely and in fact prevent inclusion of impurities in the metal produced.

Above benefits are possible only when additional heat / energy made available through application of coatings in properly utilized and for this time regulation of Graphite Electrodes during melting operation is essential.