In the upgrading of steel manufacturing and metal processing, the technical precision, energy efficiency and operational stability of melting equipment directly define production line competitiveness. Leveraging our profound expertise in industrial electrothermal equipment, we have developed the 25t high-efficiency energy-saving induction furnace in line with national standards and practical process needs. It builds a full-chain solution integrating core technical design, precise parameter configuration, standardized supply and full-process technical services, adapting to continuous high-load smelting demands and laying a solid equipment foundation for enterprises to cut costs, boost efficiency and achieve green production.
This furnace features full-process standardized design with its technical scheme optimized through multi-scenario engineering verification, forming a closed-loop system centered on “continuous production, energy saving & high efficiency, stability & reliability, safety & intelligence”. The innovative one power supply with two furnaces mode enables one furnace for smelting and the other for maintenance, eliminating production downtime caused by overhaul from the source. Its core is equipped with a 24-pulse rectifier transformer and a customized frequency conversion power cabinet, achieving a 0.95 power factor at full pressure output, precisely controlling the rated tapping temperature of 1600℃ and reaching an industry-leading level of power consumption per ton of steel. Equipped with a mechanical furnace change switch, hydraulic feeding & tilting system and PLC dual-control system, it realizes full automation of the smelting process, greatly reducing manual intervention and improving production efficiency and operational precision.
Core Technical Schemes & Parameters, Forging Core Equipment Strength
1. Standardized Technical Configuration
- Power Supply & Rectification: 12000KVA 24-pulse rectifier transformer (35KV primary/1500V secondary), no-load voltage regulation, forced oil-water cooling, with electrostatic shielding and secondary low-voltage relay protection. Effectively reduces grid harmonic pollution (compliant with GB/T14549-93) and ensures stable power supply.
- Frequency Conversion Power Supply: 10000KW rated power, 250HZ center frequency, 5000V output voltage; closed-circulation cooling water (0.12-0.15MPa, 240t/h). Equipped with high-performance SCR and renowned-brand vacuum circuit breakers, with strong overload capacity for continuous production under complex working conditions.
- Furnace Core System: Energy-saving flat-wound inductor (copper tube wall ≥8mm, Φ1830mm inner diameter, 2460mm height) with high-quality silicon steel yoke, featuring high heating efficiency and low heat loss; the furnace supports closed/open double-circulation cooling (0.25-0.3MPa, 450t/h), inlet water ≤40℃, temperature rise ≤12℃, ensuring thermal stability under long-term heavy load.
- Hydraulic & Control System: 12MPa hydraulic system (adapted to N46/68 anti-wear hydraulic oil), Φ250mm tilting cylinder (max angle ≤95° with limit switch protection); S7-1200 PLC system supports local/remote operation, realizing real-time smelting parameter monitoring and precise equipment action control.
- Cooling & Protection: Electrical system cooled by plate heat exchangers, furnace body by open cooling tower, all core components with closed-circulation cooling; equipped with leakage alarm, high-voltage protection cabinet and capacitor bank forced air cooling (≥4m/s), eliminating electrical, mechanical and thermal safety hazards in an all-round way.
2. Key Production Parameters
- Rated capacity: 25t; Max tapping capacity: 30t (adjusted by furnace lining condition)
- Melting rate: 16±10% t/h; Tap-to-tap time: 100±10% mins (heat preservation & slag discharge excluded)
- Rated tapping temperature: 1600℃ (high-precision temperature control to ensure molten steel quality)
- Auxiliary parts: 500mm² water-cooled cables, seamless oil pipes, high-precision hydraulic control boxes (all industrial-grade for long-term continuous production)
Standardized One-Stop Supply, Fully Meeting Production Needs
1. Standard Core Equipment (Single Set)
A full set of core smelting equipment without multi-party procurement: 2 GW-25 furnace bodies, 2 KGPS-0.25/5000 frequency conversion power supplies, 2 oil-immersed reactors, 1 electric heating capacitor bank, 1 mechanical furnace change switch, 1 HS-25 hydraulic system, 1 S7-1200 PLC system, 1 leakage alarm device, 1 crucible mold, 1 set of water-cooled cables. All equipment undergoes strict factory inspection with complete qualification certificates and operation instructions, ready for installation upon unpacking.
2. Free Commissioning & Spare Parts
A full set of wearing parts and commissioning spares for initial equipment operation: main control board, pulse board, SCR chip, fuse/fuse core, switching power supply, various testing instruments, non-inductive resistor, absorption capacitor, power adjustment potentiometer, transformers, etc. All spares match the original equipment specifications for perfect adaptation, shortening the commissioning cycle and ensuring smooth initial production.
3. Custom Optional Auxiliary Equipment
Personalized selection based on production line status and site conditions: all-copper 24-pulse rectifier transformer, plate heat exchanger (240t/h), open cooling tower (300t/h/450t/h), low-voltage distribution cabinet, installation materials, power/control cables within the boundary area, etc. All optional equipment is precisely matched with core equipment to ensure overall production line compatibility and stability.
National Standard-Level Quality Control, Full-Process Compliance & Traceability
- Strictly Abide by National/Industrial Standards: The whole process of equipment design, production and inspection complies with GB/T10067.3-2005, GB 5959.1-2005, JB/T4280-2004 and other national/industrial standards, with all performance and safety indicators meeting national requirements.
- High-Quality Core Components: All core parts are selected from top industry suppliers, including thick-walled inductor copper tubes, high-performance silicon steel yokes, first-line brand electrical components and high-precision hydraulic parts, ensuring the overall performance and service life of the equipment from the source.
- Multi-Round Factory Inspection: After production, the equipment undergoes full-process performance testing and trial operation covering electrical performance, smelting efficiency, safety protection, etc., and can only leave the factory after passing the test; complete test reports and qualification certificates are attached to realize full-process quality traceability.
