Steel Shell Medium Frequency Induction Furnace

Why Closed Water Cooling System is the superior Choice for foundries?
Introduction Medium frequency induction furnaces are critical to the metal processing industry. A key component of these systems is the cooling system. Kangda Electric Furnace will show you the differences between open water cooling system and closed water cooling system and why closed water cooling system is a superior choice for foundries.
1.Key Differences Between Open Cooling System & Closed Cooling Systems Open Water Cooling Systems Design: Relies on a continuous flow of fresh water to cool furnace components. The water is discharged after a single use. Water Waste: High water consumption, unsuitable for arid regions. Contamination Risk: Dust, sand, or minerals in untreated water cause scaling, corrosion, and blockages. Temperature Instability: External water sources vary in temperature, affecting furnace efficiency. Maintenance Costs: Frequent cleaning and part replacements due to sediment buildup.
Closed-Loop Cooling Systems Design: Uses a sealed circuit with water that recirculates through the furnace and the heat exchanger. Advantages Water Efficiency: Up to 90% less water usage, ideal for water-scarce regions. Controlled Quality: Water is filtered and treated, preventing corrosion and scaling. Temperature Consistency: Stable cooling performance even in extreme climates. Durability: Reduced wear, extending equipment service life.
2. Why Closed Systems Are Recommended 2.1 Climate Adaptability Closed water cooling system operates efficiently even in dust storms and limited water resources, with ambient temperatures up to 50°C (122°F). 2.2 Cost Savings Lower Water Bills: Minimizes reliance on expensive water. Reduced Downtime: Fewer maintenance interruptions mean higher productivity. Energy Efficiency: Heat exchangers optimize thermal management, cutting electricity costs. 2.3 Environmental Compliance Avoids wastewater discharge, aligning with stricter environmental regulations in regions. 2.4 Long-Term Reliability Components like pumps and pipes last longer due to cleaner water/coolant. 2.5 Technical Specifications Corrosion-resistant materials: stainless steel for harsh climates. Modular design for easy installation and scalability.
3. FAQs Q1: Which cooling system is better for desert climates? A: Closed water cooling system prevent dust contamination and reduce water use by 90%. Q2: Is closed water cooling system more expensive? A: Higher initial cost, but 50% lower service life costs due to water and energy savings. Q3: Can I retrofit my existing furnace? A: Yes! Our kits are compatible with most medium frequency induction melting furnace models.
4.Conclusion For industries in Africa, the Middle East, and Central Asia, closed water cooling systems offer unmatched durability, efficiency, and cost savings. Upgrade your medium frequency induction melting furnace and auxiliary equipment today to thrive in challenging environments!

Aluminum Shell vs. Steel Shell Medium Frequency Induction Melting Furnace The Key Differences & Why Steel Shell Medium Frequency Induction Melting Furnace Is Recommended Introduction When selecting a medium frequency induction melting furnace, choosing between steel shell induction melting furnace and aluminum shell induction melting furnace is critical. 1.Key Differences Between Steel Shell and Aluminum Shell Induction Melting Furnaces 1.1.Structural Durability Steel Shell: Built with high-grade steel, these furnaces withstand extreme temperatures, physical stress, and harsh environments. Steel’s high melting point ensures the service life in heavy-duty applications. Aluminum Shell: Aluminium is a highly corrosion resistant lightweight metal that's three times lighter than steel but has a much higher strength-to-weight ratio, which is why it's used as a furnace shell material. However, aluminium has a lower melting point, which makes it less reliable for continuous industrial use. 1.2.Heat Dissipation & Energy Efficiency Steel Shell: Superior thermal stability reduces heat loss, maintaining consistent melting efficiency. This is critical in regions with frequent power fluctuations Aluminum Shell: Aluminum dissipates heat faster, leading to energy waste and higher operational costs. 