In today’s metal melting and foundry industry, many manufacturers are facing long-standing pain points that hold back efficiency, safety and profitability:
- High energy consumption & low efficiency: Traditional melting systems waste huge power, with low power factor and unstable output, pushing electricity costs to unbearable levels.
- Frequent failures & long downtime: Unreliable power units, easy burning of thyristors, poor cooling stability cause unplanned shutdowns and heavy production losses.
- Poor power quality & grid interference: Old 6‑pulse systems create strong harmonics, affecting other equipment and even leading to penalties from power grid companies.
- Low automation & heavy labor reliance: Manual operation for tilting, monitoring and parameter adjustment brings high risks, inconsistent quality and low output.
- Safety hazards: High temperature, water leakage, unstable furnace body and lack of complete protection increase risks of splashing, burnout and accidents.
- High maintenance cost & short service life: Premature wear of coils, magnetic yokes and water cables leads to frequent replacement and high long‑term cost.
We are pleased to introduce a high‑performance 5‑ton medium frequency induction melting system with a one‑power‑supply two‑furnace structure, designed to solve these pain points for modern foundries and steelmaking workshops.
This system adopts a 12‑pulse 4000KW/0.5kHz medium frequency power supply and an integrated design of electrical control, furnace body, hydraulic tilting and closed cooling system. It features high efficiency, energy saving, stable operation, low harmonic interference and long service life, making it an ideal choice for continuous casting and steel melting production.
Core Technical Parameters
- Rated capacity: 5 tons per furnace
- Melting rate: 5 tons/hour
- Working temperature: up to 1600℃
- Power supply: 4000KW, 12‑pulse rectification
- Working frequency: 500Hz
- Power factor: ≥0.92
- Furnace tilting: hydraulic drive, tilting angle >95°
- Cooling mode: closed cooling tower
- Design service life: ≥25 years
Key Equipment & Technical Highlights
1. 12‑Pulse Medium Frequency Power Supply
- Full‑digital control system with ASIC high‑integration chip
- 100% success rate of frequency‑scanning soft start
- Constant power output, fast response to load changes
- Complete protection: overcurrent, overvoltage, phase loss, low water pressure, high water temperature
- Low harmonic interference, effectively reduces grid pollution
2. Steel Shell Furnace Body with Magnetic Yoke
- High‑purity rectangular copper tube induction coil
- 0.3mm high‑permeability silicon steel sheet magnetic yoke
- Uniform magnetic field, low heat loss, high efficiency
- Stainless steel water‑cooling ring to extend lining life
- Stable structure, strong rigidity, low noise
3. Hydraulic Tilting System
- Inverted cylinder structure for stable and smooth tilting
- Independent operation console, easy to control
- High‑quality hydraulic components, long service life
- Safe and reliable for molten metal pouring
4. Closed Water Cooling System
- Dual cooling circuits for power supply and furnace body
- Soft water circulation, no scaling, low water loss
- T2 purple copper heat exchanger, high cooling efficiency
- Water temperature & pressure monitoring and alarm
5. High‑Standard Components
- Large‑capacity rectifier & inverter thyristors
- Water‑cooled copper bars, low resistance loss
- Closed structure, safe and durable
- Easy maintenance and strong interchangeability
Performance & Application Advantages
- Energy saving: Power factor up to 0.92+, 5% higher efficiency than conventional models
- Stable: Continuous operation, low failure rate
- Flexible: One power supply with two furnaces, alternate operation for high productivity
- Eco‑friendly: Low harmonics, low noise, closed water system
- Long life: Design service life ≥25 years, low long‑term cost
This melting system is widely used in steel melting, foundry, metal smelting, continuous casting billet production and other industrial fields.
Why Choose This System
- High efficiency & energy saving
- Stable & reliable performance
- Safe operation & easy maintenance
- Long service life & low total cost
- Strong adaptability for various working conditions
