Fuel Furnaces Manufacturers Gorwa, Vadodara, Gujarat

Shaft furnace for melting- & holding of aluminiumSTØTEK Shaft furnace Fully automatic melting- & holding furnace, with hydraulic tilt. Melting capacity up to 3000 kg Aluminium pr. hour and a holding capacity up to 20.000 kg Aluminium. STØTEK shaft furnaces are constructed with a very solid steel chassis and lined with high-quality refractory products.. The furnaces are divided in two parts - a melting shaft and a holding part for the metal. The melting burners in the melting shaft are controlled independently from STØTEK shaft furnaces are fully automatic charged. This means that a signal from the shaft indicating that there is room for additional metal in the shaft, combined with the holding part not being completely full, activates an automatic charge from the elevator into the shaft.. To maintain an exact metal temperature in the holding part +/- 3 C°, STØTEK recommends that the holding part always be minimum two-three times larger than the melting capacity. This also provides a better and more homogeneous metal quality.The holding part can also be fitted with Al Clean Porous Plugs to remove possible oxides and degas the aluminium. The chimney gas from the holding part passes through the melting shaft for an effective energy utilization.

SIGNIFICANT ENERGY SAVINGS (UP TO 50%) IMPROVED CRUCIBLE LIFE VERY LOW NOISE EMISSIONS ENVIRONMENTALLY FRIENDLY EMISSIONS FURNACE DESCRIPTION The Mk V ’R’ gas furnace provides the maximum economy in energy costs and is constructed using the most efficient low thermal mass materials for the lining. By recycling part of the waste energy from the exhaust, a minimum of 25% can be saved and as high as 50% against many brick-lined furnaces. Radiation losses are minimised by use of a well insulated swingaside cover that can be sealed when no baling out is needed. The superb insulation allows for excellent melting performance from the high performance compact gas burner. The burner facilitates impr oved heat cir culation and transfer thr ough convection, pr oducing a more even heat distribution around the crucible. This promotes longer crucible life. The advanced insulation materials used in the furnace lining result in low casing temperatures, providing comfortable working conditions. Working conditions are also optimised by very low noise emissions. The exhaust r ecuperator also acts as an ef fective silencer, making the furnace much quieter than equivalent gas fired furnaces. In addition to reduced carbon dioxide emissions, the advanced burner technology minimises Nitrous Oxide (NOx) and carbon monoxide, important health and environmental issues. RADIANT PANEL ASSEMBLIESTwelve high alumina radiant panels are arranged around the crucible and extend to the full depth of the furnace chamber.The self-supporting and interlocking design facilitates ease of removal in the unlikely event the panels need to be replaced.These panels efficiently convert gas energy to radiant energy. HIGH EFFICIENCYThe combination of recuperation and effective conversion to radiant heat transfer and the use of advanced insulating materials provide a melting and holding furnace of exceptional efficiency and comfortable working conditions. SIZE RANGEThe Recuperative Gas Fired Bale Out Furnace Mk V ‘R’ is available in the size range 85kg - 1327kg aluminium.Other crucible patterns than those shown in the performance table are available to provide the capacity span indicated for each size reference. FUEL TYPESThe furnace is suitable for the following gaseous fuels: Natural Gas  9000 Kcal/m3 Propane   22000 Kcal/m3 Butane   28000 Kcal/m3 Pressure  20-50 millibar KEY FEATURES :- ADVANCED DESIGNThe Mk V recuperative furnace retains all of the advantages bestowed on the standard radiant panel heated Mk V gas furnaces and, with the exception of the control panel, has no stand-alone components. High reliability is obtained by the avoidance of moving parts (such as air dampers). GAS BURNERThe furnace is equipped with a high performance, low NOx, fully proportioning, nozzle mix gas burner. Air is delivered to the burner from a compact regenerative blower, the volume of which is regulated by a solid state inverter, thus avoiding valves and linkages. Air and gas are mixed in proportion relative to air flow, retaining the correct air/gas ratio across the turn down range. The robust burner is designed to keep NOx emissions to a very low level, (less than 125ppm) throughout the air preheat range. The burner system conforms to the highest safety standards, to meet regulations world wide.RECUPERATORThe hot air recuperator, fitted to the furnace exhaust, is of a simple and robust design, delivering up to 250°C air preheat to the bur ner. It has dimensions similar to the standard MkIV Gas exhaust extension and further reduces the already very low noise levels. CONTROL PANELA modern high quality control panel provides the followingfeatures: Circuit breaker for isolation and protection Flame failure, sequencing controller Programmable time clock switching Fully proportional metal temperature controller Policeman lining controller to protect refractories Crucible operational hour meter Burner operational hour meter Radiant heater display during gas burner operation METAL TEMPERATURE CONTROLControl may be derived from a floating pyr ometer, fixed pyrometer or one housed in the crucible.The programmable temperature controller maintains metal temperatur e within very close limits by automatic adjustment to bur ner heat input, whether melting or holding. The digital display shows both the required temperature and current metal temperature.TEMPERATURE DEPRESSIONThis energy conservation feature enables a lower holding temperature to be automatically selected during periods of non-use. The control panel contains a real-time/date clock which can be programmed to select reduced temperature and to return to operational temperature when required. Similarly, the real-timeclock can be programmed to start up and shut down the furnace a preset times and dates.OUTPUT LIMITED THERMOCOUPLE FAILURE PROTECTION (FULLY MODULATING VERSION)If the thermocouple sensor fails, this feature provides a programmed level of output power. Typically set to 10%, the proportioning power control provides sufficient heat output to maintain an aluminium charge within an acceptable temperature range. POLICEMAN CONTROLThe furnace is equipped with a "policeman" control. This feature is designed to prevent overheating of the furnace refractories and radiant panels, thus avoiding reduction of their lifespan.PYROMETRYA variety of metal temperature pyrometry can be specified. This includes floating or fixed immersion types and thermocouples housed within the cr ucible for holding applications.