1.3.Maintenance & Service life Steel Shell: Resists corrosion and mechanical wear, requiring minimal maintenance. It’s an ideal choice for foundries with limited technical support. Aluminum Shell: Easy maintenance and parts replacement due to simple structure design. 1.4.Safety Steel Shell: Robust construction prevents leaks and structural failures, crucial for protecting workers in high-risk environments. Aluminum Shell: When the reducer rotates the furnace body to 95 degrees, the entire furnace body will tilt forward, which is very safe. But higher risk of deformation under thermal stress, posing safety hazards. 1.5.Cost Effectiveness Steel Shell: Higher initial cost but lower lifetime expenses due to durability and energy savings. Aluminum Shell: Lower initial cost but the repairs and energy inefficiency increases higher long-term costs. 2.Why Steel Shell Furnaces Are Recommended Adaptability to Harsh Conditions Steel shell furnaces excel in dusty, high temperature environments. Their design ensures uninterrupted operation even during load shedding or voltage instability. Long-Term Reliability With minimal downtime and maintenance, steel shell induction melting furnace maximize productivity, which is critical for industries like metal recycling, foundries, and automotive manufacturing. Energy Savings Reduced heat loss translates to lower electricity consumption,which is a key advantage in regions with high energy costs or unreliable grids. 3.FAQs Q1: Can aluminum shell induction furnaces handle high capacity melting? A: Aluminum shell induction furnaces are better suitable for users who change production in a short time, with small tonnage. For heavy-duty industrial use , steel shell furnaces are recommended. Q2: Are steel shell Induction furnaces harder to install? A: No—both steel shell induction furnace and aluminum shell induction furnace have similar installation processes. Steel shell units often include reinforced bases for stability on uneven floors. Q3: How do I maintain a steel shell induction furnace in dusty climates? A: Regularly clean the exterior with compressed air and inspect the cooling system. Steel’s anti-corrosion coating simplifies the maintenance. Q4: Which induction melting furnace is safer for operators? A: Steel shell induction furnaces offer enhanced safety due to leak-proof designs and reduced risk of thermal deformation. Q5: Do you provide localized technical support? A: We have service center in most provinces in China, and Algeria, and are trying to setup more partners with service centers for prompt maintenance and spare parts delivery. Conclusion Medium frequency steel shell induction furnaces deliver unmatched durability, safety, high efficiency, and cost effectiveness. Contact us today to explore customized induction heating solutions tailored to your business needs!

Series Resonant Medium Frequency Power Supply vs Parallel Resonant Medium Frequency Power Supply Key Differences, Advantages & Applications 1. Fundamental Working Principles Series Resonant Systems Operate with current amplification through LC resonance Require precise impedance matching Feature automatic frequency tracking Parallel Resonant Systems Utilize voltage amplification characteristics Maintain stable output under load fluctuations Allow flexible impedance adaptation 2. Regional Advantages Analysis Series Resonance Power Supply Advantages lower energy consumption, higher power factor≥95%. Superior performance in high-altitude. Better dust resistance for desert operations . Parallel Resonant Power Supply Benefits Wider voltage tolerance (170-520V) for unstable grids. Built-in harmonic suppression. Modular design simplifies maintenance in remote area 3. Application Scenarios Optimal for Series Resonant Power Supply System Continuous production foundries. Large-scale steel plants or large power induction furnace. One-to-two or one -to- mutual induction furnaces working system. Preferred for Parallel Resonant Power Supply Systems Intermittent operation workshops. Small scale or medium scale steel foundries. Low initial investment foundries and metal processing workshop. Conclusion Contact us now to upgrade your medium frequency power solutions to meet your business needs.

