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Four-Electrode DC Plasma Smelting Furnace

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Shaanxi CHENGDA Industry Furnace MAKE Co., Ltd.

Province/State:Shaanxi

Country/Region:china

Tel:86-029-88610364-88616691

Contact Person:
Mr.Du View Contact Details

Four-Electrode DC Plasma Smelting Furnace
Brand Name Shaanxi Chengda
Model Number Negotiate based on equipment processing capacity
Certification ISO 9001
Place of Origin China
Minimum Order Quantity 1 unit
Price The price will be negotiated based on the technical requirements and supply scope of Party A
Payment Terms L/C,T/T,Western Union
Supply Ability Complete production supply chain, supply on time, and meet quality standards
Delivery Time 2 months
Packaging Details Discuss according to the specific requirements of Party A
Total Power 33000kva
Operatingtemperature Up to 1600°C
Electrode Diameter Φ300-600mm
Weight Depends on model, generally 2-15 tons
Use High-purity ternary power battery
Gas Use New clean energy
Powersource Electric or gas heating
Cost Varies depending on size and features
Coolingsystem Water-cooled or air-cooled
Country Of Origin Shaanxi, China
Detailed Product Description

Four-Electrode DC Plasma Smelting Furnace

Equipment & Technical Specification Introduction

1. Equipment Overview & Working Principle

The four-electrode DC plasma smelting furnace is a high-temperature metallurgical unit equipped with four symmetrically arranged DC plasma torches/graphite electrodes and DC rectifier power supply plus plasma gas supply system. It generates high-temperature plasma arc at 5,000~8,000℃ by ionizing inert gas (argon/nitrogen) under direct current. Adopting DC transferred arc smelting process, a water-cooled anode is embedded at furnace bottom to form a complete conductive loop. Four electrodes are arranged symmetrically in a rectangular layout to realize uniform heating across the molten bath, which differentiates it from single-electrode furnaces and three-phase AC arc furnaces. It is specially designed for refractory metals, ferroalloys, solid waste recycling (red mud/aluminum residue), and precious metal recovery.
Process Flow: Mains AC → step-down transformation → rectified into DC → four cathode electrodes powered up + process gas fed → high-frequency ignition to form non-transferred pilot arc → transferred main arc ignited between cathode and bottom anode → raw materials melted by ultra-high plasma temperature; sealed furnace enables smelting under inert atmosphere with precise oxygen control.

2. Five Core Assemblies of Furnace Structure

(1) Furnace Body Assembly

  • Furnace Shell: Steel plate welded structure with water-cooled jacket, fully sealed negative-pressure design, fitted with flue gas hood for exhaust collection.
  • Furnace Lining: Magnesia-carbon brick/corundum castable for high-temperature zone; erosion-resistant precast refractory bricks at slag line; water-cooled copper crucible equipped for lab/pilot-scale furnaces while fixed refractory hearth for large industrial units.
  • Furnace Bottom: Embedded water-cooled metal anode (positive pole of DC circuit); optional electromagnetic stirring coil to homogenize bath temperature and chemical composition.

(2) Core Four-Electrode Plasma System

Four plasma torches/graphite electrodes mounted at four rectangular corners with independent servo lifting mechanism, hydraulic fine adjustment and automatic current/voltage stabilization.
  • Standard Plasma Torch: Water-cooled cerium-tungsten cathode + water-cooled copper compression nozzle with full jacket circulating cooling.
  • Two electrode options: ① Plasma torch for high-purity special metallurgy; ② Impregnated graphite electrode for ore reduction smelting. Four independent power circuits allow continuous low-load operation of remaining three electrodes when single unit under maintenance.

(3) DC Rectifier Power Supply System

High-voltage distribution → step-down transformer → high-power SCR rectifier cabinet with four independent DC current-stabilized power sources. Separate power loop for each electrode to suppress arc fluctuation and improve thermal efficiency at 78%~82%.

(4) Process Gas Supply System

Multi-channel precision pressure-stabilized gas supply for high-purity argon, nitrogen and hydrogen mixture. Process gas injected through center of plasma torches; furnace chamber adjustable between vacuum and slight positive pressure to realize oxygen-free smelting. Complete with mass flow meters, pressure regulators and emergency cut-off valves.

(5) Automation & Auxiliary System

PLC full-process automatic control for electrode lifting, power regulation, gas supply, cooling water interlock and real-time temperature monitoring; matched circulating cooling water station, flue gas dedusting system, sealed feeding unit and tapping/slagging mechanism.