A highly insulated and efficient unit for the transfer of motten aluminium form bulk melting furnaces for application where the metal must be kept hot in the ladle whilst metal treatment is taking place. suitable for molten metal feed and overnight holding of molten metal.It can also replace the furnaces at the diecasting stations for applications where at present two furnaces per station are required- one for casting whilst the metal is being treated in the other. only one ladle needs to be positioned at the casting station at any one time.Available in six standard nominal capacities 200kg, 250kg, 300kg, 500kg, 600kg, and 700kg aluminium capacity.  ConstructionThe Morgan Electric Ladle can be supplied either with slots for use with a forklift truck or with a bewel and geared tilting mechanism for use with an overhead crane. The semi-embedded heater panels are positioned between the refractory ladle liner and the insulation backing, which is contained in a steel shell. The result is a very compact design suitable for forklift truck rotation fixtures. The ladle is fitted with a swing-aside refractory-lined cover to facilitate filling, cleaning and minimise heat loss. Standard power levels are chosen to provide a melt facility.Safety interlocks are provided to sound an alarm should an attempt be made to move the ladle without removing the plugs and to signal the presence of metal in the heater chamber should liner failure occur. Conforms to Euronorm standards

A highly efficient crucible bale out furnace for melting and holding with the following advantages: Freely radiating elements for imporved performance Very low heat loss Fast element change Low power requirement Long element life Continuous element monitoring and display for rapid diagnostics Aluminium capacities up to 1135 kg. Separate element temperature protection Half power switching Accurate metal temperatures through automatic, proportional, integral and derivative control Conforms to the relevant Indian Standards on safety. FURNACE DESCRIPTION The type HE Furnace is constructed using the most efficient low thermal mass materials for the lining and provides the maximum economy in energy cost.The superb insulation allows for excellent melting performance at high power efficiencies, consistent with long element panel life.Radiation losses are minimised by use of a well insulated swing aside cover that can be sealed when no baling out is needed. Heater AssembliesTwelve refractory heater panels are arranged around the crucible and extend to the full depth of the furnace chamber. Typical power loadings of only 3-4 watts/sq.cm ensure long life. whilst the self-supporting design facilitates ease of removal. multistrand element tails and cool stud terminals enable element changes to be made in less than 10 minutes without removing the crucible. Control PanelThe control panel provides: Circuit breaker for isolation and protection Earth leakage detection for operational safety Crucible and heater hour meters Time clock swithching. The furnace elements are depicted on a mimic diagram and ultra bright LEDs. are lit when any panel is drawing the required current Metal temperature control may be eighter from floating or fixed pyrometers or one housed within the crucible.The programmable Controller will maintain the metal temperature within very close limits by automatic adjustment to heat input, whether melting or holding.The digital display shows both the required temperature and current metal temperature.Options Details of optional extras available and furnace variants, ie: Larger capacity, low height furnaces for holding applications Electronic kilowatt hour meters for kWh totalising or with energy management output and direct kW reading. Thyristor control for contactless switching and potential use of energy management systems for multiple furnace installations conforms to the latest compatibility standards Key FeaturesImproved Temperature ControlTemperature scheduling of control terms provides maximum accuracy of metal temperature whether melting from cold or maintaining.Temperature DepressionThis energy conservation feature enables a lower holding temperature to be automatically selected during periods of ‘ non use’. The controller contains a real-time/date clock, which can be programmed to select reduced temperature and to return to operation temperature when required. Similarly, the real-time clock can be programmed to start up and shut down the furnace at preset times and dates. Enhanced Power ManagementThis feature, when selected by the panel mounted switch, reduces output power by 50% at a preset temperature below the normal operating value. output power is therefore limited to half power during holding should the temperature fall outside an acceptable limited due, for instance, to cold metal addition full power is re-established to provide rapid recovery. Half and full power switch positions are also provided.Output Limited Thermocouple Failure Protectionif the thermocouple sensor fails, this feature provides a programmed level of output power control. Typically set to 10% the time proportioning power control provides sufficient output power to maintain an aluminium charge within an acceptable temperature range.Improved Top Cover Insulation The addition of insulation with exceptional insulation properties to the furnace reduces surface temperature, thereby improving working conditions, heat loss safety.StandardsThe Morgan Electric Resistance Bale Out Furnace Type He MkIV has been designed and manufactured in accordance with the relevant national & international Standard.RangeThe Morgan Electric Resistance Bale Out Furnace Type HE MkIV is available in the size range 85 kg-1135kg aluminium. high temperature versions available up to 1050 c capacities 260 Kg.-1400 Kg brass. other crucible patterns than those shown in the performance table are available to provide the capacity spanIndicated for each size reference. 