Why Choose IGBT Medium Frequency Power Supply For Induction Furnace? Introduction Discover why IGBT medium frequency power supplies outperform traditional series/parallel systems in metal melting. Core Advantages Higher Energy Efficiency Power factor ≥0.96%，IGBT technology reduces power consumption through high inverter voltage, low current. This is crucial for regions with high electricity costs, like Africa and the Middle East, etc. Constant Power Output The IGBT power supply ensures constant power output. Even full power outputs with a small amount of metal material, speeding up the melting process. Adaptive Voltage Operation Maintains stable performance with voltage fluctuations, ideal for areas with unstable grid infrastructure. Compact Modular Design Nearly 40% smaller footprint vs traditional systems, reducing installation costs in space-constrained facilities. Intelligent Protection Systems Automatic safeguards against common operational challenges: Over-temperature shutdown (50°C+ environments) Dust-resistant cooling systems Surge protection for voltage spikes Lower Maintenance Costs Solid-state design eliminates mechanical wear parts, reducing downtime in remote locations. Conclusion IGBT power supply, KGCL power supply, KGPS power supply and series connected multi-melting power supply system are all available at Kangda Electric Furnace factory. Welcome to contact us for the most suitable power supply for your business needs.

With 24+ years of expertise in industrial induction heating and melting solutions, Shandong Kangda Electric Furnace is a certified high-tech enterprise dedicated to engineering premium medium frequency melting furnaces. Our end-to-end service system, from R&D and manufacturing to global logistics, installation, and lifetime support, ensures the Turnkey solutions tailored to your foundry needs. Trusted Globally, Proven Locally ISO 9001-certified quality with 100+ patented technologies Serving 1,000+ foundries across 30+ countries Core strengths: Safety-first design, High efficiency, energy saving and stable performance. We prioritize operational reliability and cost-saving efficiency, delivering induction melting furnaces that reduce downtime and energy consumption by up to 30%. Backed by 24/7 technical support and a spare parts network, we guarantee your productivity never stops. Shandong Kangda Electric Furnace, Where innovation meets industrial trust.

What About The Delivery, Payment, OEM & More 1. What is the standard delivery time for induction melting furnaces? The typical delivery time ranges is 6–8 weeks from the date of order confirmation, depending on order volume, customization requirements, and production schedules. Bulk orders or complex OEM designs may require additional time. Expedited delivery (4–5 weeks) may be available for urgent orders, subject to detailed information. 2. What payment terms do you accept for international orders? We primarily use T/T (Telegraphic Transfer) with a 50% deposit down payment and 100% payment before shipment. For long-term partners, flexible terms like LC (Letter of Credit)  payments can be negotiated. 3. Do you support ocean freight for global shipping? Yes, Ocean freight is our default shipping method for cost effective bulk shipments. We offer EX Works, FOB or CIF terms depending on the buyer's preference. 4. Can you provide customized or OEM or induction melting furnaces? Yes. We specialize in customized solutions, including: Power supply customization Induction melting furnace customization Closed water cooling system customization Auxiliary equipment customization Branding and labeling per client specifications Submit your technical drawings or requirements for a tailored quote. 5. Is there a minimum order quantity (MOQ)? For standard models: MOQ = 1 unit. OEM orders may require higher MOQs to offset setup costs. Welcome to contact us for trial orders. 6. What certifications do your products have? Our furnaces comply with ISO 9001, but Custom certifications available upon request. 7. How do you ensure product quality during transit? International orders are normally loaded into 20GP, 40GP or 40HQ containers for safe shipment. 8. Do you offer after-sales support and warranties? Yes, all products include free online technical support against manufacturing defects forever. We provide: Remote troubleshooting via video call, photos, videos. On-site technician dispatch (cost to be borne by buyers) 9. Can you assist with customs clearance? We supply full export documentation, including commercial invoices, packing lists, bills of lading, and certificates of origin. Buyers are responsible for local duties/taxes. 10. How energy-efficient are your induction melting furnaces? Our advanced models achieve ≥95% thermal efficiency with IGBT medium frequency power supply. Optional energy recovery modules can reduce power consumption by 15–20%. 11. What materials can your furnaces melt? Steel, iron, copper, aluminum and alloys. Share your material specs for furnace configuration guidance. 12. Do you provide installation training? Yes, free manual instruction are included. For complex installations, we recommend hiring local electricians or arranging our technician’s on-site support. For more information, welcome to contact us at your convenience, thanks.

