Steel mills & alloy foundries are constantly troubled by high melting costs, frequent production halts, grid harmonic pollution and inadequate safety protection. Traditional single furnaces force full-line shutdown during lining maintenance with outdated manual monitoring.
This article introduces a mature 35-ton dual induction furnace package, ideal for new melting workshop construction or energy-saving retrofits.
1. Dual Furnace Design: Non-Stop Production
One power unit serves two furnaces: one runs continuous melting, the other handles baking & heat preservation via dedicated baking power.
The mechanical furnace switch comes with safety interlocks and automatic grounding for idle coils to eliminate live-switch risks.
Two wireless hydraulic charging trolleys work alternately with large-capacity hoppers for smooth scrap feeding.
Two independent closed plate heat exchangers separately cool electrical components and furnace coils. Low-conductivity purified water minimizes scaling & overheating to extend service life.
2. Stable & Reliable Melting Performance
All performance indicators pass strict hot melting acceptance tests with reasonable tolerance ranges.
- Rated tapping capacity: 35t, supports higher safe load temporarily
- High melting efficiency with controllable melting cycles
- Much lower power consumption than conventional single furnaces
- Fits carbon steel & low-alloy steel production with standard tapping temperature
Continuous stable tapping is required for acceptance. We optimize coils, power supply and control programs on-site if actual output fails to meet design standards.
3. 24-Pulse Rectifier Transformer – Eliminate Grid Harmonics
Medium-frequency furnaces are heavy non-linear loads that easily distort factory power grids. Our split 24-pulse rectifier transformer effectively suppresses low-order harmonics.
- Full copper windings with electrostatic shielding
- Secondary microcomputer overcurrent protection
- Instant high-voltage trip signals for transformer faults (high oil temperature, gas relay alarms)
- Forced oil-water closed cooling & off-circuit voltage regulation, adaptable to unstable industrial power grids
4. Low-Loss & Durable Furnace Body
The induction coil adopts thick T2 copper flat winding with high-temperature insulation between turns, integrally poured with refractory materials at factory to avoid arcing damage.
Surrounding waterless magnetic yokes absorb stray flux, cut energy loss and prevent overheating of steel structures.
The hydraulic tilting mechanism achieves full tapping with a large tilt angle. Explosion-proof safety valves on cylinders stop sudden furnace drop if oil pipes break; safety limit structures on the furnace frame guarantee tapping stability.
5. Intelligent PLC Control System with Multi-Layer Safety Protection
Equipped with professional melting control system + HMI touch screen, supporting 3 operation modes: local manual, centralized auto control, wireless remote tilting.
Key Advantages
✅ Real-time monitoring of power, cooling water and lining insulation status
✅ Multiple safety interlocks to reduce power or shut down automatically under abnormal conditions
✅ Auto storage of operation curves & alarm logs for quick troubleshooting
✅ Built-in IoT module for cloud data upload & remote diagnosis
✅ Fiber-optic signal transmission: heat, dust & electromagnetic interference resistant
An independent earth leakage detector monitors lining insulation in real time to predict lining damage and prevent steel leakage accidents.
6. All-In-One Complete Supply Scope
Full package includes:
Dual furnace bodies, frequency power supplies, reactors, capacitor banks, furnace switch, hydraulic tilting station, plate heat exchangers, hydraulic charging trolleys, PLC intelligent control system, water-cooled cables, full set of spare parts, CAD drawings & operation manuals.
7. Basic Operation & Safety Guidelines
The equipment fits standard workshop altitude, electrical room temperature and grid fluctuation ranges. Low-conductivity purified water is required for inner circulation, with emergency cooling water prepared for power failure.
Core safety rules:
- Ground idle coils fully before maintenance
- Discharge capacitors completely before cabinet inspection
- Flush hydraulic pipelines to standard cleanliness before commissioning
- No sealed or flammable scrap inside the furnace
- Complete transformer withstand voltage test after long idle periods
8. Full-Round Professional Technical Support
We provide full-cycle technical services, covering site layout survey, installation guidance, hot commissioning and operator training.
Core electrical components are covered under warranty. Our after-sales team offers fast global response & on-site maintenance, with stable long-term supply of genuine spare parts.
Closing Remarks
With stricter global energy-saving policies and grid access standards, outdated single furnaces can no longer match modern high-efficiency metallurgical production.
This 35t dual induction furnace integrates four core strengths: non-stop dual-furnace production, harmonic suppression, independent closed cooling and full-process safety interlocks, delivering high throughput, low energy consumption, grid compatibility and safe operation.
If you plan a new melting line or energy-saving upgrade for your existing furnaces, send me a DM with your production requirements, and I will share customized technical data & solution reference.
Comment Prompt
What’s your biggest pain point with your current melting furnace? High power consumption, frequent downtime, grid harmonics or insufficient safety systems? Feel free to share your thoughts below.
