\n| Industrial<\/td>\n | 1\u20135 t<\/td>\n | 750\u20133 500 kW<\/td>\n | 0.15\u20131 kHz<\/td>\n | 350\u20133 500 kg\/h<\/td>\n | 380\u2013430 kWh\/t<\/td>\n | 150\u2013400<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n Input voltages range from 3\u00d7380\/415 V up to 6\u201310 kV for larger units. Power factor is maintained \u22650.95 with automatic correction. Water-cooled copper induction coils and multi-layer refractory linings (high-purity alumina, magnesia or chrome-magnesia) provide thermal insulation and chemical resistance to molten copper at 1 100\u20131 300 \u00b0C.<\/p>\n Technological Process Overview<\/h2>\nScrap Copper Melting & Refining Route<\/strong><\/p>\nRed copper scrap is charged via automated or semi-automatic charging system \u2192 enters the melting furnace (shaft, tilting or reverberatory) \u2192 controlled melting under optimized atmosphere \u2192 slag removal and refining (fluxing, deoxidation) \u2192 precise hydraulic tilting with laser-guided flow control \u2192 high-purity molten copper transferred directly to CCR line, ingot casting machine, or cathode casting turntable.<\/p>\n Advanced regenerative burners and high-temperature refractory linings minimize oxidation, maximize thermal efficiency, and ensure consistent melt chemistry. Waste heat recovery systems further improve overall plant energy balance.<\/p>\n \u0627\u0644\u0645\u0632\u0627\u064a\u0627 \u0627\u0644\u062a\u0642\u0646\u064a\u0629 \u0627\u0644\u0623\u0633\u0627\u0633\u064a\u0629 \u0648\u0627\u0644\u0641\u0648\u0627\u0626\u062f \u0627\u0644\u062a\u0634\u063a\u064a\u0644\u064a\u0629<\/h3>\nMultiple Flexible Furnace Configurations<\/strong><\/p>\n\n- Shaft-type Furnaces<\/strong>: Continuous high-output melting (10\u201340 t\/h). Excellent thermal efficiency through counter-current heat exchange between rising hot gases and descending charge. Ideal for large-scale cable scrap recycling plants feeding CCR lines. Typical natural-gas consumption 30\u201340 Nm\u00b3\/t.<\/li>\n
- Round Tilting Furnaces<\/strong>: Batch operation with easy charging and precise tilting for controlled pouring. Suitable for capacities from 1\u201380 tons.<\/li>\n
- Tilting Scrap Copper Melting Furnaces<\/strong>: Designed for convenient slag removal and refining. Handles 25\u2013150 ton batches with \u226590% copper scrap (including minor lower-grade material). Hydraulic tilting angle up to \u226470\u00b0 ensures controlled outflow. Typical melting cycle 3\u20134 hours per batch.<\/li>\n
- \u0623\u0641\u0631\u0627\u0646 \u0639\u0627\u0643\u0633\u0629<\/strong>: Large-scale refining and holding capacity (25\u2013150 tons). Excellent for maintaining molten copper quality and integrating with downstream processes.<\/li>\n<\/ul>\n
Regenerative Combustion System<\/strong><\/p>\nSupports natural gas, LPG, heavy oil, diesel, or coal gas with high-efficiency regenerative burners. These systems recover 70\u201385% of waste heat, reducing fuel consumption by up to 30\u201350% compared with conventional burners. Lower operating costs and reduced emissions align perfectly with sustainability targets.<\/p>\n Premium Refractory Lining & Construction<\/strong><\/p>\nHigh-grade refractory materials selected for long service life under continuous high-temperature operation and thermal cycling typical in Middle East plants.<\/p>\n Intelligent HMI + PLC Control System<\/strong><\/p>\nCentralized monitoring, automatic data logging, real-time process visualization, carbon monoxide tracking, and touch-screen operation. Reduces operator dependency, improves safety, and supports predictive maintenance.