IMPROVES THE THERMAL EFFICIENCY OF THE MELTING PROCESS ALUMINIUM CAPACITIES UP TO 1327 KG The Morgan MK V Gas Furnace is constructed using the most efficient low thermal mass materials for the lining and provides the maximum economy in energy costs.Morgan’s Gas Fired Bale Out Furnace FURNACE DESCRIPTION The superb insulation allows for excellent melting performance from the high performance compact gas burner. Radiation losses are minimised by use of a well-insulated swing-aside cover that can be sealed when no baling or filling is needed. A low casing temperature provides comfortable working conditions RADIANT PANEL ASSEMBLIESTwelve refractory, radiant heater panels are arranged around the crucible and extend to the full depth of the furnace chamber. The self-supporting design facilitates ease of removal in the unlikely event the panels need replacement. These panels efficiently convert gas energy to radiant energy. HIGH EFFICIENCYThe combination of radiant heat transfer and the use of advanced insulating materials provides a melting and holding furnace of exceptional efficiency and comfortable working conditions. SIZE RANGEThe furnace is available in sizes ranging up to 1327 kg for melting. Other crucible patterns than those shown in the performance table are available to provide the capacity span indicated for each size reference. FUELTYPESNatural Gas: 9000 Kcal/m3Propane: 22000 Kcal/m3Butane: 28000 Kcal/m3Pressure: 20—millibar Data for zinc and zinc alloys available one request.Above data based on optimum foundry conditions. For normal foundry operations a performance of 90% of these ratings is typical. KEY FEATURES :- GAS BURNERThe furnace is equipped with an advanced self-contained nozzle mix gas burner. The burner provides maximum melt rates with efficient fuel inputs. This maximises crucible life and performance. The controller and fast response rate of the furnace nearly eliminate temperature overshoot. This reliable, fully-modulating industrial grade burner utilises anultra-violet detector to monitor the presence of combustion. Accurate ratio control minimises emissions of NOx and CO. CONTROL PANEL Circuit breaker for isolation and protection Proportional control gas burner Crucible and heater hour meters Programmable time clock switching Mimic display Flame failure, sequencing controller Metal temperature control may be either from a floating or fixed pyrometer or one housed within the crucible. The programmable controller will maintain the metal temperature within very close limits, by automatic adjustment to heat input, whether melting or holding. The digital display shows both the required temperature and current metal temperature.TEMPERATURE DEPRESSIONThis energy conservation feature enables a lower holding temperature to be automatically selected during periods of non use. A dedicated real-time/date clock can be programmed to select reduced temperature and to return to operational temperature. when required. Similarly, the real-time clock can be programmed to start up and shut down the furnace at preset times and dates. OUTPUT LIMITEDTHERMOCOUPLE FAILURE PROTECTIONIf the thermocouple sensor fails, this feature provides a programmed level of output power. Typically set to 10-30%, the time proportioning power control provides sufficient heat output power to maintain an aluminium charge within an acceptable temperature range.lifespan.POLICEMAN CONTROL The furnace is equipped with a ”policeman” control. This feature is designed to prevent overheating of the furnace refractories and radiant panels, thus avoiding reduction of their lifespan. PYROMETRYA variety of metal temperature pyrometry can be specified. This Includes floating or fixed immersion types and thermocouples housed within the crucible for holding applications.OPTIONS AVAILABLESpilt metal detection, low metal temperature alarm, in-range indicating beacons, pneumatic swing-aside cover, and metal temperature overshoot control 

