What Is the Electric Induction Melting Furnace?

The HLQ KGPS Electric Induction Melting Furnace is an intermediate-frequency, SCR/thyristor-controlled coreless induction furnace system for batch melting of steel, cast iron, copper, aluminum and compatible alloys. The published product range covers nine furnace charge classes from 10–50kg to 1500kg, rated power classes from 50–1000kW, and operating frequencies of 0.8–2.5kHz. It is designed for industrial foundries requiring a matched power converter, capacitor bank, refractory-lined furnace, cooling system and pouring arrangement. Rated charge capacity is measured in kilograms per batch, not kilograms per hour. Actual melting efficiency, production output and electrical performance must be validated under defined operating conditions.

Quick Answer: Product Overview

For a detailed comparison of electrical power converters, explore HLQ’s
KGPS induction generator power supplies.

Key Applications

Industrial electric induction melting furnaces convert electrical energy into heat inside conductive metal. Their applications include steel casting, iron foundries, nonferrous alloy production and metal recycling.

Industrial Application Comparison

Typical Foundry Process Requirements

For ferrous metal applications, see HLQ’s
induction furnaces for melting iron and steel.

Suitable Materials

Induction melting efficiency depends on the electromagnetic and thermal properties of the charge, including electrical resistivity, magnetic permeability, thermal conductivity, density and melting enthalpy.

Material Compatibility

Material Properties Affecting Induction Melting

For larger copper melting applications, explore HLQ’s
induction copper melting furnace solutions.

Working Principle

The KGPS induction melting system uses SCR-controlled power electronics to generate intermediate-frequency alternating current.

Alternating current passes through a water-cooled copper induction coil surrounding the melting chamber.

The resulting alternating magnetic field induces eddy currents within conductive metal. Electrical resistance converts these currents into heat, progressively melting the charge.

Electromagnetic forces can also produce circulation within the molten bath, depending on the furnace construction and operating conditions.

Figure 1. KGPS Induction Melting Furnace Working Principle

         THREE-PHASE AC POWER
                  |
                  v
       +---------------------+
       | SCR RECTIFIER       |
       +---------------------+
                  |
                  v
       +---------------------+
       | DC LINK / REACTOR   |
       +---------------------+
                  |
                  v
       +---------------------+
       | THYRISTOR INVERTER  |
       +---------------------+
                  |
                  v
       +---------------------+
       | COMPENSATION        |
       | CAPACITOR BANK      |
       +---------------------+
                  |
                  v
       +---------------------+
       | WATER-COOLED        |
       | INDUCTION COIL      |
       +---------------------+
                  |
                  v
        ALTERNATING MAGNETIC
                FIELD
                  |
                  v
       +---------------------+
       | REFRACTORY-LINED    |
       | METAL CHARGE        |
       +---------------------+
                  |
                  v
           EDDY CURRENTS
                  |
                  v
         HEAT GENERATION
                  |
                  v
         COMPLETE MELTING
                  |
                  v
       TEMPERATURE / CHEMISTRY
                  |
                  v
           SAFE POURING

Working Principle by Component

Technical Specifications

The following specifications are based on the original HLQ product information. Rated power, electrical consumption and melting time should be confirmed during factory testing.

General Technical Specifications

KGPS Furnace Capacity and Electrical Parameters

Electrical clarification: The original page uses the input-voltage label “380-2” for the 1000kg and 1500kg configurations. This entry must be clarified by the manufacturer. It should not be interpreted as a confirmed electrical supply specification.

Published Electrical Energy Consumption

The electrical consumption and melting-time values above are published reference data. They do not establish guaranteed performance under identical cold-start conditions, tapping temperatures or electrical measurement boundaries.

Recommended Model Selection

The recommended induction furnace should be selected according to metal grade, charge weight, temperature, required production rate, electrical supply, cooling and refractory requirements.

