Types of Shanghai melting furnaces
The Shanghai melting furnace is a key industrial heating equipment used to melt raw metals during alloy production or for foundry casting purposes. There are various types of melting furnaces, each category with its subtypes. The melting furnace is generally categorized based on heat source, method of operation, capacity, and construction material.
- By heat source, there are electric, gas, and air or flame melting furnaces. Electric melting furnaces can be further classified into induction, arc, and resistance electric melting furnaces.
- By method of operation, there are batch-type and continuous-type melting furnaces. A batch-type melting furnace is the more common type and is produced by the melting rate. On the other hand, a continuous type melts at a constant rate.
- By capacity, the melting furnaces are either roll or stack-up type. The roll-type melting furnaces can also be referred to as rotary melting furnaces.
- By construction material, specifications, and design, the melting furnaces are lined with bricks, ceramic materials, etc. Some melting furnaces, such as the vacuum-oxygen refining melting furnace, feature complex systems like the deoxidization tank and atmosphere control unit.
Among the melting furnaces listed above, the electric induction melting furnace is one of the most popular types of melting furnaces. Electric induction melting furnaces utilize electricity or inductor coils to melt metals with electromagnetic induction. The induction coil heats up the charged metal indirectly through radiation. Induction melting furnaces have a high production efficiency.
Specifications and Maintenance
Specifications
- Capacity: Shanghai melting furnaces are designed to handle different capacities, with typical ranges between 1 ton and 25 tons. The ability of the furnace to hold and process raw materials is defined by the capacity.
- Temperature Range: Depending on the kind of furnace and its intended use, Shanghai melting furnaces often feature maximum operating temperatures that range from 1,600 to 1,800 degrees Celsius (2,912 to 3,272 degrees Fahrenheit).
- Heating System: The essential parts of a Shanghai melting furnace are the heating necessary and the power it produces. The furnace may be powered by electricity (electric resistance heating), natural gas (combustion of natural gas), induction coils (induction heating), or other forms of energy. The specific kinds of heating and power sources available will differ from one model to another.
- Furnace Lining: The interior of a Shanghai melting furnace is lined with high-temperature-resistant and melt-resistant materials. These materials vary in composition, durability, and temperature resistance depending on the kind of lining (acidic, basic, etc.).
- Power: The power of the furnace is usually measured in kilowatts (kW), representing the amount of electric power it consumes during operation. For instance, an electric melting furnace might have a power rating of around 100 kW.
Maintenance
- Regular Inspections: Conduct regular inspections of electrical induction melting furnaces according to the usage requirements to check the components and parts for signs of damage or wear. Specifically, check the thermal insulation, furnace lining, heating elements, control system, etc., and repair or replace them in time if any abnormalities are found.
- Environmental Cleaning: Keep the interior and exterior of the melting electric furnace clean to prevent dust, metal chips, and other impurities from entering the equipment, ensuring proper heat dissipation and safe operation. Pay particular attention to the cleaning of the cooling air holes for furnace bodies and control boxes.
- Replacement of Consumables: The electric melting furnace's furnace lining serves an essential function in protection and insulation. After extended use, its quality will deteriorate, leading to increased energy consumption of the equipment. Therefore, it is necessary to change the furnace lining at the prescribed time to ensure that it operates correctly and stably.
- Pay Attention to Lubrication: Lubricate the relevant components of the melting electric furnaces regularly, such as the bearings of the fan and motor, to ensure their better operation and reduce the friction and wear of the parts.
- Operating Records: Record the operating parameters and changes of melting electric furnaces regularly, including temperatures, power, time, etc. These records help monitor the melting furnace's operating status and maintenance needs later.
- Staff Training: Staff training on electric melting furnaces' proper operating methods and maintenance knowledge ensures following the manufacturer's guidance and advice for equipment maintenance and care. This can rule out potential risks and ensure its long-term, stable operation.
Scenarios of shanghai melting furnaces
A shanghai melting furnace caters to various industries because of its metal-melting capabilities. The following are melting furnace usage scenarios:
- Smelting copper alloys: Copper-based metals like brass and bronze are first melted in shanghai copper melting furnaces to form ingots. Copper ores containing copper metal are then fed into shanghai melting furnaces along with fluxes. The furnaces heat the mixture until the copper metal melts. Unwanted impurities are then removed from the copper melt to create high-quality copper.
