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Gas-Fired Metal Melting Furnace
Gas-Fired Metal Melting Furnace for Aluminum and Copper
COOLDO gas-fired metal melting furnaces use a controlled burner to heat a replaceable crucible for aluminum, copper and technically approved non-ferrous alloys. The standard catalogue covers 80–1000 kg aluminum and 100–1000 kg copper reference capacities. Every furnace is configured around the real metal, batch, fuel specification, melting or holding duty, charging method and pouring workflow.
When is a gas-fired crucible furnace the right choice?
A gas-fired crucible furnace is a practical direction when natural gas or LPG is economical and stable, available electrical capacity is limited, and the foundry needs flexible batch melting or holding of non-ferrous metal. It is especially relevant to aluminum casting shops, copper-alloy foundries, ingot production and jobbing foundries that change alloy or batch size. It should not be selected from capacity alone: fuel pressure and calorific value, burner turndown, exhaust, crucible material, metal-transfer method and batches per shift determine whether the furnace will meet the production target.
How the gas crucible melting process works
Confirm the charge
Define the metal, clean-return percentage, normal batch, maximum batch and required melt or holding temperature before the crucible and burner are selected.
Ignite safely
The configured burner completes its purge and automatic ignition sequence. Flame detection and temperature limits supervise burner start and shutdown.
Melt and hold
Hot combustion gases circulate around the crucible wall. The controller modulates burner output to reach the process temperature without unnecessary overheating.
Transfer metal
Molten metal is ladled or discharged through the confirmed handling arrangement into a die-casting machine, sand mold, ingot mold or downstream process.
Furnace structure and burner-control features
Welded furnace shell
- Round-column shell fabricated from sealed welded steel plate.
- Structure sized around the crucible, lining, lid, burner and service access.
- Stationary installation is standard on this published range; confirm any tilting requirement before quotation.
Insulated refractory package
- Morgan insulation block and blanket direction in the existing COOLDO specification.
- Calcium-silicate insulation helps limit shell heat loss.
- Lining thickness and hot-face material must match aluminum or higher-temperature copper service.
Automatic combustion system
- Temperature control and adjustable burner output.
- Automatic ignition and flame-detection functions.
- Automatic burner start or shutdown at configured temperature limits.
- Fuel train is engineered for the confirmed gas type, pressure and local requirements.
Crucible and metal handling
- Morgan MORGANITE or technically approved equivalent crucible direction.
- Crucible grade is selected separately for aluminum and copper service.
- Ladle access, lid opening, charging height and downstream mold position are reviewed together.
Gas-fired aluminum melting furnace models
The BN series is the standard gas-fired aluminum melting furnace direction for foundry and casting applications. The capacity below is standing capacity, not guaranteed hourly output. Actual melting rate depends on burner input, furnace condition, charge form, starting temperature, alloy, lid practice and operating cycle.
| Model | Reference temperature | Standing capacity | Crucible direction |
|---|---|---|---|
| BN80 | 1000°C | 80 kg | Morgan MORGANITE or approved equivalent |
| BN100 | 1000°C | 100 kg | As confirmed |
| BN150 | 1000°C | 150 kg | As confirmed |
| BN200 | 1000°C | 200 kg | As confirmed |
| BN250 | 1000°C | 250 kg | As confirmed |
| BN300 | 1000°C | 300 kg | As confirmed |
| BN350 | 1000°C | 350 kg | As confirmed |
| BN400 | 1000°C | 400 kg | As confirmed |
| BN500 | 1000°C | 500 kg | As confirmed |
| BN600 | 1000°C | 600 kg | As confirmed |
| BN800 | 1000°C | 800 kg | As confirmed |
| BN1000 | 1000°C | 1000 kg | As confirmed |
Common long-tail applications: 100 kg gas-fired aluminum melting furnace, 300 kg aluminum crucible furnace, 500 kg natural-gas aluminum melting furnace and 1000 kg industrial aluminum melting furnace. These phrases describe capacity directions; the correct model still requires production and fuel data.
Gas-fired copper melting furnace models
The BX range is configured for the higher process temperature of copper. Brass, bronze or other copper alloys require separate confirmation because alloy chemistry, zinc loss, fume extraction, crucible compatibility and pouring practice can change the furnace specification.
| Model | Reference temperature | Standing capacity | Crucible direction |
|---|---|---|---|
| BX100 | 1450°C | 100 kg | Morgan MORGANITE or approved equivalent |
| BX247 | 1450°C | 247 kg | As confirmed |
| BX323 | 1450°C | 323 kg | As confirmed |
| BX416 | 1450°C | 416 kg | As confirmed |
| BX476 | 1450°C | 476 kg | As confirmed |
| BX531 | 1450°C | 531 kg | As confirmed |
| BX626 | 1450°C | 626 kg | As confirmed |
| BX779 | 1450°C | 779 kg | As confirmed |
| BX1000 | 1450°C | 1000 kg | As confirmed |
Capacity note: The published values are catalogue references. Safe usable capacity depends on crucible working volume, alloy density, freeboard, charge form and operating practice. Do not size a copper furnace from an aluminum kilogram rating.
