Types of electric furnaces
Electric furnaces are equipment used to melt metal by using electricity as their main energy source. Suppressing fossil fuel usage and protecting the environment makes them a preferable option for industries. Below are some types of electric furnaces.
- Induction electric furnaces: An electric current passes through a conductive coil, inducing heat in the metal through electromagnetic induction. Induction electric furnaces offer many benefits such as no environmental pollution, saving time and energy, higher melting rates, and better quality of molten metals. Three-phase induction furnaces with 200-3000Kg capacities are suited for casting steel and iron. Medium frequency induction furnaces oscillate from 1000 to 3000HZ and are used for non-ferrous metals, for example, brass and copper.
- Arc electric furnaces: Arc electric furnaces generate heat by passing electric arcs between electrodes and the metal to be melted. This type of electric furnace produces heat rapidly and can reach high temperatures. Electric arc furnaces (EAFs) are mainly applied to steel-making industries. They are also used to produce alloys such as titanium, nickel, and ferroalloys.
- Resistance electric furnaces: Resistance electric furnaces produce heat by the resistance of the metal to be melted when electricity passes through it. These types of furnaces can be built into various shapes, such as box, swing, and circle types, which would meet different manufacturing needs. They are generally suited for small-scale production or as part of manufacturing lines.
- Vacuum electric furnaces: As the name suggests, this kind of electric furnace is completely or partially placed in a vacuum. This makes it possible to melt metals without oxidization, thus improving the quality of the melted metals. Vacuum electric furnaces are well suited for high-value metals such as titanium and superalloys.
- Central heating electric furnaces: Central heating electric furnaces are a substitute central heating for gas furnaces. This kind of electric furnace heats the house by passing electricity through heat exchangers, radiators, etc. It can give off more than 50,000 BTUs.
Specification and Maintenance
Specification
- Sizes: The industrial electric furnace size may differ from the average electric furnace for homes. Units can measure anywhere from 10ft, 20ft, 30ft and more, with greater heating capacities for industrial purposes.
- Kilowatt power: Larger electric furnaces can go as high as 750kW. They will have a higher power output to process large quantities of metals.
- Temperature: Industrial electric furnaces must reach much higher temperatures than those used in homes. Typical temperatures are at 1300-1600°C for melting purposes. Some furnaces can go as high as 2200°C.
- Heating method: Different electrical heating furnaces use different heating methods that affect how they are set up, how well they work, and what they do.
- Control system:Modern industrial electrical heating furnaces have control systems that let them tell things like temperature, time, and power, as well as automatic operations like over-temperature protection, fault alarms, and so on.
- Elements: The heating element in an industrial electric furnace is usually made of silicon carbide, molybdenum disilicide, or metallic silicon carbide, among other things. These materials can easily bear high temperatures and corrosion, which is important for the life of the heating element.
Maintenance
- Cleaning of Surfaces: To keep electric furnaces clean, a dry and clean cloth or sponge that is not dirty or damaged should be used to wipe the outside and inside of the door frames. Cleaning solutions or sprays with any kind of oil should not be used. Never spill any liquid on or inside the cook top area. When handling the porcelain enamel surfaces, it's essential to remember that the more gentle and less abrasive is better.
- Fasteners: Checking the fasteners' tightness periodically and tightening any loose ones can help avoid potential failures and safety hazards caused by loose fittings.
- Electrical connections: Users should examine the electrical connectors and wires to see if there are any loose, broken, or worn parts. Any cleaning, adjustment, and repair requirements should be attended to immediately to help prevent electrical malfunctions and safety hazards.
- Thermostat Calibration:User should seek assistance from specialized technicians for routine thermostat calibration to ensure accurate temperature control and optimal furnace performance.
- Gas connections and leaks: Users should have the professionals check the gas connections and gas leaks regularly to ensure safety and proper furnace operation.
- Lubrication of moving parts: Lubrication of the electric furnaces moving and revolving components, including bearings and shafts, is done on an as-needed basis and is subject to regular inspections.
- Refractory maintenance: The furnace's refractory lining should be checked for cracks, wear, or damage. Any defects should be repaired promptly to maintain thermal efficiency and prevent heat loss.
- Safety checks:It's important to conduct regular safety checks, testing the function of safety devices such as pressure relief valves and emergency stop switches, etc., to ensure their proper operation and prevent potential safety risks.
