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Large-capacity white fused alumina arc furnaces are core thermal equipment for producing high-purity white fused alumina (α-Al₂O₃). Using industrial alumina powder as raw material, they melt, purify and recrystallize the material at temperatures above 2000℃ generated by electrode arcs. "Large capacity" generally refers to equipment with a transformer capacity ≥ 4000 kVA and single furnace output ≥ 5 tons, featuring high efficiency, low energy consumption and stable performance for large-scale production.
1. Core Equipment Structure
1.1 Furnace System
Furnace Shell: Welded with 20g boiler steel plate, thickness 18–25 mm, circular structure without stiffeners, ensuring tightness and strength.
Furnace Lining: Constructed with high-alumina refractory bricks or castables, resistant to temperatures above 2200℃, corrosion and erosion, with adequate permeability to prevent melt blowback.
Furnace Cover: Water-cooled composite steel structure, cylindrical type, equipped with electrode holes, charging holes and observation ports, rotatable and liftable.
Tilting Mechanism: Fixed type (block furnace) or hydraulic tilting type, tilting angle 0–45°, convenient for slag and block discharge.
1.2 Electrode System
Electrodes: High-power graphite electrodes, commonly Φ300–Φ450 mm for large-capacity furnaces, arranged in an equilateral triangle.
Lifting Device: Driven by variable-frequency motor, lifting speed 1.5–2.5 m/min, stroke 1600–2200 mm, with automatic constant-current / constant-power regulation.
Clamping System: Belt-type or hydraulic chucks, water-cooled, ensuring reliable conductivity and clamping.
1.3 Electrical System (Core)
Transformer: Special on-load voltage-regulating rectifier transformer, commonly 6000–10000 kVA (6–10 MVA) for large-capacity models.
Short Network: Composed of water-cooled cables, copper bars and conductive cross-arms, arranged in triangular form with three-phase impedance unbalance < 8% to reduce energy consumption.
Control System: Fully automatic PLC control, monitoring current, voltage, power, temperature and electrode position.
1.4 Auxiliary Systems
Cooling System: Spray cooling for furnace walls, internal water cooling for furnace cover, electrodes and short network; water consumption 150–300 t/h, equipped with pressure and temperature alarms.
Charging System: Top furnace bin / charging tank, automatic or semi-batch feeding.
Flue Gas Dedusting: Fully sealed gas hood with bag filter to meet environmental emission standards.
Oxygen Injection: Top-blowing oxygen device for auxiliary melting, stirring and impurity removal.
2. Typical Large-Capacity Specifications
Item
4000 kVA (5t)
6300 kVA (8t)
10000 kVA (12–15t)
Transformer Capacity
4000 kVA
6300 kVA
10000 kVA
Rated Furnace Capacity
5 tons/heat
8 tons/heat
12–15 tons/heat
Furnace Shell Inner Diameter
Φ2800 mm
Φ3400 mm
Φ4200 mm
Furnace Shell Depth
1400 mm
1700 mm
2000 mm
Graphite Electrodes
Φ250 mm × 3
Φ350 mm × 3
Φ450 mm × 3
Secondary Voltage
180–390 V (22 steps)
160–360 V (27 steps)
140–320 V (33 steps)
Rated Current
Approx. 9200 A
Approx. 14500 A
Approx. 22000 A
Smelting Cycle
6–7 hours
7–8 hours
8–10 hours
Unit Power Consumption
1700–1900 kWh/t
1650–1800 kWh/t
1600–1750 kWh/t
Cooling Water Volume
Approx. 200 t/h
Approx. 250 t/h
Approx. 300 t/h
Furnace Type
Fixed / Tilting
Tilting
Tilting
Total Equipment Weight
Approx. 120 t
Approx. 180 t
Approx. 260 t
3. Working Principle & Process
Raw Material: Industrial alumina powder (Al₂O₃ ≥ 98.5%), with strict control of Na₂O, SiO₂ and Fe₂O₃ impurities.
Arc Ignition: Electrodes lower down and energize to start arcing, raising furnace temperature to 2200–2300℃.
Smelting: Batch feeding with closed-chamber method (thick material layer) for high thermal efficiency and low energy consumption.
Refining: Holding for 4–6 hours to separate and remove impurities; β-Al₂O₃ (sodium impurities) segregated and eliminated.
Cooling: Natural cooling for 24–36 hours after power-off to form dense white fused alumina clinkers.
Post-Treatment: Crushing, sieving, acid washing and sorting to obtain finished product with Al₂O₃ ≥ 99%.
4. Performance Features
High Purity: Product Al₂O₃ ≥ 99.0%, high whiteness and low impurities.
High Output: 10000 kVA furnace achieves daily output of 30–35 tons, suitable for mass production.
Low Energy Consumption: Higher thermal efficiency in large-capacity furnaces, unit power consumption 5–10% lower than small furnaces.
Stability & Reliability: High automation, long furnace lining life, stable continuous operation.
Environmental Protection: Fully sealed structure with high-efficiency dust removal, flue gas meets emission standards.
5. Main Applications
Abrasives & Grinding Tools: Ceramic / resin abrasives, sandpaper, abrasive belts, grinding powders for precision grinding and polishing.
Refractory Materials: High-grade refractory bricks, castables, nozzles, sliding plates for metallurgical, building materials and petrochemical high-temperature kilns.
Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. is a high-tech enterprise specialized in the research, design, and manufacturing of various industrial furnaces, including AC and DC steelmaking electric arc furnaces, ladle refining furnaces, ferroalloy ore thermal furnaces, ferroall... Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. is a high-tech enterprise specialized in the research, design, and manufacturing of various industrial furnaces, including AC and DC steelmaking electric arc furnaces, ladle refining furnaces, ferroalloy ore thermal furnaces, ferroall...