3. Key Equipment Advantages

  1. Symmetric four-electrode layout ensures even bath temperature with fluctuation ≤±50℃ and minimal component segregation, ideal for high-purity alloy & single crystal production.
  2. Ultra-high plasma arc temperature (5,000~8,000℃ vs. max 3,000℃ of conventional AC arc), boosting melting efficiency by over 40% for refractory oxide such as alumina and red mud.
  3. Stable DC current reduces electrode consumption by 35%~50% compared with three-phase AC furnaces to cut running cost.
  4. Flexible atmosphere control: vacuum/inert/reducing atmosphere available via sealed furnace to avoid metal oxidation; precious metal recovery rate ≥92%.
  5. High operational tolerance: independent four-circuit power design avoids full-line shutdown for single-electrode overhaul.

4. Main Application Fields

  1. Special Metallurgy: Melting of Ti, Zr, W, Mo, Nb and other refractory metals, superalloy & high-entropy alloy for aerospace industry.
  2. Solid Waste Resource Utilization: Red mud ironmaking, calcium aluminate smelting, silicon/ferrous metal recovery from steel slag/fly ash and hazardous waste vitrification treatment.
  3. Ferroalloy Production: Metallic silicon, ferrosilicon, ferrochrome and ferronickel reduction.
  4. Advanced New Materials: High-purity ceramic powder, nitride/oxide raw material synthesis.

II. Graded Technical Parameters (Lab / Pilot / Large Industrial Grade)

1. Lab Four-Electrode Vacuum Plasma Furnace (50~200kW, lab ingot sample)


ItemSpecification
Rated Total Power50kW / 100kW / 200kW (split into four equal single-torch power)
Single Electrode DC ParameterNo-load:80~120V; Working voltage:25~55V; Max single-pole current:1,500A
Ultimate Vacuum6.7×10⁻⁴Pa, pressure rise rate ≤0.5Pa/h
Smelting Temperature2,200~3,200℃
Single Batch Feeding Capacity50g ~ 2kg
Protective GasHigh-purity Argon (99.999%), single-torch Ar flow:0.5~3Nm³/h
Total Cooling Water Consumption8~25m³/h
Control ModePLC + HMI touch screen auto-control, auto high-frequency arc transfer

2. Pilot Industrial Furnace (500kW~3,000kW, semi-continuous batch production)


ItemSpecification
Installed Total Power500 / 1,250 / 2,500 / 3,000kW, evenly split into four power loops
DC OutputWorking voltage:60~110V; Total current:3,000~25,000A (four-way equal split)
Daily Output0.8~8 tons (varies by raw material property)
Power Consumption per Ton520~750kWh/t for alloy smelting; 9,800~11,500kWh/t for metallurgical silicon reduction
Total Gas Consumption12~45Nm³/h argon, switchable to nitrogen
Circulating Cooling Water60~220m³/h, inlet water temp ≤32℃
Service Life of Furnace Lining120~180 heats for regular smelting
Working ConditionSlightly positive sealed atmosphere, optional intermittent vacuum mode

3. Large-Scale Industrial Four-Electrode DC Plasma Submerged Arc Furnace (5MW~25MW, mass production line)


ItemSpecification
Rated Installed Power5MW~25MW with four independent rectifier power sources
Total Working Current30,000~150,000A balanced among four poles
Daily Raw Material Handling25~120 tons, finished product output:10~55 tons
Power Consumption per Ton8,500~11,000kWh/t for ferroalloy; 600~900kWh/t for solid waste recycling
Plasma Process GasN₂-Ar mixed gas, total consumption:80~350Nm³/h
Total Cooling Water350~1,200m³/h
Flue Gas TreatmentNegative-pressure gas collection + dry-type dedusting system
AutomationFull DCS remote control with intelligent electrode lifting & power stabilization

III. Optional Auxiliary Configurations

  1. Electromagnetic Stirring System: 0~50Hz variable-frequency adjustable stirring intensity for molten bath.
  2. Fully Sealed Continuous Feeder: Screw-type sealed feeding to prevent ambient air infiltration.
  3. Vacuum Pump Unit: Mechanical pump + molecular pump set (optional for ultra-high purity material production).
  4. On-line Temperature Measuring & Sampling: Continuous infrared pyrometer and in-furnace real-time sampling analyzer.
Product Tags: four-electrode DC smelting furnace   plasma smelting furnace for ferroalloy   DC plasma furnace with four electrodes  
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