Induction Smelting Furnaces for Mining Industry

1. Introduction

In today’s competitive mining environment, every gram of recovered precious metal counts. Modern refineries and gold- or silver-processing plants increasingly depend on induction smelting furnaces to transform concentrates and precipitates into high-purity bullion. These systems combine electromagnetic precision with clean, fuel-free heating — producing faster melts, lower energy bills, and consistent metal quality.

At Electroheat Induction, Our advanced electric induction smelting furnaces are designed for continuous operation in tough mining environments, offering efficient melting, uniform temperature control, and safe, smoke-free performance supported worldwide by our engineering team.

 Our  induction furnaces for silver and gold precipitate  (product of Merrill-Crowe Process or Electrowinning Process) ensure that you receive optimal metal recovery, while delivering extraordinary energy efficiency through the most advanced induction melting technologies available.

2. Induction Smelting in the Mining Industry

Induction furnaces are transforming precious metal recovery in the mining industry, offering a superior solution for smelting gold and silver, especially precipitates from processes like Merrill-Crowe or electrowinning. This advanced technology provides numerous benefits:

• Direct and Efficient Heating: Heat is generated directly within the metal, leading to rapid and even melting.
• High Purity: The flame-free process prevents contamination, ensuring pure alloys.
• Customizable Solutions: Furnaces can be customized for various metals and alloys.
• Improved Operations: Boosts throughput and enhances recovery rates.
• Optimized Gold Recovery: Advanced techniques, like in-situ iron collection, improve gold recovery from complex materials such as cyanidation tailings

3. Technical Specifications and Capacity Range

Electroheat provides a comprehensive portfolio of industrial induction smelting furnaces, ranging from compact laboratory-scale models to large-capacity units engineered to process multiple tons of material per batch.

The layout below (Figure 1) illustrates a standard induction smelting configuration commonly employed in Electroheat’s mining furnace designs, showing the relationship between the power supply, coil, and crucible.

Each furnace incorporates advanced technical features, including water-cooled copper coils, robust refractory linings, and medium-frequency power supplies designed to optimize electromagnetic stirring, thereby ensuring homogenous heating throughout the melt. This precise control over the molten bath enhances metallurgical reactions and contributes to the production of high-purity metals.

Specifications:

• Output Power Rating: 50 kW to 2000 kW
• Melting Capacity: 50 kg to 3 tons working capacity 
• Application: Suitable for medium and large-sized applications
• Frequency: Medium and Low frequency depends on the application 

4. Intelligent Features and Control Systems

• Real-time Monitoring: Advanced Human-Machine Interface provides instant insights into critical operational parameters like temperature, voltage, and current.
• Data-Driven Precision: Meticulously log up to 10 years of production data and track precise process parameters for unparalleled analysis.
• Remote Expertise: Secure remote diagnostics and troubleshooting via a static IP connection ensure continuous support.
• Elevated Safety: Sophisticated automation capabilities significantly enhance operational safety.
• Maximized Uptime: Minimize unscheduled downtime, ensuring continuous and reliable production.
• Repeatable Excellence: Guarantee highly consistent smelting cycles, a fundamental attribute of modern medium-frequency induction furnace designs.

5. Why Choose Induction Over Conventional Smelting

Induction technology eliminates the inefficiencies of fuel-based furnaces. It provides precise temperature control, faster melting, and zero direct emissions — all key advantages for sustainable mining.

Feature	Induction Smelting Furnace	Conventional Fuel Furnace
Heating Type	Electromagnetic, clean energy	Combustion-based heat
Energy Efficiency	70 – 80 %	35 – 50 %
Metal Purity	High – no fuel contamination, uniform melt	Moderate – possible fuel impurities, uneven heating
Environmental Impact	Zero direct CO₂ or particulate emissions, quiet operation	High emissions, smoke, noise pollution
Process Repeatability & Data	Digital automation, precise control, data logging for consistency	Manual operation, variable control, limited data for analysis
Operational Safety	No open flame, reduced heat loss to surroundings, safer work environment	Open flame, high radiant heat, risks associated with fuel handling
Maintenance	Low – simple refractory change, fewer moving parts, increased uptime	High – frequent repairs, burner maintenance, reduced uptime

6. Applications Across Mining and Refining

Electroheat Induction furnaces are used in key mining and refining applications:

• Gold and Silver Smelting: Efficiently smelt concentrates, particularly from Merrill-Crowe or electrowinning, ensuring high recovery yields with precise temperature control.
• Precious Metal Recovery: Recover residual metals from challenging materials like metallurgical slags and mine tailings, enhancing resource utilization.
• High-Purity Bullion Production: Produce market-ready bullion with controlled heating that minimizes contamination, meeting stringent quality standards.

These clean, energy-efficient systems help mining and refining operations achieve consistent production, comply with environmental regulations, and support sustainable practices.

7. Global Reach and Technical Support

With installations across Africa, Europe, the Middle East, and the Americas, Electroheat Induction provides full project support — from design and manufacture to commissioning and operator training. Our technical teams offer on-site service and remote diagnostics, ensuring your equipment maintains maximum uptime.

“Providing Worldwide Installation and Expert Consultation.”

8. Why Electroheat Induction

As a pioneer in IGBT-based induction technology, Electroheat delivers reliable, energy-efficient smelting solutions tailored for the mining sector. Each industrial induction smelting furnace is engineered to deliver superior heat uniformity, lower operating costs, and long service life — proven across foundries and refineries worldwide.

Electroheat furnaces are outfitted with a built-in diagnostic tool called HMI screen. Graphical display of electrical parameters provided on the control screen. Data logging facility can store up to 10 years’ data such as kW’s consumed, daily and minute wise reports. Remote web monitoring/control can be done using static IP for trouble shooting purpose.

In partnership with our clients, we combine engineering precision, sustainability, and global support to redefine metal recovery excellence.
👉 Contact us today for a free quote on a custom-designed induction smelting furnace for your mining or refining facility.

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Crucible Number (EX/EHM)	Outside Diameter (D) (mm)	Height (H) (mm)	Brass Capacity (Kg)	Brass Capacity (Lbs)	Brimful Capacity (Litres)
EX323	165	318	25	55	4.3
EX1601	222	470	60	132	10
EX447	254	400	75	165	13
EX444	254	475	90	200	15
EX552	295	450	114	250	20
EX329	330	530	148	325	25
EX330	330	635	183	402	31
EX390	362	508	178	392	30
EX185	390	460	185	407	31
EX187	390	535	218	480	37
EX181	390	632	260	572	44
EX702	445	635	359	790	61
EX703	445	585	329	724	56
EX71	445	660	374	823	64
EX70	445	762	435	957	74
EX722	500	560	371	816	64
EX72	500	775	540	1188	92
EX75	530	650	524	1153	90
EX572	570	710	683	1502	117
EX573	570	755	729	1604	125
EX574	570	825	801	1762	137
EX575	570	865	842	1852	144
EX576	570	890	867	1907	148
EX571	570	900	878	1931	150
EX570	570	1000	980	2156	168
EX650	645	1000	1072	2358	183
EX651	649	1150	1272	2798	217
EX652	650	1190	1327	2919	227
EX800	800	1100	2199	4838	376
EX860	800	600	1152	2534	196
EX875	800	750	1466	3225	250
EX905	905	1100	3115	6853	533

• All above crucibles can be supply with spout upon request.
• Wall thickness of the crucible vary from size to size of the crucible. Wall thickness will be approx. 25 mm for small crucible and 45 mm for large size crucible. Contact us for more information.

We provide Silicon Carbide and Graphite Crucible. Contact us for quote.