- Preventive maintenance:Users should develop a preventive maintenance schedule for regular inspections, repairs, and replacements of critical components as per the manufacturer's instructions, ensuring the electric furnace's reliable operation and extended lifespan.
Scenarios of electric furnaces
The electric melting furnace has a wide range of applications in different industries.
- Steel industry: Induction furnaces are primarily used in the steelmaking industry for steel smelting and refining. They can quickly melt scrap steel, alloy steel, and other materials to produce high-quality steel. Electric arc furnaces are also widely used in steelmaking processes as the primary equipment for smelting steel.
- Nonferrous metal industry: Electric furnaces are extensively used to melt nonferrous metals such as aluminum, copper, zinc, lead, magnesium, and alloys. In the manufacture of metals like aluminum, large quantities of aluminum scraps and ingots are melted in electric furnaces. Copper wire remnants, copper materials, and alloy materials are melted in electric arc furnaces.
- Foundry industry: The foundry industry is responsible for producing casting parts, which are typically made using electric induction furnaces. These furnaces are used to melt various metals and alloys for casting production.
- Ceramic and glass industry: Electric furnaces play a crucial role in the ceramic and glass industries. They are used for melting and shaping materials to produce glass products such as glass containers, flat glass, vitreous enamel, and glass ceramics.
- Chemical industry: The chemical industry widely uses electric furnaces for chemical reduction, thermal cracking, and other processes. For instance, electric furnaces can be employed to produce compounds like silicon carbides, phosphorous, and sodium.\
- Aerospace and automotive industries: The aerospace and automotive industries rely heavily on electric furnaces for production. These furnaces are essential for melting metals and alloys used to manufacture components and structures for aircraft, missiles, automobiles, and various other aerospace and automotive products.
How to choose electric furnaces
When selecting industrial electric furnaces for sale, consumers should pick a type according to the target audience's needs. They can determine the intended use by surveying the audience. They can also consider the size and capacity needed for their applications. For example, small-scale foundries or laboratories may require compact furnaces, while larger industrial facilities will need higher-capacity electric furnaces.
Ask the suppliers if the available electric furnace models have varying temperature ranges. It's essential to offer customers a variety of options to suit different materials and processes. The audience will likely prefer easy-to-use models with programmable controls, digital displays, and automated features. So, ensure the models selected have those desirable features.
Opt for electric melting furnaces made with quality materials like ceramic, metal alloys, and BaF2. Such a choice may have a long service life even when subjected to the highest temperatures. A good electric furnace with superior insulation minimizes heat loss and reduces energy consumption. It's also important to consider safety measures like over-temperature protection, emergency shut-off, and proper ventilation. Since many customers have energy efficiency in mind, choose models with high energy efficiency. Such a model will have faster heating rates and minimal heat loss.
FAQ
Q1: What is the difference between air and electric furnaces?
A1: Air furnaces use gas to heat homes, while electric furnaces rely on electricity. Electric furnaces are simple, providing heat by blowing over heated coils. While less efficient, electric furnaces need less maintenance than gas ones.
Q2: What materials are suitable for an electric furnace?
A2: The choice of materials for an electric furnace depends on the specific type and application of the furnace. Generally, the key components of the electric furnace are made of the following materials. Steel: The structural frame of the electric furnace is usually made of steel, which has high strength and is able to withstand the weight and operating conditions of the electric furnace. Refractory materials: Refractory materials are specialized high-temperature resistant materials that can withstand high-temperature electric furnaces without being damaged. Power components: Electric furnaces power parts include the power supply, relays, switches, etc. These components are usually made of high-quality plastic and metal to ensure safety and reliability.
Q3: What are the safety precautions for operating an electric furnace?
A3: When using the electric furnace markup, some suggested safety precautions are: Regular inspection: check the power lines, heating elements, temperature controller, and other parts to ensure that there is no leakage, exposure, short circuit, overheating, etc. Take proper ventilation: keep the electric furnace well-ventilated to avoid the accumulation of flammable and explosive gas. Avoid overload use: use electric furnaces according to the rated power and load to avoid overload use. Fire safety: pay attention to firefighting when using electric furnaces, prepare firefighting equipment, and escape tools.