<\/p>\n Hydraulic Tilting & Precision Flow Control<\/strong><\/p>\nLaser-guided pouring ensures stable, controlled molten copper flow, minimizing turbulence and oxidation while delivering consistent quality to downstream casting equipment.<\/p>\n Seamless Plant Integration<\/strong><\/p>\nDesigned to integrate directly with our Copper Rod Continuous Casting and Rolling Lines, ingot casting machines, or cathode production systems \u2014 creating complete, high-efficiency secondary copper production plants.<\/p>\n These features translate into high metal recovery rates (typically 95%+ with proper operation), excellent melt cleanliness, reduced dross formation, and reliable 24\/7 performance.<\/p>\n ![\"Scrap](\"https:\/\/doingcable.com\/wp-content\/uploads\/2026\/04\/571f303cf940bffd3a0f18775a716b5.png\") <\/p>\n
\u0627\u0644\u0645\u0648\u0627\u0635\u0641\u0627\u062a \u0627\u0644\u0641\u0646\u064a\u0629<\/h3>\n\n\n\n| Furnace Type<\/th>\n | Material (Copper Content)<\/th>\n | Energy Source<\/th>\n | Capacity \/ Tonnage<\/th>\n | Primary Function & Product Output<\/th>\n<\/tr>\n<\/thead>\n | \n\n| Scrap Copper Shaft Type<\/td>\n | \u226592% red copper scrap<\/td>\n | Natural gas \/ LPG<\/td>\n | 10\u201340 T\/h<\/td>\n | High-output melting; pairs with refining furnace for rod\/ingot\/cathode<\/td>\n<\/tr>\n | \n| Round Tilting Furnace<\/td>\n | \u226592% red copper scrap<\/td>\n | Natural gas \/ LPG \/ heavy oil \/ diesel \/ coal gas<\/td>\n | 1\u201380 T<\/td>\n | Batch melting & refining for rod, ingot, cathode<\/td>\n<\/tr>\n | \n| Tilting Scrap Copper Melting Furnace<\/td>\n | \u226590% red copper scrap (with minor \u226485%)<\/td>\n | Natural gas \/ LPG \/ heavy oil \/ diesel \/ coal gas<\/td>\n | 25\u2013150 T<\/td>\n | Tilting design for easy slag removal and refining<\/td>\n<\/tr>\n | \n| Reverberatory Furnace<\/td>\n | \u226590% red copper scrap (with minor \u226485%)<\/td>\n | Natural gas \/ LPG \/ heavy oil \/ diesel \/ coal gas<\/td>\n | 25\u2013150 T<\/td>\n | Large-scale refining and holding for rod\/ingot<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n Custom capacities, hybrid configurations, and waste heat recovery packages are available to match specific production requirements and local energy infrastructure.<\/p>\n ![\"Large](\"https:\/\/doingcable.com\/wp-content\/uploads\/2026\/04\/Large-Scrap-Copper-Smelting-Reverberatory-Furnace.avif\") <\/p>\n
Process Requirements for Electrical-Grade Copper<\/h3>\nCopper for power and control cables must meet strict purity and oxygen limits. Cu-ETP (electrolytic tough pitch) typically contains 0.02\u20130.04 % oxygen and delivers ~100 % IACS. Oxygen-free grades (Cu-OF, Cu-OFE) require inert-gas or charcoal cover and sealed systems to keep oxygen below 10\u201350 ppm. Melting practice therefore includes:<\/p>\n \n- Pre-dried, sorted charge (cathode, high-grade scrap \u226592 % Cu preferred).<\/li>\n
- Protective cover (charcoal or argon\/nitrogen) to limit oxidation.<\/li>\n
- Precise superheat control before transfer to continuous casting or holding furnaces.<\/li>\n
- Optional electromagnetic stirring and sampling for chemistry verification.<\/li>\n<\/ul>\n