Precautions for the Use of Closed Water Cooling System for Medium Frequency Induction Melting Furnace I. Requirements for the Use Environment 1.Avoid places with acidic exhaust gas, explosive dust, severe coal smoke, and excessive water vapor. 2.If installed beside a building, maintain a sufficient distance (0.5 - 3M, depending on the model) from the air inlet. 3.If installed in a well or enclosed area, be cautious of hot, humid air re-circulation, which can impede heat dissipation. Consider using exhaust fans in such environments. II. Anti - freezing Measures in Cold Winter 1.Antifreeze Solutions: To prevent freezing of the circulating water, an appropriate amount of antifreeze (such as ethylene glycol solution) can be added to the circulating water. Monitor the concentration to ensure effective freeze protection without compromising heat transfer efficiency. 2.Leakage: Regularly check for leaks. If there is a leak in the circulating water, the water additions can dilute the antifreeze, reducing its effectiveness, please note that. 3.Drainage: the water in the spray tank can be discharged cleanly or flow back to the remote warm water tank after shutdown to prevent freezing. III. Pipe Fitting Issues 1. Piping: Install piping, pumps and valves below the operating water level to avoid overflow and air intake. 2. Pump Capacity: Ensure the pump has sufficient head to account for pressure losses in the piping and cooling coils. Consider the location of the equipment should be placed, there should be enough head of the pump, should be considered along the pressure losses in the piping and cooling coils. 3. Support: The interface flange pressure for fluid cooling is designed to be 1Mpa. Use proper hangers or supports for all piping to maintain stability and prevent damage. IV. Requirements for the Spray System 1. Water Quality: Regularly check and clean the water tank to remove mineral deposits and impurities. This helps prevent scaling and maintains water quality. Cleaning frequency should be weekly in summer and once every two weeks in winter. 2. Water Treatment: Follow the GB50050-95 standard for industrial circulating cooling water treatment. In areas with poor water quality, consider using purified or softened water. V. Circulating Water Use of Pure Water: The circulating water should be pure water (softened water, distilled water) with calcium and magnesium ions removed to minimize scaling and improve system efficiency. VI. Temperature Control Automatic Operation: Set the circulating water temperature to automatically start the spray pump, ensuring consistent cooling performance. Ethylene Glycol (wt%)01020304050588090100 Freezing Point (℃)-0.0-0.0-8-15-24-36-48-47-29-13 For further assistance, please contact your professional induction melting furnace solution provider at +86 15314416872

Pre-Operation Checklist for Medium Frequency Induction Melting Furnace Kangda Electric Furnace will lead you to the safety Pre-operation inspection of industrial metal melting furnaces today. I. Safety Checks in the Induction Melting Furnace Working Area Before starting melting operations, ensure no unauthorized personnel are present near the furnace body or in the control room. Inspect the furnace, pipelines, and copper busbars for obstructions or abnormalities. Verify that there are no foreign objects on the feeding cart and tracks, and the surrounding area is clean for safe operator access. II. Auxiliary Equipment Status Verification Make sure all the following auxiliary equipment have been operating normally before the induction melting furnace works: 1.Check the Water Cooling System for Induction Furnace External/Internal Water Circulation: Turn on the external water circulation control switch and confirm whether the water temperature gauge displays the water temperature.Set the main pump to ON and standby pump to OFF (switch to standby pump if the main pump fails). Ensure spray pumps are in AUTO mode and fans are working.Follow the same procedure to open the internal water circulation control switch. 1.1 Check the water pressure: When the water pump is working normally The Medium frequency power supply: 0.1–0.15 MPa (stable). The Induction Melting furnace: 0.15–0.25 MPa (stable). Notify maintenance if pressure is unstable or insufficient. 1.2 Check The Water Temperature : The outlet of internal and external water circulation are equipped with thermometers, under the working condition of water cooling system, the cooling water temperature should be kept below 40℃ (in summer).If the cooling water temperature is too high,please check whether the closed water cooling system is working normally and the cooling water circulation is smooth. Power supply components: The temperature of the cooling return water for the components inside the medium frequency power supply can be monitored by a temperature inspection instrument. If the water temperature exceeds the set value of the inspection instrument, a temperature alarm is generated. After the cause of the high temperature has been confirmed and eliminated by the equipment maintenance personnel, the temperature will return to the set temperature. The water temperature alarm can be reset by pressing the alarm reset button. 1.3 Check The Water Quality (Optional): Maintain water conductivity <500 μS/cm (25°C) to prevent scaling or contamination. 1.4 Check The Water Flow Rate: Ensure the flow rate is >30 m³/h. Low flow rate caused by leakage will trigger system alarm. 2. Medium Frequency Power Supply Verification Confirm that the high voltage transformer is supplying power to the medium frequency power supply. Confirm that the input voltage of the medium frequency power supply is normal. 3.Check The Hydraulic System Make sure that the signal indicator, the working pressure and the oil level are normal when the hydraulic system is in operation. 4.Leakage Current Monitoring Post-startup, check leakage current values on the local control panel. Normal values are low but may fluctuate with furnace lining wear. Immediate maintenance is required if values exceed safety limit and an alarm is generated.

