Project Background and Core Process Requirements

WONDERY recently completed the delivery of a custom WDL-DM-200 Medium Frequency Induction Melting Furnace for a client in Lebanon (Rashid). The project supports a 250kg iron melting operation. Given the high melting point of iron and the need for rapid heating, the client’s core requirements were high heating efficiency, a stable tilting control system, and operational safety under high-temperature conditions (up to 1650 ℃).

Technical Solutions and Parameterized Evidence

1. IGBT Induction Power System (98% Startup Success Rate)

To achieve fast melting and lower energy consumption, WONDERY implemented advanced induction technology:

• Core Power: Features a 200kW Medium Frequency IGBT induction power supply with an input voltage of 3×380V/50Hz.

• Frequency Management: The output frequency ranges from 1-10kHz, automatically adjusting based on the charge state to ensure maximum melting efficiency.

• Reliability: The system is designed with a 98% startup success rate, minimizing production downtime caused by initialization failures.

2. Reinforced Steel Shell and High-Conductivity Induction Coil

Engineered for a working temperature of 1650 ℃ (maximum 1800 ℃), the furnace body is highly specialized:

• Induction Coil: Fabricated from high-purity copper tubing, providing superior conductivity and water-cooling performance to prevent overheating under high current densities.

• Furnace Structure: Utilizes a robust steel shell design, which offers better electromagnetic shielding and structural stability compared to aluminum shells, making it ideal for the high-temperature demands of iron melting.

• Crucible Mold: Delivered with a dedicated 250kg crucible mold to facilitate on-site lining construction for the client.

3. Precision Hydraulic Tilting System

To ensure safe and smooth pouring of molten iron, the equipment integrates a comprehensive hydraulic power unit:

• System Composition: Includes a hydraulic tank, pump, precision valves, and pressure gauges.

• Operational Control: Operators can manage tilting, stopping, and resetting the furnace via buttons or manual handles, ensuring precise movement and preventing accidental splashing of molten metal.

4. High-Efficiency Cooling and Water-Cooled Cables

• Water-Cooled Cables: Equipped with heavy-duty water-cooled cables to connect the power supply to the furnace. These manage the 200kW load while utilizing internal water circulation to maintain safe operating temperatures.

• Closed Cooling Tower: Accompanied by a 30T closed cooling tower (optional) to provide a continuous loop of pure cooling water for the power supply, induction coils, and cables, preventing internal scaling and blockages.

Delivery Specifications and Key Parameters

• Melting Capacity: 250 kg (Iron).

• Maximum Operating Temperature: 1800 ℃.

• Rated Output Power: 200 kW.

• Transformer Requirement: 250 kVA.

• Scope of Supply: Medium frequency control cabinet, steel shell furnace body, hydraulic system, water-cooled cables, crucible mold, and closed cooling tower.