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Syed Rashid Ahmed ButtShaanxi Chengda Industrial Furnace Co., Ltd. completed the commissioning of electric arc furnace, the workers carefully cooperated with Chengda engineers to learn and operate the equipment, showing the deep friendship and excellent cooperation between the people of China and Pakistan. -
AboubacarAfter more than 1 month of intense production and debugging, 2 sets of heat exchange flue gas settling chamber equipment has been successfully put into operation ~ All the personnel involved in the project have worked hard! ~ -
Ji-hwan【 Warm congratulations 】 Shaanxi Chengda Industrial Furnace Manufacturing Company in South Korea, North Chungcheong County precious metal smelting furnace equipment installation and careful manufacturing and strict commissioning, looking forward to the future in more fields to achieve mutually beneficial win-win cooperation!
Contact Person :
Du
Phone Number :
13991381852
Four-Electrode DC Plasma Smelting Furnace
| Place of Origin | China |
|---|---|
| Brand Name | Shaanxi Chengda |
| Certification | ISO 9001 |
| Model Number | Negotiate based on equipment processing capacity |
| Minimum Order Quantity | 1 unit |
| Price | The price will be negotiated based on the technical requirements and supply scope of Party A |
| Packaging Details | Discuss according to the specific requirements of Party A |
| Delivery Time | 2 months |
| Payment Terms | L/C,T/T,Western Union |
| Supply Ability | Complete production supply chain, supply on time, and meet quality standards |
Product Details
| Total Power | 33000kva | Operatingtemperature | Up To 1600°C |
|---|---|---|---|
| Electrode Diameter | Φ300-600mm | Weight | Depends On Model, Generally 2-15 Tons |
| Use | High-purity Ternary Power Battery | Gas Use | New Clean Energy |
| Powersource | Electric Or Gas Heating | Cost | Varies Depending On Size And Features |
| Coolingsystem | Water-cooled Or Air-cooled | Country Of Origin | Shaanxi, China |
| Highlight | four-electrode DC smelting furnace,plasma smelting furnace for ferroalloy,DC plasma furnace with four electrodes |
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Product Description
Four-Electrode DC Plasma Smelting Furnace
Equipment & Technical Specification Introduction
1. Equipment Overview & Working Principle
The four-electrode DC plasma smelting furnace is a high-temperature metallurgical unit equipped with four symmetrically arranged DC plasma torches/graphite electrodes and DC rectifier power supply plus plasma gas supply system. It generates high-temperature plasma arc at 5,000~8,000℃ by ionizing inert gas (argon/nitrogen) under direct current. Adopting DC transferred arc smelting process, a water-cooled anode is embedded at furnace bottom to form a complete conductive loop. Four electrodes are arranged symmetrically in a rectangular layout to realize uniform heating across the molten bath, which differentiates it from single-electrode furnaces and three-phase AC arc furnaces. It is specially designed for refractory metals, ferroalloys, solid waste recycling (red mud/aluminum residue), and precious metal recovery.
Process Flow: Mains AC → step-down transformation → rectified into DC → four cathode electrodes powered up + process gas fed → high-frequency ignition to form non-transferred pilot arc → transferred main arc ignited between cathode and bottom anode → raw materials melted by ultra-high plasma temperature; sealed furnace enables smelting under inert atmosphere with precise oxygen control.
2. Five Core Assemblies of Furnace Structure
(1) Furnace Body Assembly
- Furnace Shell: Steel plate welded structure with water-cooled jacket, fully sealed negative-pressure design, fitted with flue gas hood for exhaust collection.
- Furnace Lining: Magnesia-carbon brick/corundum castable for high-temperature zone; erosion-resistant precast refractory bricks at slag line; water-cooled copper crucible equipped for lab/pilot-scale furnaces while fixed refractory hearth for large industrial units.
- Furnace Bottom: Embedded water-cooled metal anode (positive pole of DC circuit); optional electromagnetic stirring coil to homogenize bath temperature and chemical composition.
(2) Core Four-Electrode Plasma System
Four plasma torches/graphite electrodes mounted at four rectangular corners with independent servo lifting mechanism, hydraulic fine adjustment and automatic current/voltage stabilization.
- Standard Plasma Torch: Water-cooled cerium-tungsten cathode + water-cooled copper compression nozzle with full jacket circulating cooling.
- Two electrode options: ① Plasma torch for high-purity special metallurgy; ② Impregnated graphite electrode for ore reduction smelting. Four independent power circuits allow continuous low-load operation of remaining three electrodes when single unit under maintenance.
(3) DC Rectifier Power Supply System
High-voltage distribution → step-down transformer → high-power SCR rectifier cabinet with four independent DC current-stabilized power sources. Separate power loop for each electrode to suppress arc fluctuation and improve thermal efficiency at 78%~82%.