Industrial Medium Frequency Induction Melting Furnace: Operation & Safety Manual Kangda Electric Furnace will show you the key point from how to Start Up the Induction Melting Furnace to how to the Shut down the induction furnace. 1.Starting Up the Furnace Pre-Start Checks: Ensure cooling water circulation is active. Verify input voltage matches equipment requirements. Confirm the power regulator is set to zero. Power-On Sequence: 1.Turn on the control switch and press the Main Circuit On button. Listen for contactor engagement and motor charging sounds. 2.Confirm both circuit breakers are engaged. 3.After confirming both circuit breakers are engaged, activate the Rectification Start button. Gradually increase DC voltage. 4.Once the DC voltage stabilizes, press the Inverter Start button. A continuous medium-frequency hum indicates successful startup. 5.Slowly rotate the power knob clockwise to maximum capacity. Shutdown for Tapping: Reduce power to minimum (counterclockwise). Press Inverter Stop and pour molten metal. Reload material and adjust the power to continue melting. 2. Shutdown Normal Shutdown: Reduce power knob to minimum. Press Inverter Stop, then turn off the rectifier start knob. Turn off the main circuit breaker and control switch.  Warning: Do not touch the equipment until DC voltage drops to zero. 3.Rapid Discharge: Activate the control switch and press Inversion Start to discharge DC voltage slowly. Monitor until DC voltage reaches 0V, then press Inverter Stop and shut down. 4. Charging, Slag Removal & Molten Metal Handling Charging Guidelines: Avoid damp, contaminated, or sealed materials (e.g., hollow containers, pressurized tanks). Pre-sinter new linings at full capacity. Subsequent charges must stay below the initial sintering level. Add low-melting-point materials (e.g., aluminum) carefully to high-temperature molten pools to prevent explosions. Safety Protocols: Reduce power slightly during charging to minimize mechanical impact on the furnace lining. Prevent electrify and overheating. Wear protective gear during slag removal and maintain a safe distance from the furnace. Tapping Precautions: Ensure no personnel are near the furnace platform. Tilt the furnace slowly and monitor all safety parameters. 5.Material Sticking Prevention & Troubleshooting Preventive Measures: Monitor melting speed and material flow. Address slow feeding immediately. Maintain consistent charging intervals to avoid blockages. Material sticking Resolution: Reduce power to 25% to prevent overheating. Tilt the furnace to allow molten metal to contact the material sticking. Once a hole forms, return the furnace upright and add small amounts of material to dissolve the material sticking. Post-Shutdown Material sticking: Contact maintenance technicians or Shandong Kangda Electric Furnace for guidance. Never attempt manual removal without approval. 6. Cooling System Shutdown Internal Circulation Cooling: Turn off all controls (main pump, spray, fan) after complete furnace shutdown. External Circulation Cooling: Delay shutdown until furnace temperature drops. Set the external circulation system’s timer and switch to Delay Mode. The system will auto-stop after the preset time. Turn off the Delay Knob before the next operation. For more technical support, welcome to contact Shandong Kangda Electric Furnace.

