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Medium-frequency melting furnace The melting metal core operates at a maximum temperature of up to 1600℃ and is classified as high-risk equipment. Once the equipment—especially... Steel-shell furnace A malfunction in the equipment could lead to a serious accident; therefore, it is of great significance to perform thorough maintenance and upkeep of medium-frequency melting furnaces down to the smallest details and to acquire basic knowledge about safety precautions for medium-frequency furnaces.

Common accidents involving medium-frequency furnace bodies include furnace leakage and furnace penetration. If such accidents occur without taking appropriate measures, they can lead to rupture of the coil copper tubes, causing molten iron to come into contact with the cooling liquid and resulting in an explosion. This could trigger serious equipment accidents or even casualties. Therefore, it is essential to provide detailed explanations on the potential causes of these accidents, the preventive measures that should be implemented, and the emergency response plans that must be followed in the event of an accident.

Steel-shell furnace Causes of furnace leakage and furnace penetration accidents

(1) If the molten iron is allowed to cool for too long and forms a crust, it will expand again upon reheating. The resulting pressure on the furnace lining can cause cracks to develop in the lining, allowing molten iron to seep out through these cracks during the melting process. This can lead to furnace breakthrough or, if the crust bursts open, result in a furnace explosion accident.

(2) As the furnace age increases, the lining volume expands. The amount of molten iron inside the furnace rises, while the lining becomes thinner, leading to localized inability to withstand the pressure from the molten iron and eventually causing furnace breakthrough.

(3) During furnace lining ramming, certain areas failed to meet the required standards or impurities were inadvertently introduced into localized areas without being detected. As a result, these defects became apparent during melting.

(4) Rapid cooling of the furnace lining causes cracks, which then propagate through the cracks during the melting process.

Preventive measures

(1) Starting from the furnace construction stage, a dedicated person must be assigned to strictly manage the process, ensuring that each section of furnace lining is uniformly compacted. It is strictly prohibited for any foreign objects to fall into the furnace lining during compaction.

(2) Before each addition of material, inspect the furnace lining for cracks, perforations, or other conditions that could lead to furnace failure. If any issues are found, they must be addressed immediately.

(3) During the melting process, if prolonged furnace downtime occurs due to equipment failure or other factors, the molten iron should be tipped out of the furnace to prevent it from solidifying and forming a crust.

During the smelting process, if a leakage accident occurs in the furnace body of a medium-frequency induction furnace, it can result in severe losses. Not only will the entire batch of molten steel be scrapped, but the furnace’s core components will also be damaged or even rendered unusable. Moreover, such an incident could pose a serious risk to human safety. Therefore, to avoid unnecessary losses and disruptions to production, it is absolutely critical to prevent leakage accidents when operating a medium-frequency induction furnace. Generally speaking, installing a leakage detection and alarm system is a necessary measure to ensure the safe operation of the medium-frequency furnace and can help prevent accidents from escalating. Currently, there are two common approaches: One involves mounting stainless steel plates on the inner side of the induction coil as a secondary electrode. Six to seven stainless steel wires arranged like claws come into contact with the liquid metal and serve as the primary electrode. If molten metal leaks through the furnace lining and comes into contact with the stainless steel plates, the leakage detection and alarm system will immediately trigger an alarm.