Recommended Furnace Capacity Selection

These are the published KGPS furnace classes, not independently validated production recommendations. Final power selection requires measured real input power, actual metal temperature and melt-cycle verification.

Customer Model Selection Checklist

For aluminum production, compare HLQ’s
induction aluminum melting furnace equipment.

Process Workflow

An industrial melting process should follow a documented procedure covering material inspection, furnace preparation, controlled induction heating, melt analysis and safe pouring.

Figure 2. Industrial Induction Melting Workflow

      MATERIAL IDENTIFICATION
                |
                v
       CLEAN AND DRY CHARGE
                |
                v
     REFRACTORY LINING CHECK
                |
                v
    COOLING AND SAFETY CHECK
                |
                v
        CONTROLLED CHARGING
                |
                v
      START INDUCTION MELTING
                |
                v
      ELECTRICAL MONITORING
                |
                v
     MELT TEMPERATURE CONTROL
                |
                v
       METAL CHEMISTRY CHECK
                |
                v
       PREPARE DRY LADLE
                |
                v
       CONTROLLED POURING
                |
                v
       RECORD PRODUCTION
                |
                v
        FURNACE INSPECTION

Production Quality Control

Coil and Fixture Design

The induction coil, refractory lining and furnace structure must be designed as an integrated system. Coil turns, copper conductor dimensions, compensation capacitance and cooling arrangements depend on the metal charge and resonant electrical conditions.

Induction Coil Design Requirements

Cooling Water Engineering

For ordinary cooling water:

Cooling Load (kW) = 1.163 × Water Flow (m³/h) × Temperature Rise (°C)

The following calculations assume a 5°C temperature increase between cooling-water inlet and outlet.

These are theoretical water-side calculations, not confirmed cooling capacities for particular HLQ furnaces. Final cooling selection requires measured heat rejection, hydraulic pressure losses, branch flow and water-quality requirements.

Control System and Automation

The KGPS system uses thyristor-based electrical power control. The original product description also mentions automatic load tracking, electrical protection and optional temperature feedback and PLC/HMI integration.

Control and Safety Functions

Recommended Production Monitoring Parameters

Common Problems and Solutions

Engineering Selection Guide

Selecting an industrial induction melting furnace requires consideration of thermal energy, electrical power, melting capacity, production cycle, utility infrastructure and refractory conditions.

1. Calculate Electrical Energy Required for Melting

Electrical Energy (kWh) = Charge Weight (tonnes) × Specific Electricity Consumption (kWh/t)

For example, the original catalog lists a 500kg steel furnace with a specific electricity consumption of 700kWh/t.

Energy = 0.5 × 700 = 350kWh

This calculation reproduces the catalog relationship. It is not an independent performance measurement.

2. Calculate Energized Melting Time

Estimated Energized Time (min) = 60 × Electrical Energy (kWh) / Average Real Input Power (kW)

Published Steel Melting Data: Engineering Consistency Check

Engineering finding: Assuming the published rated power represents sustained real electrical input and the energy values use the same measurement boundary, the calculated steel melting times for 150kg, 250kg, 350kg and 500kg exceed their corresponding published maximum melting times.

The manufacturer should clarify the power-rating definition, initial furnace condition and melting-energy measurement boundary before offering a guaranteed cycle time.

Figure 3. Electrical Power vs. Melting Time

ILLUSTRATIVE 500kg STEEL MELT
ASSUMED ELECTRICAL ENERGY = 350kWh

AVERAGE INPUT        ENERGIZED TIME

150kW   ############################  140min

200kW   #####################         105min

250kW   #################              84min

300kW   ##############                 70min

Calculation only.
Not measured HLQ furnace performance.

3. Calculate Actual Production Capacity

The rated furnace charge capacity does not equal hourly production.

Gross Production (t/h) = 60 × Charge Weight (tonnes) / Tap-to-Tap Time (minutes)

For example, a 500kg furnace with a hypothetical 115-minute complete cycle provides:

Gross Production = 60 × 0.5 / 115 = 0.261t/h

Illustrative Production Comparison

These are hypothetical arithmetic examples and are not guaranteed HLQ production capacities.