Gas-fired furnace or induction melting furnace?
Both technologies can be appropriate. The lower purchase price is not always the lower production cost, so compare the complete energy, infrastructure, maintenance, metal-loss and operator requirements for your location.
Choose a gas-fired crucible furnace when
- Natural gas or LPG is economical and reliably supplied.
- Electrical capacity is limited or expensive to expand.
- The project needs flexible batch melting or holding of non-ferrous metal.
- Your site can provide a compliant fuel train, ventilation, flue and combustion-air arrangement.
- Operators already understand crucible, burner and combustion-system maintenance.
Compare an induction furnace when
- Precise power response and repeatable melting cycles are priorities.
- The workshop wants no on-site combustion at the furnace.
- Metal loss, temperature consistency and faster process adjustment justify the electrical infrastructure.
- Electricity pricing is competitive with delivered gas cost.
- The plant requires integration with steel-frame, hydraulic-tilting or automated melting systems.
Review the aluminum and steel-frame induction melting furnace →
Applications and production planning
Aluminum foundry applications
- Melting and holding aluminum for sand casting.
- Supplying prepared metal to gravity or pressure die casting.
- Aluminum ingot and master-alloy batch preparation.
- Remelting clean, sorted production returns after process review.
Copper-alloy applications
- Copper melting for ingot or foundry casting.
- Brass and bronze projects after alloy and fume review.
- Batch preparation for molds, ladles or downstream casting equipment.
- Jobbing foundries that need flexible capacity and crucible changes.
Utilities to confirm
- Natural-gas or LPG composition, pressure and available flow.
- Control voltage, plant power and grounding.
- Combustion air, extraction, flue route and local emission requirements.
- Floor loading, access, charging height and metal-transfer route.
Information for model selection
- Metal and full alloy composition.
- Normal batch, maximum batch and batches per shift.
- Cold-start and hot-start production targets.
- Melting only, holding only, or combined melting-and-holding duty.
- Ladling, tilting, pump transfer or downstream equipment arrangement.
What determines gas metal melting furnace price?
A useful quotation must describe the whole working furnace, not just a shell and burner. Gas-fired metal melting furnace price changes with metal, capacity, operating temperature, burner rating, fuel train, crucible, refractory package, control level, lid, exhaust, transfer method, local certification and shipping destination.
Process data
Metal, alloy, batch, target melt rate, holding time and daily duty cycle.
Site data
Fuel type, gas pressure, calorific value, voltage, altitude, exhaust and installation limits.
Supply scope
Crucible, burner and fuel train, control cabinet, lid, transfer method, spares, commissioning and documentation.
For an accurate 100 kg, 500 kg or 1000 kg gas-fired melting furnace quotation, send both the required standing capacity and the desired kilograms per hour. They are different specifications.
Gas-fired metal melting furnace FAQ
Can the furnace use natural gas or LPG?
The burner and fuel train must be configured for the confirmed fuel composition, inlet pressure and available flow. Do not change between natural gas and LPG without the correct burner setup and technical approval.
What capacities are available for aluminum?
The published BN range covers 80, 100, 150, 200, 250, 300, 350, 400, 500, 600, 800 and 1000 kg standing capacities. Final usable capacity depends on the selected crucible and safe working level.
What capacities are available for copper?
The BX catalogue covers 100, 247, 323, 416, 476, 531, 626, 779 and 1000 kg reference standing capacities at a 1450°C reference temperature.
Can one gas furnace melt both aluminum and copper?
Do not assume that one standard configuration suits both. Copper requires higher temperature and may need a different burner, lining, crucible, controls and extraction. Tell COOLDO the complete alloy range before the furnace is engineered.
Is the listed capacity the hourly melting rate?
No. It is standing capacity. Hourly output depends on burner input, charge form, starting temperature, alloy, furnace condition, lid practice and loading or discharge time.
How can gas consumption be estimated?
Gas consumption cannot be estimated reliably from kilograms alone. The calculation needs metal, starting temperature, target temperature, desired melt rate, burner efficiency, fuel calorific value, holding time and heat losses.
Is this a stationary or tilting furnace?
The published BN and BX page represents a stationary crucible direction. If the process needs hydraulic or mechanical tilting, provide mold height, pouring side and loaded crucible weight so a suitable structure can be reviewed separately.
Which crucible should be used?
Crucible material and size are selected from metal, alloy chemistry, temperature, batch, flux practice and required service life. Morgan MORGANITE or a technically approved equivalent is the published direction, but the exact grade must be confirmed.
What is required for installation?
The site normally needs the confirmed fuel supply and fuel train, control power, combustion air, safe flue and extraction route, suitable foundation, charging and ladling access, guarding, PPE and local safety approval.
What should I send for a quotation?
Send metal and alloy, normal and maximum batch, kilograms per hour, batches per shift, fuel type and pressure, local voltage, discharge method, plant layout, destination country and required certification.
Get a gas-fired furnace configured for your foundry
Send your metal, batch, target output, available fuel specification and site layout. COOLDO will compare the BN or BX capacity, burner and fuel train, crucible, refractory lining, controls, exhaust and metal-transfer scope before quotation.