How the Induction Furnace Helped Improve Copper Melting

induction furnace for copper melting Set up

Why induction furnace is perfect for melting copper:

There are various methods for melting copper, such as melting copper on a stove, with a torch or using an induction furnace. Melting copper by using an induction heating furnace is the most effective method than any other method and this method is highly preferred by the industries. Copper has a very high melting point which is nearly equal to 1084 degrees Celsius. In the copper smelting industry, the temperature applied in the copper smelting process usually ranges from 1000-1200 degrees Celsius. For this reason, the induction furnace heating process is a good match for melting copper.

Working principle of induction furnace:

  • The induction heating furnace applies electromagnetic current to heat conductive metal copper. The heat produced by the current can dissolve a big quantity of copper within a few minutes.
  • The dimension and power of the induction system are dependent on the needs. A mini furnace can be used to melt copper if the quantity of copper is less.
  • The copper needs to be turned into small pieces. If the copper scrap is used, it must be free of any contaminants, such as rust and paint.
  • Copper scraps need to be placed into the crucible. Crucible containers should have enough capacity for bearing high temperatures. The crucible should be placed in the middle of the induction heating coil.
  • The induction heating system should be turned on and the power and frequency should be set up according to the copper’s melting temperature. Within a few minutes, the copper will start melting after reaching its melting point
  • The induction heating system should be turned on immediately once the copper has been heated. Then, the molten copper should be poured into the mold or container. Once the molten copper is cooled and solidified, then it should be refined again for required usage
Induction Furnace Sectional View
Induction Furnace Sectional View

Applications of melted copper:

Copper is melted through the induction heating method which is an efficient melting process with minimal material loss. Melted copper has numerous useful applications in various areas, such as:

  • Manufacturing: Melted copper can be used in tubing, wire, and sheet metal for applications in electronics, HVAC networks and other usages.
  • Reusing: Once the copper is melted, the copper castings are produced and those castings can be used in alternative products.
  • Ornamentation: After melting the copper in the induction furnace, the melted copper can be shaped into complicated designs and patterns which can be used to generate jewelry designs and parts.

How the induction furnace helps to improve copper melting:

  • Regulated temperature: One of the key benefits of using an induction furnace for melting copper is that it provides accurate temperature regulation. Thus, it assures a compatible and steady melting process of copper. By controlling the appropriate temperature, an induction furnace can help to improve the copper melting process.
  • Fast melting: An induction melting process is always a better choice for melting copper than any conventional copper melting system because it takes very less time to melt the copper. Thus, an induction furnace can improve copper melting by saving melting time.
  • High productivity: Induction heating raises the productivity rate becausethe induction furnace can melt copper with speed and efficiency. When the matter of melting of high quantity of copper comes into consideration, an induction furnace is always the best choice.
  • Power efficiency: Since induction furnace applies less power to melt copper through the electromagnetic induction method, its power efficiency is quite high. Thus, an induction furnace can improve copper melting process by saving high amount of power.
  • Operating cost: Although the induction furnace system is an expensive system due to the requirement of its advanced technology, it is the best choice for energy efficiency and less maintenance. It is a more reliable and safer system than any other system.
  • Materials supplying rule: To melt copper alloy, the metal which has the most charge should be supplied into the furnace first for melting to create a molten metal pool. After that, other metal materials need to be added to reduce to lower the melting loss of metal materials.
  • Melting ordering: Readily oxidized and volatile alloy elements should be placed into the furnace last for melting, which can avoid a huge amount of volatilization and burning loss.

 

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