Main Types of Copper Melting Furnaces and their differences

        Main Types of Copper Melting Furnaces and their differences

Smelting furnace refers to a machine for melting metal ingots, certain scrap metals and some  alloy ingredients into required alloys through slagging, refining and other operations. Choosing a copper smelting furnace is mainly based on the two parameters:  1: Scrap metal (copper, bronze, brass)  2: End Products.

Usually we will adopt the raw material like Copper ,brass alloy, and after melting we will cast the end product into  copper rods, ingots, bars electronic products etc.

Here we will Clarify the difference of  the Different types of  Copper Melting Machine In the Market

Classification based on heating energy  

According to the type of heating energy, copper melting furnaces can be divided into three  categories:

1:Heated by fuels  –  natural gas, petroleum liquefied gas, gas, diesel, heavy oil,  These fuel sources generate thermal energy by fuel combustion which heats up the furnace.

2:Electric heating:  generates thermal energy by electrifying the resistor unit to heat the metals. This method is commonly used in Silicon Carbon Rod melting copper furnaces.

3:Induction Heating:  based on the principle of electromagnetic induction heating that alternating current generates a magnetic field, it heats up the furnace utilizing induction current.

See the following chart:

    Gas Fired Copper Melting furnace Induction Copper melting furnace Silicon Carbon rod Copper melting furnace
Heating principlenatural gas, liquefied petroleum gas, gas, diesel, heavy oil and coke.electromagnetic inductionhigh-temperature silicon carbide rod
Maximum temperature1350C1700C1350C
Heating

time

2.5 h40mins- 1 h3h
AdvantagesNo Need electricity; Suitable for some customers with electricity supply problems 

Fast speed of melting; High efficiency,24 hours continuous working

Simple and convenient; No need electricity and gas;  Can Use directly after installation
DisadvantagesCustomers need to provide natural gas sourcesPower consumption is larger   Melting speed is not so fast

Next, we are going to elaborate detail  on the advantages and disadvantages of various melting furnaces.

MF(Medium Frequency) Induction Melting Furnace:

brass melting furnaceMF Copper Induction melting furnace;

Power supply range: 80~2500KW;

Main purpose: smelting Scrap copper ,brass, bronze metal materials;

Melting Capacity: 0.05T-5T;

Advantage:

1:High efficiency in melting; significant power saving; compact structure and strong overload capacity.

2:far less smoke and dust which creates a better working environment

3:Simple operating process coupled with reliable smelting

4:Even metal composition and alloying

5:The melting temperature rises fast and also easy to control

6:These furnaces have a high utilization rate and easily replaceable parts.

7:Shielding leakage of the long arc magnetic yoke;Reduction of external magneto resistance;Magnetic flux leakage at both ends of the shielded coil as well  as the yoke cross section are the seamless and compact inner wall of the arc increase the effective magnetic conductivity area and give the lower ring better support:The unique positive and negative rotation coil greatly improves the efficiency of the system

Industrial Gas-Fired Melting Furnace

Gas metal melting furnace-applicationCurrently, the copper melting furnace with gas (or LPG) as fuel is a lot more cost-effective and eco-friendly.

The general structure of the gas melting furnace is that the shell is welded from strong steel and 20G. The interior has a refractory and heat insulation layer. An industrial burner is installed in the furnace body which can burn the metal and melt the non-ferrous metal with speedy melting speed, and additionally, fans, gas managing shutoffs are also equipped. Gas fired Copper melting furnace normally includes cupola shaft furnace, turning heater (or converter), reverberatory furnace and so on, this mainly used for the manufacturing of copper poles. but this type of gas-fired metal melting furnace usually has a higher requirement of the raw material

 

Gas copper melting furnace: gas (fuel) crucible melting and holding furnace can be used for melting, casting and hot plating of nonferrous metals such as aluminum, zinc, silver, lead, tin, and copper.

Advantage;

1:It is clean and safe to use natural gas (light diesel) as fuel, which helps in keeping the workshop neat, clean and easy to manage.

2:Heat efficiency is high and running costs are low. Compared to electric heating crucible furnaces, their melting capacity and efficiency are high. Energy consumption is low, which completely eliminates the cost of replacing the electric heating body.

3:Cooldo Gas melting furnaces use an imported, well known international brand burner to burn the diesel fuel completely. Exhaust emissions are completely free from pollution. The design of multiple heat flux passages makes full use of the energy generated by the burner, which greatly improves the efficiency of heat work ( not sure what this means) resulting in big energy savings.

4:They are especially suitable for low electricity availability. The power consumption of a single furnace is only 180 ~ 300VA  so, there is no need to worry about increasing power capacity in order to ramp up production.

5:Cooldo Patented designed gas-fired metal melting furnace make the high-temperature exhaust gases emitted from the furnace into a high-temperature hot air curtain. This will help to heat and preheat the melt thus shortening the melting time and improving working efficiency. With its dual temperature control, it can automatically regulate temperature, automatic melting, automatic thermal insulation, and is also able to conduct on-site temperature detection of molten metal. There is a safety door at the bottom of the furnace. In the unlikely event of an accident in the crucible, an alarm bell will sound giving the operator time to take relevant action and minimize any potential loss. Large batch and long-time continuous production will greatly improve the productivity of these melting furnaces thus giving better economic performance than coke and coal.

Silicon  carbon rod  melting furnace:

silicon carbide rod melting furnace_1

 

Industrial Resistance melting furnaces are industrial furnaces that use electric current to heat the electric heating element, thereby heating the workpiece or material. They are heating furnaces which use current to generate heat energy through the resistive material.

In mechanical industry,  resistance furnaces are used to heat metal pre-forging;  heat treatment; brazing;  powder metallurgy sinter; glass ceramics roast and anneal; low melting point metal melt; sand and paint film drying, etc.

In general, electric furnaces will select the heating element based on the different working temperatures you require, Commonly, the temperature of an iron-chromium  aluminum wire furnace reach temperature less than 1200 degrees, and the electric furnace of silicon carbide rod can be used to about 1400 degrees.If need  Higher temperatures , we suggest  use silicon molybdenum rod and ZrO2 electric furnaces. In industry, silicon carbide melting furnaces are widely used becasue of their simple, stable and reliable operating characteristics.

Advantage:

Silicon and carbon bar smelting furnace:

1:Easily attained high temperatures compared to fuel furnaces.

2:It can heat the inside of the material.

3:Easy to use in a controlled atmosphere and vacuum furnaces.

4:Resistance furnaces do not have the exhaust heat loss of fuel furnaces which means that thermal efficiency is high.

5:Easily controlled temperature, remote control and fine-tuning.

6:It can be heated quickly.

7:Superior operating performance without pollution.