- Jewelry casting: Jewelry manufacturers use shanghai melting furnaces to create exquisite jewelry pieces. The manufacturers first melt metal alloys that include gold, silver, and platinum using the melting furnace. A shanghai melting furnace ensures an even and linear jewelry metal melt. Once the metal is melted, it is poured into molds to create the desired jewelry shapes.
- Foundry operations: Foundry operators use shanghai melting furnaces to melt metals like iron, steel, and aluminum. The operators first prepare and cut the scrap metal into small pieces. Afterward, the furnace is set at a specific temperature to ensure a consistent metal melt. Once the desired temperature is reached, the scrap metal is introduced into the furnace and allowed to melt. The melted metal can then be cast into various components.
- Steel manufacturing: Steel manufacturers use shanghai melting furnaces in the electric arc process to produce high-quality steel. The shanghai melting furnace is first charged with scrap steel and steel-making alloys. An electric arc is then struck, raising the furnace temperature and melting the steel. After the steel melts, the manufacturers refine it to remove impurities and enhance its quality.
- Ceramics and glass production: Glass manufacturers use shanghai melting furnaces to produce glass. The manufacturers introduce raw materials like quartz, feldspar, and silicates into the glass melting furnace. Then, the furnace is lit and allowed to reach an exceedingly high temperature to melt the raw materials. Once melted, the glass is either molded or blown into various desired shapes.
- Metal recycling: Recycling companies use shanghai melting furnaces to recycle metal scrapes into valuable metal resources. The scrapes are fed into the furnace, which heats them up and melts them down. After melting, the furnace refines the metal to remove impurities before the metal is cooled and formed into ingots.
How to choose Shanghai melting furnaces
Equip the customers with the following tips before they go to the market to buy furnaces.
- Determine the required material: Different industrial applications require specific metals, such as copper, brass, iron, cast iron, zinc, aluminum, carbon steel, etc. Therefore, knowing the type of material is crucial.
- Determine the melting capacity: It will depend on the current volume or capacity being processed at the foundry. Presently, what is being melted? Will it be increased or decreased? What materials have been listed under the previous question? What were the limitations of the current melting furnace that was being used? Was there more opportunity if a greater capacity became available? It is important to know the answers to these questions to choose a furnace with the right capacity.
- Consider the energy source: What is the current energy source? Are there any alternative energy sources available? What are the advantages and disadvantages of each? For example, if natural gas is the current energy source, are there pipeline issues if using that? Is there enough pressure in the pipeline to provide the right amount of gas for the required furnace? If gasoline is used, what are the storage and transportation limitations? Searching the answers to these questions will help to choose a suitable melting furnace.
- Check the vacuum/atmospheric requirements: In some cases, the melting process is done under vacuum or atmospheric pressure. The temperature requirements may vary in these cases, as well as the type of furnace required.
- Evaluate the furnace's efficiency: Electric furnaces are usually more efficient than gas, oil, or diesel-designed furnaces. Specific information about the efficiency of the energy-to-melting ratio will help to choose the most efficient furnaces among the available options.
- Safety features: Issues like lockout/tag-out procedures, explosion risks, fire hazards, and emergency protocols should be at the top of the buyer's list. Doing a risk assessment of all safety hazards while getting qualitative and quantitative information about the previous melt safety procedures will help choose a melting furnace with the necessary safety features.
- The lifespan of the furnace: On average, induction melting furnaces last about 10 years; however, depending on the maintenance and operational process, some can last 15 years. The depreciation in the asset scale and its impacts will affect the financial decision to choose the melting furnace.
- Consider the cost: Apart from the buying price, the things mentioned above also impact the overall cost. A foundry with heavy operational constraints and many limitations in the energy sources to choose from may find melting furnaces with greater energy efficiency a better option in the long run, even if it has a higher initial price.
Q&A
Q1:Are melting furnaces environmentally friendly?
A1:Melting furnaces are often associated with high carbon emissions. However, manufacturers are striving to make the processes more environmentally friendly by utilizing recycling materials and improving energy efficiency.
Q2:How is the melting furnace supplied global market trend?
A2:In 2022, the global melting furnace market was valued at US$ 16.7 billion and is expected to reach a value of US$ 25.8 billion by 2030, with a CAGR of 5.7% during the forecast period.
Q3:Does the melting furnace work with any type of metal?
A3:No, because of the specific qualities and demands of various metals, such as their melting points, densities, and chemical compositions, melting furnaces are frequently customized to suit particular kinds of metals.
Q4:How Many Tons Per Hour Can A Melting Furnace Handle?
A4:While some furnaces are designed to process half a ton or one ton per hour, larger units can handle up to five tons per hour.