Which Essential Industrial Medium Frequency Melting Furnace Parts That Require Regular Replacement? Industrial medium frequency melting furnaces are vital for efficient metal processing, but their durability and performance depend on proactive maintenance. Regularly replacing critical components minimizes unplanned downtime, enhances safety, and extends equipment lifespan. Below, we outline the key parts needing periodic replacement, their service life, and best practices for optimal furnace operation. 1. High-Frequency Wear Parts (Critical Replacements) 1.1. Induction Coils Recommended Frequency: Inspect every 3–6 months; replace every 1-2 years depending on usage intensity Why Replace?: Prolonged exposure to high temperatures, electromagnetic forces, and molten metal splatter causes oxidation, deformation, or short circuits. 1.2. Crucible/Furnace Lining (Refractory Material) Recommended Frequency: 3–6 months for induction melting furnaces; 6–12 months for molten metal holding furnaces. Why Replace?: Thermal stress and molten metal erosion lead to cracks, risking leaks or accidents. 1.3. Resonance Capacitors Recommended Frequency: 6–12 months. Why Replace?: High-frequency voltage stress causes overheating, capacity loss, or breakdown. 2. Cooling System Components 2.1. Water-Cooled Cables Recommended Frequency: 1–2 years. Why Replace?: Frequent bending and high-temperature water flow degrade insulation, causing leaks. 2.2. Cooling Hoses & Connectors Recommended Frequency: Silicone hoses (2–3 years); metal hoses (3–5 years). Why Replace?: Aging, corrosion, or scale buildup reduces cooling efficiency. 2.3 Heat Exchangers & Cooling Plates Recommended Frequency: 3–5 years (or earlier if clogged). Why Replace?: Scale accumulation lowers heat dissipation, risking IGBT/capacitor failure. 3. Electronic Components (Preventive Maintenance) 3.1. IGBT Modules/Thyristors Recommended Frequency: 2–3 years (or after 10,000 operating hours). Why Replace?: Cumulative switching losses degrade performance, increasing failure risk. 3.2. DC-Link Capacitors Recommended Frequency: 3–5 years. Why Replace?: Electrolyte drying or capacity loss destabilizes DC voltage. 3.3 Fast-Acting Fuses Recommended Frequency: Replace immediately if blown; inspect every 1–2 years. Why Replace?: Aging alters fuse characteristics, compromising circuit protection. 4. Mechanical Components 4.1 Hydraulic Seals (Tilting Mechanism) Recommended Frequency: 1–2 years. Why Replace?: Wear and tear cause leaks, affecting tilting precision. 4.2. Copper Busbars & Connectors Recommended Frequency: 3–5 years (or if heavily oxidized). Why Replace?: Oxidation increases resistance, leading to localized overheating. 5. Other Critical Parts 5.1 Magnetic Yokes (Ferrite Cores) Recommended Frequency: 2–3 years. Why Replace?: Heat and vibration cause cracks, reducing magnetic efficiency. 5.2. Coil Insulation (Mica Sheets/High-Temp Tape) Recommended Frequency: Inspect annually; replace if damaged. Why Replace?: Carbonization from heat degrades insulation, risking short circuits. Harmonic Filter Reactors Recommended Frequency: 5–8 years. Why Replace?: Continuous current surges degrade coil insulation. Proactive Maintenance Tips Track Replacements: Maintain logs with dates, part conditions, and operational data. Stock Critical Spares: Keep high-wear parts (e.g., crucibles, capacitors) and electronics (e.g., IGBTs, fuses) in inventory. Adapt to Conditions: Shorten cycles for harsh environments (e.g., continuous operation, high dust). Why Regular Replacement Matters Cost Efficiency: Avoid costly breakdowns and energy waste. Safety First: Prevent leaks, electrical faults, or fires. Maximize Output: Ensure consistent melting quality and productivity. Need OEM parts or a customized maintenance plan?  Welcome to Contact Us