(4) Process Gas Supply System
Multi-channel precision pressure-stabilized gas supply for high-purity argon, nitrogen and hydrogen mixture. Process gas injected through center of plasma torches; furnace chamber adjustable between vacuum and slight positive pressure to realize oxygen-free smelting. Complete with mass flow meters, pressure regulators and emergency cut-off valves.
(5) Automation & Auxiliary System
PLC full-process automatic control for electrode lifting, power regulation, gas supply, cooling water interlock and real-time temperature monitoring; matched circulating cooling water station, flue gas dedusting system, sealed feeding unit and tapping/slagging mechanism.
3. Key Equipment Advantages
- Symmetric four-electrode layout ensures even bath temperature with fluctuation ≤±50℃ and minimal component segregation, ideal for high-purity alloy & single crystal production.
- Ultra-high plasma arc temperature (5,000~8,000℃ vs. max 3,000℃ of conventional AC arc), boosting melting efficiency by over 40% for refractory oxide such as alumina and red mud.
- Stable DC current reduces electrode consumption by 35%~50% compared with three-phase AC furnaces to cut running cost.
- Flexible atmosphere control: vacuum/inert/reducing atmosphere available via sealed furnace to avoid metal oxidation; precious metal recovery rate ≥92%.
- High operational tolerance: independent four-circuit power design avoids full-line shutdown for single-electrode overhaul.
4. Main Application Fields
- Special Metallurgy: Melting of Ti, Zr, W, Mo, Nb and other refractory metals, superalloy & high-entropy alloy for aerospace industry.
- Solid Waste Resource Utilization: Red mud ironmaking, calcium aluminate smelting, silicon/ferrous metal recovery from steel slag/fly ash and hazardous waste vitrification treatment.
- Ferroalloy Production: Metallic silicon, ferrosilicon, ferrochrome and ferronickel reduction.
- Advanced New Materials: High-purity ceramic powder, nitride/oxide raw material synthesis.
II. Graded Technical Parameters (Lab / Pilot / Large Industrial Grade)
1. Lab Four-Electrode Vacuum Plasma Furnace (50~200kW, lab ingot sample)
| Item | Specification |
|---|---|
| Rated Total Power | 50kW / 100kW / 200kW (split into four equal single-torch power) |
| Single Electrode DC Parameter | No-load:80~120V; Working voltage:25~55V; Max single-pole current:1,500A |
| Ultimate Vacuum | 6.7×10⁻⁴Pa, pressure rise rate ≤0.5Pa/h |
| Smelting Temperature | 2,200~3,200℃ |
| Single Batch Feeding Capacity | 50g ~ 2kg |
| Protective Gas | High-purity Argon (99.999%), single-torch Ar flow:0.5~3Nm³/h |
| Total Cooling Water Consumption | 8~25m³/h |
| Control Mode | PLC + HMI touch screen auto-control, auto high-frequency arc transfer |
2. Pilot Industrial Furnace (500kW~3,000kW, semi-continuous batch production)
| Item | Specification |
|---|---|
| Installed Total Power | 500 / 1,250 / 2,500 / 3,000kW, evenly split into four power loops |
| DC Output | Working voltage:60~110V; Total current:3,000~25,000A (four-way equal split) |
| Daily Output | 0.8~8 tons (varies by raw material property) |
| Power Consumption per Ton | 520~750kWh/t for alloy smelting; 9,800~11,500kWh/t for metallurgical silicon reduction |
| Total Gas Consumption | 12~45Nm³/h argon, switchable to nitrogen |
| Circulating Cooling Water | 60~220m³/h, inlet water temp ≤32℃ |
| Service Life of Furnace Lining | 120~180 heats for regular smelting |
| Working Condition | Slightly positive sealed atmosphere, optional intermittent vacuum mode |
3. Large-Scale Industrial Four-Electrode DC Plasma Submerged Arc Furnace (5MW~25MW, mass production line)
| Item | Specification |
|---|---|
| Rated Installed Power | 5MW~25MW with four independent rectifier power sources |
| Total Working Current | 30,000~150,000A balanced among four poles |
| Daily Raw Material Handling | 25~120 tons, finished product output:10~55 tons |
| Power Consumption per Ton | 8,500~11,000kWh/t for ferroalloy; 600~900kWh/t for solid waste recycling |
| Plasma Process Gas | N₂-Ar mixed gas, total consumption:80~350Nm³/h |
| Total Cooling Water | 350~1,200m³/h |
| Flue Gas Treatment | Negative-pressure gas collection + dry-type dedusting system |
| Automation | Full DCS remote control with intelligent electrode lifting & power stabilization |
III. Optional Auxiliary Configurations
- Electromagnetic Stirring System: 0~50Hz variable-frequency adjustable stirring intensity for molten bath.
- Fully Sealed Continuous Feeder: Screw-type sealed feeding to prevent ambient air infiltration.
- Vacuum Pump Unit: Mechanical pump + molecular pump set (optional for ultra-high purity material production).
- On-line Temperature Measuring & Sampling: Continuous infrared pyrometer and in-furnace real-time sampling analyzer.
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