Customer Application Case: An In-Depth Analysis of the 10-ton Energy-Saving Series Resonant Medium Frequency Induction Aluminum Melting Furnace

When a melting system achieves a specific power consumption of ≤505 kW·h/t and an aluminum scrap loss rate firmly controlled below 1.18%, it is no longer just a piece of equipment. It becomes the core engine for a foundry to reduce costs, increase efficiency, and enhance competitiveness. The 10-ton energy-saving series resonant medium frequency induction aluminum melting furnace from Arkora is precisely such a solution, designed to redefine industry benchmarks.

Facing increasingly fierce market competition and rising energy costs, aluminum casting enterprises are urgently seeking melting equipment that can deliver high output, extreme energy efficiency, and stable reliability simultaneously.

Traditional melting methods, plagued by high energy consumption or significant metal loss, struggle to meet the demands of modern lean production. Drawing on over seventy years of experience in electric furnace design and manufacturing and a deep understanding of customer pain points, our newly developed GWLJ10-6000 series aluminum melting furnace was created to address these challenges.

In the cost structure of aluminum melting, power consumption and metal loss are two primary variables. The 10-ton energy-saving medium frequency furnace achieves industry-leading breakthroughs in both key metrics.

This furnace model is equipped with our independently developed, industry-advanced series resonant medium frequency power supply, with a rated power as high as 6000 kW. Its revolutionary achievement lies in successfully controlling the specific power consumption for melting per ton of aluminum to an exceptionally low level of ≤505 kW·h/t.

Compared to the typical energy consumption of similar products on the market, generally ranging from 560-600 kW·h/t, this means saving at least 55 kWh of electricity for every ton of aluminum produced.

Taking a workshop with a daily capacity of 200 tons (based on 20 operating hours) as an example, this translates to annual savings of millions in electricity costs alone, significantly shortening the investment payback period.

The lower energy consumption stems from the system's efficient design: a power conversion efficiency as high as 96% and a power factor consistently maintained above 0.95 ensure that electrical energy is maximally converted into effective thermal energy, greatly reducing line and conversion losses.

Beyond energy consumption, the utilization rate of metal materials directly determines profit margins. This equipment excels in controlling oxidation loss, with a guaranteed scrap loss rate of <1.18% for materials like aluminum chips.

This figure is far lower than the 3%-8% loss levels typical of gas furnaces and many traditional induction furnaces. For enterprises heavily using recycled aluminum, every percentage point increase in metal yield means a direct reduction in raw material costs and tangible profit growth.

The low loss rate is achieved thanks to the stable melting environment created by the optimized electromagnetic field design, precise temperature control, and the fully enclosed pure water cooling system, which effectively suppresses excessive oxidation of the aluminum melt.

High productivity and high reliability are the cornerstones of modern industrial production. The 10-ton melting furnace boasts a designed melting efficiency of ≥12 tons/hour, with its powerful 6000 kW power ensuring rapid heating and melting.

To guarantee production continuity, the entire system incorporates multiple redundancies and high-reliability design. The hydraulic tilting system features a dual-pump configuration, and the closed-loop pure water cooling system is also equipped with standby pumps, ensuring continuous operation even if a single component fails.

Core electrical components, such as the PLC control system, utilize Siemens brands; contactors and relays are selected from equivalents like Siemens and Schneider; and the coil copper tubes come from top domestic suppliers like Zhongluo Copper. This sourcing from the outset ensures the equipment's long-term stable operation.

The standard remote operation console and computer melting management system elevate the operational experience to new heights. The system integrates advanced functions such as automatic furnace drying, cold furnace startup, fault diagnosis and storage, and operational information display.

All parameters are clearly presented on a touchscreen with a Chinese interface, making the control process digital and visual. The system also features network communication interfaces and wireless transmission capabilities, providing convenient ports for future intelligent expansion, data collection, and integration into Industrial IoT platforms, assisting enterprises in their transition towards smart manufacturing.

Arkora provides not just a set of equipment, but a complete solution. The package encompasses a "turnkey" project, including everything from the dedicated oil-immersed transformer and emergency generator set to full installation, commissioning, and training.

The after-sales service commitment reflects the company's confidence: the equipment warranty period extends for 24 months. In case of a failure within the warranty period, technical staff will respond via phone within 4 hours, and if on-site service is required, arrival is guaranteed within 24 hours.

This comprehensive support ensures customers can commence production without worries and quickly generate value.

The 10-ton energy-saving series resonant medium frequency induction aluminum melting furnace, with its ultra-low specific power consumption of ≤505 kW·h/t, exceptionally low scrap loss rate of <1.18%, high-efficiency melting capacity of ≥12 t/h, and high reliability built upon top-tier brands, represents the advanced level of current medium frequency aluminum melting technology.

It is not merely an upgrade to a single production step but a strategic choice for aluminum casting enterprises to systematically optimize production costs, improve product quality, and enhance market competitiveness.

As green manufacturing and lean production become mainstream today, choosing such a melting solution that integrates efficiency, energy savings, and intelligence is undoubtedly a wise investment for the future.