Forever Electromechanical Completes Energy-Saving Retrofit of Slab Induction Heat Treatment Production Line, Cutting Power Consumption by 21.5%

Date: July 14, 2026

Recently, Forever Electromechanical, a leading domestic manufacturer of induction heat treatment equipment, successfully delivered a full energy-saving technical renovation project for slab induction heat treatment production line to a large steel rolling enterprise in North China. Targeting high power loss, low heating uniformity and outdated control systems of the original slab heating line, Forever’s R&D and after-sales technical team carried out systematic hardware replacement and intelligent software iteration. After 10 days of on-site installation, commissioning and 72-hour full-load continuous production test, the upgraded slab heat treatment line achieves a comprehensive power saving rate of 21.5%, while stabilizing slab metallographic quality and cutting carbon emissions, creating a replicable green upgrading model for domestic and foreign steel billet processing factories.

The customer’s original slab indiction heat treatment line had run for over eight years with traditional SCR thyristor medium-frequency power supply, which exposed multiple prominent energy-wasting drawbacks under long-term continuous production. First, the old power cabinet featured low power factor fluctuating below 0.82, massive reactive power loss and high standby power consumption during material gaps; its electrothermal conversion efficiency stayed merely 83%, leading to excessive power waste per ton of slab. Second, the original single-layer induction coil lacked magnetic field simulation optimization, causing obvious temperature difference between slab edges and core. Operators had to extend heating time repeatedly to meet rolling temperature standards, which further raised electricity cost and aggravated slab surface oxidation decarburization. Third, the open circulating cooling system was equipped with fixed-frequency water pumps without waste heat recovery, and the furnace frame lacked high-performance thermal insulation layers, resulting in massive radiant heat dissipation into the workshop.

 Facing surging industrial electricity prices and stricter dual-carbon assessment standards, the aging slab line severely restricted the factory’s profit margin and low-carbon factory certification progress.

To solve the above pain points, Forever Electromechanical customized an all-round energy-saving renovation plan covering four core modules: IGBT induction heating power supply upgrade, optimized induction coil reconstruction, closed constant-temperature cooling transformation and full-digital intelligent control iteration. The first core upgrade is replacing all SCR power units with self-developed full-digital IGBT medium-frequency power cabinets. The new power supply maintains power factor above 0.97 under variable load conditions, lifts electrothermal conversion efficiency to over 95%, and eliminates idle power consumption during blank intervals. Second, technical engineers redesigned multi-layer magnetic shielding induction coils via finite element simulation, adopting high-conductivity oxygen-free copper and segmented heating layout, which narrows slab overall temperature deviation within ±3℃ and avoids energy waste from supplementary heating. Third, the open cooling circuit was transformed into closed constant-temperature circulation system with variable-frequency energy-saving water pumps and waste heat recovery exchangers, cutting auxiliary cooling power consumption by 34%. Fourth, the outdated single PLC controller was upgraded to Forever self-developed AI closed-loop temperature control system, which automatically adjusts heating power, line speed and water flow according to slab size, steel grade and target temperature, realizing full-process adaptive energy regulation without manual intervention.

After official customer acceptance, the economic and environmental benefits of the renovation are fully verified by actual production data. Based on the factory’s daily output of 150 tons of quenched and heated slabs, unit power consumption per ton steel drops from 620 kWh to 486.7 kWh, saving nearly 19,995 kWh monthly and over 240,000 kWh every year. Calculated at industrial electricity price, the enterprise can cut power expenditure by more than 168,000 RMB annually, and the total renovation investment can be fully recovered within 8 months. In environmental indicators, reduced power consumption annually lowers carbon dioxide emissions by around 188 tons, helping the enterprise pass provincial low-carbon production audit smoothly. Meanwhile, uniform induction heating effectively reduces slab deformation and surface oxide loss, lifting finished product yield by 1.6% and bringing extra stable production revenue growth.

Industry insiders pointed out that billet and plate heat treatment equipment are core supporting equipment for hot rolling, forging and machinery raw material processing. A large number of early-generation SCR power induction lines still operate across global steel factories with low energy efficiency. This energy-saving renovation case undertaken by Forever Electromechanical proves that targeted systematic upgrade without replacing the whole production line can realize dual gains of energy conservation and quality improvement.

As a professional induction heating equipment supplier with 18 years of R&D experience, Forever Electromechanical will further promote standardized energy-saving renovation schemes for slab, bar and steel plate induction heat treatment lines to global metal processing manufacturers. The brand will continue to deliver customized low-carbon equipment solutions, helping the whole metal thermal processing industry cut energy consumption and accelerate sustainable green manufacturing transformation worldwide.