4. Electrical Infrastructure Calculation

For a balanced three-phase supply:

Apparent Power (kVA) = 1.732 × Line Voltage (V) × Line Current (A) / 1000

Real Power (kW) = Apparent Power (kVA) × True Power Factor

Actual transformer and cable selection must consider supply voltage, current, harmonics, electrical protection and measured power factor.

Electrical Design Checklist

5. Electricity Cost per Accepted Tonne

Electricity Cost per Accepted Tonne = Electrical Energy per Batch × Electricity Tariff / Accepted Metal (tonnes)

Consider a hypothetical 500kg charge consuming 350kWh, with 95% accepted-metal yield and electricity priced at USD 0.12/kWh.

Electricity cost per batch:

350 × 0.12 = USD 42

Accepted metal:

500 × 0.95 = 475kg

Electricity cost per accepted tonne:

42 / 0.475 ≈ USD 88.4/t

This is an illustrative electricity-cost calculation. It excludes raw materials, refractories, labor, maintenance, capital costs and other operating expenses.

6. Factory Acceptance Test

Advantages

Limitations

Why Choose HLQ Induction Equipment?

HLQ Induction Equipment Co., Ltd. supplies intermediate-frequency induction power supplies and industrial metal melting systems.

For foundry applications, selecting the correct furnace requires matching electrical power, operating frequency, charge capacity, refractory lining, cooling system and pouring equipment.

Customers should request accurate technical specifications, measured energy consumption and factory acceptance results using representative production materials.

For additional furnace configurations, explore HLQ’s
industrial induction furnace systems.

Technical Information Required for Quotation

Core FAQs

FAQ 1. What is an electric induction melting furnace?

An electric induction melting furnace uses alternating magnetic fields to generate electrical currents and heat within conductive metal. The HLQ product page describes an industrial KGPS/SCR intermediate-frequency melting system designed for batch metal production.

FAQ 2. What melting capacities are available?

The published furnace capacities include 10–50kg, 100kg, 150kg, 250kg, 350kg, 500kg, 750kg, 1000kg and 1500kg.

These values represent charge capacities rather than guaranteed hourly production.

FAQ 3. What power and frequency does the furnace use?

The original product table lists power ratings from 50kW to 1000kW and operating frequencies of 0.8–2.5kHz.

The correct frequency depends on the specific furnace size and its resonant electrical load.

FAQ 4. Can the furnace melt steel, copper and aluminum?

The published performance table includes steel, cast iron, copper and aluminum. Each material requires suitable crucible or refractory construction, temperature control, charging procedures and quality inspection.

FAQ 5. How is induction melting time calculated?

A preliminary energy-based estimate can be calculated by dividing total electrical energy for the charge by the average real electrical input power.

The complete production cycle also includes charging, superheating, chemical analysis and pouring.

FAQ 6. Why do some published melting times differ from the calculated values?

For certain furnace capacities, the original power ratings and specific electricity-consumption values produce calculated energized times longer than the stated melting-time ranges.

Possible explanations include different test conditions, warm-furnace operation, power-rating definitions or outdated data.

The manufacturer should clarify these differences using measured factory performance records.

FAQ 7. What cooling system is required?

The original page lists cooling-water flow from 3t/h to 25t/h depending on furnace capacity.

The complete cooling system must also satisfy water-temperature, pressure, water-quality and heat-rejection requirements.

Final selection should follow the manufacturer’s hydraulic and thermal design.

FAQ 8. How should an industrial induction melting furnace be selected?

Customers should specify the metal grade, required charge weight, production rate, tapping temperature, electrical supply, cooling conditions and pouring arrangement.

The final equipment should be validated through a factory acceptance test covering actual input power, electrical energy consumption, melt time, metal quality, cooling performance and safety systems.