Clear Supply-Demand Responsibilities, Ensuring Smooth Project Implementation
1. Supplier’s Core Responsibilities
- Customize equipment design and issue layout/basic condition drawings according to customer site and production needs.
- Undertake the production, outsourcing selection and quality control of all equipment within the supply scope.
- Timely dispatch senior engineers to the site for installation guidance and commissioning assistance, and follow up the whole project progress.
- Provide free professional technical training for customer’s operation and maintenance personnel, covering operation, debugging, fault troubleshooting and other contents.
2. Demander’s Core Responsibilities
- Design and manufacture the equipment foundation according to the supplier’s drawings to meet installation requirements.
- Prepare on-site installation tools such as overhead cranes and hoisting tools to cooperate with the supplier for on-site installation.
- Complete the on-site installation and commissioning cooperation of the equipment in accordance with the supplier’s technical guidance.
- Be responsible for the test and acceptance of high-voltage facilities such as transformers and high-voltage cabinets by the local power supply department.
Full-Process Technical Services & Improved After-Sales Support
1. Pre-Project & On-Site Services
- Customized Design: Issue personalized layout drawings based on customer’s workshop data and provide professional suggestions for production line connection and capacity expansion.
- Standardized Data Delivery: Provide basic design data shortly after the contract takes effect, and deliver a full set of technical documents (paper + electronic version) before equipment delivery.
- On-Site Technical Support: Timely dispatch engineers to guide installation and solve technical problems on site immediately when encountered; provide free theoretical + practical training for operators to ensure proficient mastery of equipment operation and daily maintenance.
2. Comprehensive After-Sales Guarantee
- Bear full responsibility for the quality of components during commissioning (excluding human operation and non-compliant working conditions).
- Provide free repair/replacement warranty for core components (vacuum circuit breaker, capacitor, hydraulic device, etc.), excluding non-equipment factors such as furnace penetration, insufficient water supply and misoperation.
- Provide free equipment maintenance during the warranty period, with rapid response and on-site treatment as soon as possible after receiving maintenance demands.
- Establish a long-term spare parts supply system and provide various spare parts at a preferential price lower than the market price to ensure the long-term stable operation of the equipment.
Strict Working Condition & Operation Specifications, Ensuring Long-Term Equipment Stability
1. Standard Working Condition Requirements
- Environment: Altitude ≤2000m; Temperature 0～40℃; Monthly average humidity ≤90% (wettest month); No conductive dust, flammable, explosive or corrosive gas; Seismic intensity ≤8 degrees.
- Power Supply: 50HZ power frequency; Three-phase voltage unbalance ＜2%; Voltage fluctuation ＜±5%; Voltage waveform distortion rate ＜3%.
- Water Quality: Cooling water pH 7～8.5, suspended solids ＜10mg/L, average chloride ion ＜60mg/L; Closed-circulation cooling water conductivity ＜20μs/cm, meeting softened water standards.
2. Professional Operation & Maintenance Specifications
- It is recommended that furnace lining materials and coil casting slurry be supplied and constructed by professional manufacturers; re-insulate the inductor coil when replacing the slurry.
- Prohibit water flushing during furnace lining disassembly and assembly; regularly check the furnace tilting limit switch and add lubricating oil to the rotating parts of the furnace body.
- Adopt the one-in-use one-standby working mode; ground/power off the standby furnace during maintenance, and reduce the medium frequency output voltage to a safe range when measuring temperature and sampling of the working furnace.
- Prohibit faulty operation and live maintenance of the equipment; arrange production links compactly and feed materials in a timely manner; classify steel scrap and prevent flammable and explosive materials from being mixed into the furnace charge.
Multi-Dimensional Core Value, Your Premium Steel Melting Partner
✅ Efficient Production: One power supply with two furnaces mode + high melting rate, ensuring uninterrupted production line operation and maximizing capacity release.
✅ Energy Saving & Cost Reduction: 24-pulse rectification technology + high-efficiency inductor, realizing low power consumption per ton of steel, reducing grid harmonic pollution and conforming to the trend of green production.
✅ Stable & Reliable: Industrial-grade core components + multiple protection systems, low equipment failure rate and long service life, reducing downtime and maintenance costs.
✅ Intelligent & Convenient: PLC dual control + automatic hydraulic system, simple operation and precise control, lowering the threshold of manual operation and labor costs.
✅ One-Stop Service: Customized design + standardized supply + full-process technical support, solving all customer worries from design to operation in an all-round way.
✅ High Adaptability: Fully compliant with national standards, customizable design according to site and production line needs, adapting to different production scenarios.
Against the background of the steel industry’s upgrading towards high efficiency, green and intelligence, this 25t high-efficiency energy-saving induction furnace is an ideal choice for melting line upgrading and new line construction. Widely applicable to steel manufacturing, casting production, metal processing, rolling mill production and other fields, it helps enterprises optimize energy consumption and operation costs while improving capacity and ensuring molten steel quality, comprehensively enhancing core market competitiveness.
Jointly Build Efficient Steel Melting Lines, Create Industrial Upgrading Value
With technology as the core and customer demand as the guide, we focus on the R&D and solution provision of industrial electrothermal equipment, with a professional design team, mature production technology and improved service system. We provide customized solutions for steel manufacturing enterprises worldwide, and protect customer interests with professional and rigorous services throughout the whole process.
If you have demands for melting equipment upgrading, capacity expansion or new production line construction, we can customize exclusive technical schemes according to your actual working conditions and provide all-round technical consultation and one-stop equipment supporting services!
📩 Professional Technical Consultation & Customized Scheme Docking
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Email: hengyuan6@hotmail.com