The Morgan Basin Tilting Furnace is specially designed for efficient, rapid, bulk melting of metals for both die- casting and non- ferrous foundries. The standard furnace utilizes the supercharge preheating technique where the waste gases, being exhausted over the top of the cruThe steel furnace casting is lined to suit the application with either Morganite radiant panels backed by premium grade insulation or, for higher temperature applications, high alumina brick linings. cible, preheat the solid charge.

IMPROVES THE THERMAL EFFICIENCY OF THE MELTING PROCESS DUAL ENERGY SOURCE: GAS MELT, ELECTRIC HOLD, OR MOST ECONOMICAL ENERGY SOURCE SELECTION FURNACE DESCRIPTION Essentially designed to exploit the advantages of gas melting and electric holding, the Dual Energy Bale-Out Furnace can operate with both gas and electric energy inputs automatically with respect to temperature. Alternatively, the furnace will operate solely on gas or electricity according to the source selected. Should gas heating fail, electric heating is automatically selected. The combination of radiant heat transfer and the use of advanced insulating materials provides a melting and holding furnace of exceptional efficiency and comfortable working conditions. Heater AssembliesTwelve refractory, radiant heater panels are arranged around the crucible and extend to the full depth of the furnace chamber. The formation consists of six gas and six electric radiant panels. Uniquely designed panels efficiently convert gas energy to radiant energy when this heat source is selected. The self-supporting design allows ease of removal. Multi-strand element tails and cool stud terminals enable electric heater changes to be made in less than 10 minutes without removing the crucible. SIZE RANGE• 84—1327 kg Aluminium    KEY FEATURES :- GAS BURNERThe furnace is equipped with an advanced self-contained nozzle mix gas burner. This reliable on/off industrial grade burner utilises an ultra-violet detector to detect and monitor the quality of combustion.Fully modulating burner also available for proportional gas heating.  Circuit breaker for isolation and protection• Earth leakage detection for operational safety and personnel protection• Crucible and heater hour meters• Programmable time clock switching• Mimic display for rapid diagnostics The element panels are depicted on a diagram and ultra bright LEDs are lit when any electric panel is drawing the required current. Metal temperature control may be either from an adjustable or fixed pyrometer.The programmable controller will maintain the metal temperature within very close limits by automatic adjustment to heat input, whether melting or holding. The digital display shows both the required and current metal temperature. TEMPERATURE DEPRESSION This energy conservation feature enables a lower holding temperature to be automatically selected during periods of non use.A dedicated real-time/date clock can be programmed to select reduced temperature and to return to operational temperature when required. Similarly, the real-time clock can be programmed to start up and shut down the furnace at preset times and dates. OUTPUT LIMITEDTHERMOCOUPLE FAILURE PROTECTION (electric hold) If the thermocouple sensor fails, this feature provides a programmed level of output power. Typically set to 10–30%, the time proportioning power control provides sufficient heat output power to maintain an aluminium charge within an acceptable temperature range. POLICEMAN CONTROLThe furnace is equipped with a "policeman" control. This feature is designed to prevent overheating of the furnace refractories and radiant panels, thus avoiding reduction of their lifespan. PYROMETRYA variety of metal temperature pyrometry can be specified. This includes floating or fixed immersion types and thermocouples housed within the crucible for holding applications. OPTIONS AVAILABLESpilt metal detection, low metal temperatur e alarm, in range indicating beacons, thryistor power control, metal temperature overshoot control, kWh meter.

Støtek’s energy-efficient furnaces for melting, holding and dosing aluminium are in all ways a sound investment, in the environment, security and not least on the bottom line.Reliable furnaces with accurate dosing +/-1% and savings of approx. 40% CO2! Prompt dosing Accurate dosing +/-1 % Low air consumption for dosing (2.500,- €/year/sawing) Option of dosing with protective gas Low energy consumption (5.000,- to 25.000,-€/year/sawing) High metal quality, because there is no pressure in the furnace Metal filling from low height (-1400mm) Dosing weights from 0,5 kg 65 kg/Al. Spare part replacement - even during production Removable lid/door for accessible cleaning of the metal The option of mounting a filter in the furnace part and in the dosing pump improves the metal quality Automatic dosing adjustment Hydraulic height adjustment Tilting for change of alloy Standard spare parts