Choosing the Best Furnace for Your Operations

Melting furnaces for foundry casting alloys can take many forms depending on many factors ;

  • Alloy to be melted and cast; aluminum, zinc, magnesium.
  • Metal demand – volume of molten metal needed every hour.
  • Type of charge material and mix.
  • Transfer rates, ladle size.
  • Holding temperatures.
  • Heating system; electric, gas, oil, etc.
  • Central melt or “point of Use” melting.
  • Working hours ; 8×5 days shift to 24/7 continuous.

Crucible furnaces

  • These are the simplest, most flexible and most cost effective melting solution for smaller foundries.
  • Simple to operate and maintain.
  • Smallest installation footprint allows melt and hold at point of use. Allow for quick alloy changes.
  • Suitable for Al alloys, Zn alloys, Mg alloys and lead.
  • Flexible melting rates from a few lbs depending on metal and alloys .
    • Aluminum to 2,000 lbs/hr (~900 kg/h).
    • Magnesium to 3,000 lbs/hr (~1350 kg/h).
    • Up to 4,000 lbs of aluminum, 18,000 lbs magnesium.
  • Static or tilting versions allow for multi furnace installations combine bulk melt and holding.
  • Electric or fuel fired units available (fuel fired with natural gas, propane, town gas, or oil).

Reverberatory furnaces

  • Bulk melting and holding furnaces with largest capacity range 3,000 to 300,000 lbs holding capacity.
  • Melting achieved on a dry hearth or directly in the bath.
  • Dry hearth and wet bath melting possible in the same furnaces.
  • Generally fuel fired heating using natural gas or oil.
  • Some smaller capacity units can be specified with electric radiant heating.
  • Restricted to a single alloy due to the large holding capacity.
  • Variable efficiency depending on degree of utilization and melting style specification.

Shaft melting furnaces

  • Most efficient fuel fired melting furnaces.
  • Melting capacity limited to approx. 5,000 kg/h (11,000 lbs/hr).
  • Melt on demand performance separates holding and melting performance.
  • Allows for smaller holding capacity and reduced energy consumption Always fuel fired using natural gas, propane or oil.
  • Operation can be automated extensively and integrated with material and molten metal handling systems.
  • Most complex of all the furnace systems but with best capital payback rates.

Chip melting furnaces

  • Purpose designed furnace systems or integrated into conventional melting furnaces or retrofitted to existing furnace installations.
  • Requires a purpose built pocket(s) to install a pump and vortex inducing system for chip submergence.
  • Options for mechanical or EM style metal pumping systems to circulate metal.
  • Melting capacity limited to max 10% of molten bath holding capacity. Burner capacity of holding.
  • Bath must be upgraded from holding only.

Custom Melting Furnaces

  • Every foundry and die caster is a unique operation with a variety of requirements that don’t always fit a “standard” furnace design.
  • SINC Thermal can develop and combine furnace designs in unique and innovative ways to suit your particular requirements.