Channel Induction furnace-Metallurgical Furnace-Changsha Metalcess Intelligent Equipment Co., Ltd.-Metallurgical Equipment Design and Manufacturing, Process Technology Package Delivery, and Automation Integration

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Channel Induction furnace

Metalcess can supply channel induction furnaces for zinc melting, zinc alloy mixing and casting, tailored to customers’ production volumes and configuration requirements. For clients with existing induction furnaces, Metalcess can also supply channel inductors as replacing spare units. Our inductors are guaranteed to provide trouble-free operation for over two years. Channel induction furnaces are available in both tilting and fixed type.

Channel induction furnace overview

The channel induction furnace is a core-type induction furnace specifically designed for the melting and heat holding of Zinc and Zinc alloys. Its name derives from its unique structure, which features one or more channel-type inductors (also known as inductors) mounted on the furnace bottom or side wall.

Name: Channel induction furnace, core-type induction furnace, Zinc melting furnace Application: Zinc and zinc alloys melting and heat holding

Types: Fixed or tilting type

Power: From 250 kW to 3,000 kW and above

Capacity: From 1.0 tonnes to 50 tonnes or more

Melt discharge method: Continuous or batch (via launder/pumps)

Key features:

1)The inductor for Zinc melting furnaces is of long service life and high melting efficiency, with a max. lifespan of up to 15 years.

2)The automatic control system comprises a distributed control system consisting of a host computer HMI, a PLC S7-1500 programmable controller, and an Ethernet switch. It enables comprehensive data acquisition and monitoring across the entire system.

3)This system truly replaces manual labour, thereby reducing long-term operating costs for clients.

4)A normal service life of the inductor exceeds two years with no Zinc leakage.

Channel-Type Inductors

Metalcess can supply both air-cooled and water-cooled inductors as per requirements.

Our inductor can be purchased separately to replace old or damaged inductors for the channel induction furnace.

The refractory material for the induction body’s melting channel can be configured using wet castable or dry ramming castable. The dry ramming castable utilises imported materials from United Mining (USA). It offers excellent dimensional stability and strong resistance to expansion and thermal shock. Our specially formulated wet castable boasts excellent dimensional stability, strong resistance to thermal shock, and superior chemical properties.

We guarantee a normal service life of the inductor exceeding 2 years (with no Zinc leakage).

As the inductor is a single-phase load, a three-phase balancing system comprising balancing capacitors, reactors and compensation capacitors has been installed to balance the three-phase power grid; the power factor after compensation can reach 0.98 or higher.

Channel-type Zinc melting furnaces applications

Cathode Zinc casting lines: the channel induction furnace serves as the melting equipment, continuously melting Zinc sheets or cathode Zinc to provide molten Zinc at a stable temperature for the ingot casting machine. Metalcess can provide complete Zinc melting and automatic stacking solutions tailored to customer requirements, comprising an automatic feeder, a channel induction furnace, a linear ingot casting machine , a stacking robot (ABB) and specialised clamps, an automatic binding machine, an ingot stack conveyor, an electrical control system, safety netting, and etc.

Zinc alloy (Zn-Al/Zn-Al-Mg) mixing and casting: Can be equipped with molten zinc stirring units, Zinc alloy ladles and water-cooled baths. Zinc ingots or molten Zinc are fed via feeding equipment into the channel induction furnace to be melted into molten Zinc. Alloying elements such as aluminium and magnesium are then added. Once the furnace temperature reaches the process temperature, the molten Zinc is thoroughly stirred using the stirring apparatus. Following the slagging and degassing process, samples are taken and sent to the laboratory for analysis to verify compliance with specifications. Qualified alloy molten Zinc is then poured through the ladle into ingot moulds, where it is cooled and demoulded to produce compliant alloy products.

Hot-dip galvanizing production: Used to melt Zinc ingots and maintain the temperature of the molten Zinc, ensuring the quality and uniformity of the galvanized coating.

Zinc Alloy Die Casting: This process supplies die casting machines with a continuous, clean and temperature-stable zinc alloy melt, serving as the key equipment for producing high-precision zinc alloy die-cast components. Zinc-aluminium alloys, zinc-aluminium-magnesium alloys, etc.