Failure modes to avoid include excessive oxygen (causes porosity and reduced conductivity), hydrogen absorption (steam embrittlement risk in reducing atmospheres), and refractory contamination that introduces iron or other impurities lowering IACS values.<\/p>\n \n \n \n ![\"Induction](\"https:\/\/doingcable.com\/wp-content\/uploads\/2026\/04\/Induction-Furance-for-all-metal-doingcable.jpg\") <\/div>\n<\/div>\n<\/div>\n<\/div>\n Integration with Cable Manufacturing Lines<\/h3>\nIndustrial copper melting furnaces are routinely paired with continuous casting and rolling (CCR) systems to produce 8\u201320 mm oxygen-controlled rod for subsequent drawing into cable conductors. Shaft-type or large tilting induction units supply molten copper at controlled temperature and oxygen level directly to the casting machine. Regenerative or induction holding furnaces maintain bath quality during continuous operation.<\/p>\n Typical downstream targets for cable rod:<\/p>\n \n- Oxygen content 200\u2013350 ppm (ETP) or <50 ppm (OF).<\/li>\n
- Conductivity \u2265100 % IACS.<\/li>\n
- Surface quality free of oxide inclusions that would cause drawing breaks.<\/li>\n<\/ul>\n
Selection Guidelines for Reliable Long-Term Operation<\/h3>\n\n- Match power density (250\u2013600 kW\/t) to desired melt rate and charge form.<\/li>\n
- Select frequency according to capacity: higher frequencies for small batches, lower frequencies for deep penetration in large melts.<\/li>\n
- Specify hydraulic tilting for capacities above ~100 kg to ensure safe, controlled pouring.<\/li>\n
- Choose refractory grade according to alloy family and oxygen-control requirements (magnesia preferred for pure copper).<\/li>\n
- Include closed-loop water cooling, earth-leakage monitoring, and PLC\/HMI with recipe storage for repeatable quality.<\/li>\n
- Verify lining life and change-out time; modern split-coil designs can reduce relining from days to hours.<\/li>\n<\/ol>\n
These systems support both primary cathode melting and secondary scrap recycling while maintaining the metallurgical quality required by IEC, GB, UL and ASTM standards for electrical conductors.<\/p>\n Key technical takeaways<\/strong><\/p>\n\n- Medium-frequency induction delivers the highest combination of energy efficiency, melt purity and process control for electrical copper.<\/li>\n
- Specific energy of 380\u2013520 kWh\/t and metal loss <1 % provide measurable operating-cost advantages.<\/li>\n
- Precise oxygen and temperature management is non-negotiable for cable-grade rod conductivity and drawability.<\/li>\n
- Scalable platforms from 5 kg laboratory units to 5-tonne industrial furnaces cover the full range of cable manufacturing needs.<\/li>\n<\/ul>\n
For detailed technical proposals, capacity calculations, energy-consumption estimates tailored to your rod or cable line, or custom configurations meeting specific oxygen and purity targets, Inquiry Now.<\/p>","protected":false},"excerpt":{"rendered":" \u0641\u0631\u0646 \u0635\u0646\u0627\u0639\u064a \u0627\u062d\u062a\u0631\u0627\u0641\u064a \u0644\u0635\u0647\u0631 \u0627\u0644\u0646\u062d\u0627\u0633\u060c \u0645\u0635\u0645\u0645 \u062e\u0635\u064a\u0635\u064b\u0627 \u0644\u0635\u0647\u0631 \u0627\u0644\u0646\u062d\u0627\u0633 \u0627\u0644\u0646\u0642\u064a \u0648\u0627\u0644\u0646\u062d\u0627\u0633 \u0627\u0644\u0623\u0635\u0641\u0631 \u0648\u0627\u0644\u0628\u0631\u0648\u0646\u0632 \u0648\u0633\u0628\u0627\u0626\u0643 \u0627\u0644\u0646\u062d\u0627\u0633 \u0628\u0633\u0631\u0639\u0629 \u0648\u0646\u0638\u0627\u0641\u0629. \u064a\u062a\u0648\u0641\u0631 \u0628\u062a\u0642\u0646\u064a\u0629 \u0627\u0644\u062d\u062b \u0627\u0644\u0643\u0647\u0631\u0648\u0645\u063a\u0646\u0627\u0637\u064a\u0633\u064a \u0645\u062a\u0648\u0633\u0637 \u0627\u0644\u062a\u0631\u062f\u062f (\u0628\u062f\u0648\u0646 \u0642\u0644\u0628 \u0645\u063a\u0646\u0627\u0637\u064a\u0633\u064a) \u0648\u0628\u062a\u0635\u0645\u064a\u0645\u0627\u062a \u0642\u0627\u0628\u0644\u0629 \u0644\u0644\u0625\u0645\u0627\u0644\u0629\u060c \u0628\u0633\u0639\u0627\u062a \u062a\u062a\u0631\u0627\u0648\u062d \u0645\u0646 50 \u0643\u062c\u0645 \u0625\u0644\u0649 \u0639\u062f\u0629 \u0623\u0637\u0646\u0627\u0646. \u064a\u0648\u0641\u0631 \u0646\u0633\u0628\u0629 \u0627\u0633\u062a\u0631\u062f\u0627\u062f \u0639\u0627\u0644\u064a\u0629 \u0644\u0644\u0645\u0639\u0627\u062f\u0646\u060c \u0648\u062a\u062d\u0643\u0645\u064b\u0627 \u062f\u0642\u064a\u0642\u064b\u0627 \u0641\u064a \u062f\u0631\u062c\u0629 \u0627\u0644\u062d\u0631\u0627\u0631\u0629 (\u00b15 \u062f\u0631\u062c\u0629 \u0645\u0626\u0648\u064a\u0629)\u060c \u0648\u0641\u0642\u062f\u0627\u0646\u064b\u0627 \u0645\u0646\u062e\u0641\u0636\u064b\u0627 \u0628\u0633\u0628\u0628 \u0627\u0644\u0623\u0643\u0633\u062f\u0629 (<1%)\u060c \u0648\u0643\u0641\u0627\u0621\u0629 \u0637\u0627\u0642\u0629 \u062a\u0632\u064a\u062f \u0639\u0646 95%. \u0645\u062b\u0627\u0644\u064a \u0644\u0625\u0646\u062a\u0627\u062c \u0642\u0636\u0628\u0627\u0646 \u0627\u0644\u0643\u0627\u0628\u0644\u0627\u062a\u060c \u0648\u0627\u0644\u0635\u0628 \u0627\u0644\u0645\u0633\u062a\u0645\u0631\u060c \u0648\u0635\u0628 \u0627\u0644\u0645\u0639\u0627\u062f\u0646 \u0641\u064a \u0627\u0644\u0645\u0633\u0627\u0628\u0643\u060c \u0648\u0625\u0639\u0627\u062f\u0629 \u062a\u062f\u0648\u064a\u0631 \u0627\u0644\u062e\u0631\u062f\u0629. \u064a\u062f\u0639\u0645 \u0627\u0644\u062d\u0644\u0648\u0644 \u0627\u0644\u0645\u062e\u0635\u0635\u0629.<\/p>","protected":false},"featured_media":29879,"comment_status":"open","ping_status":"closed","template":"","meta":{"_joinchat":[]},"product_brand":[],"product_cat":[21,80,81],"product_tag":[514,512,517,513,516],"class_list":{"0":"post-28391","1":"product","2":"type-product","3":"status-publish","4":"has-post-thumbnail","6":"product_cat-all-product","7":"product_cat-cable-machinery","8":"product_cat-casting-and-rolling-production-line","9":"product_tag-copper-scrap-melting-furnace","10":"product_tag-melting-furnaces-for-copper","11":"product_tag-reverberatory-copper-furnace","12":"product_tag-scrap-copper-melting-furnace","13":"product_tag-tilting-copper-melting-furnace","15":"first","16":"instock","17":"shipping-taxable","18":"product-type-simple"},"_links":{"self":[{"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/product\/28391","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/product"}],"about":[{"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/types\/product"}],"replies":[{"embeddable":true,"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/comments?post=28391"}],"version-history":[{"count":12,"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/product\/28391\/revisions"}],"predecessor-version":[{"id":30968,"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/product\/28391\/revisions\/30968"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/media\/29879"}],"wp:attachment":[{"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/media?parent=28391"}],"wp:term":[{"taxonomy":"product_brand","embeddable":true,"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/product_brand?post=28391"},{"taxonomy":"product_cat","embeddable":true,"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/product_cat?post=28391"},{"taxonomy":"product_tag","embeddable":true,"href":"https:\/\/doingcable.com\/ar\/wp-json\/wp\/v2\/product_tag?post=28391"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}} | |
![\"Reverberatory](\"https:\/\/doingcable.com\/wp-content\/uploads\/2026\/04\/Reverberatory-Refining.jpg\")
<\/p>\n