Editorial Technical Reference

Electroslag Remelting Furnace

This page explains how Electroslag Remelting Furnace is classified within Basic Metal Manufacturing. Technical values and manufacturer relationships are research references; confirm the current specification and supplier evidence for each order.

Technical Definition & Core Assembly

An industrial furnace used in basic metal manufacturing for secondary refining of alloys through the electroslag remelting (ESR) process.

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Electroslag Remelting Furnace in a manufacturing environment
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Product Specifications

Technical details and manufacturing context for Electroslag Remelting Furnace

Definition
An industrial furnace used in basic metal manufacturing for secondary refining of alloys through the electroslag remelting (ESR) process. It produces high-purity, homogeneous metal ingots with superior mechanical properties by melting consumable electrodes through a conductive slag layer. This equipment is essential for aerospace, power generation, and tool steel applications requiring exceptional material quality. The furnace operates by passing an electric current through a conductive slag layer, which generates heat and melts the tip of a consumable electrode. The molten metal droplets pass through the slag, undergoing refining reactions that remove impurities and control solidification. The refined metal collects in a water-cooled copper crucible, solidifying into an ingot with a controlled structure. Key components include the electrode holder assembly, copper crucible, refractory lining, water cooling system, and slag mixture. Typical parameters include ingot diameters from 200 to 1200 mm, melting rates of 0.5 to 5 kg/h, power consumption of 1200 to 1800 kWh per ton, slag temperatures of 1500 to 1800 °C, and rated capacities of 5 to 50 tons per heat. The electrode stroke ranges from 1000 to 3000 mm, with drive speeds of 0.1 to 1.5 m/min. Electrical supply is typically 380–660 V at 50/60 Hz, with protection class IP54–IP65. Cooling water flow rates are 20–80 m³/h at pressures of 0.3–0.6 MPa. The machine weight ranges from 20 to 100 tons. These values are reference ranges; verify model-specific specifications with the manufacturer.
Working Principle
A consumable electrode is suspended above a water-cooled copper crucible containing a pre-melted conductive slag. An electric current passes through the electrode and slag, generating resistive heat that melts the electrode tip. Molten metal droplets fall through the slag, where refining reactions occur, removing impurities and controlling composition. The droplets collect in the crucible and solidify into an ingot. The slag layer also acts as a thermal barrier, promoting directional solidification and a homogeneous structure.
Common Materials
copper crucible, refractory lining, electrode holder assembly, water cooling system, slag mixture
Technical Parameters
ParameterTypical rangeNotes & selection driver
Ingot DiameterRequired200–1200 mmMaximum ingot diameter
Melting RateRequired0.5–5 kg/hTypical melting speed
Power ConsumptionRequired1200–1800 kWh/tonEnergy per ton produced
Slag TemperatureRequired1500–1800 °COperating slag temperature
Rated Capacity5–50 tMaximum ingot weight per heat
Electrode Stroke1000–3000 mmDetermines electrode feed range
Electrode Drive Speed0.1–1.5 m/minControls melting stability
Voltage380–660 VInput supply voltageIEC 60038
Frequency50/60 HzMains frequencyIEC 60038
Cooling Water Flow Rate20–80 m³/hEnsures proper cooling of mold and furnace
Cooling Water Pressure0.3–0.6 MPaMaintains adequate flow
Operating Temperature0–45 °CAmbient temperature range
Protection ClassIP54–IP65Dust and water protection for electrical enclosuresIEC 60529
Machine Weight20–100 tAffects foundation and installation

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Application & selection

Application Fit & Sizing Matrix

Operational Limits
pressure: Atmospheric to 0.5 bar gauge (slag pool pressure)
other spec: Electrode feed rate: 0.5-10 mm/min, Cooling water flow: 50-500 m³/h, Power input: 1-10 MW
temperature: 1500-1800°C (operating melt pool temperature)
Media Compatibility
✓ High-alloy steels (tool steels, stainless) ✓ Nickel-based superalloys ✓ Titanium alloys
Unsuitable: Reactive metals in air atmosphere (requires inert gas protection)
Sizing Data Required
  • Required ingot diameter (mm)
  • Annual production capacity (tons/year)
  • Maximum alloy segregation tolerance (chemical homogeneity specification)

Risk, maintenance & compliance

Reliability & Engineering Risk Analysis

Failure Mode & Root Cause
Electrode degradation and breakage
Cause: Thermal fatigue from repeated heating/cooling cycles, mechanical stress from electrode positioning systems, and oxidation at high temperatures leading to embrittlement.
Refractory lining failure
Cause: Thermal shock during rapid temperature changes, chemical erosion from molten slag and metal interactions, and mechanical wear from slag movement and cleaning operations.
Maintenance Indicators
  • Unusual arcing sounds or visible sparking outside normal electrode-slag interface
  • Visible cracks or bulging in furnace shell, or abnormal temperature readings on infrared scans
Engineering Tips
  • Implement predictive maintenance using vibration analysis on electrode positioning systems and thermal imaging to detect refractory hot spots before failure
  • Optimize slag chemistry and temperature control to minimize corrosive wear, and establish strict thermal cycling protocols to reduce thermal shock on refractory materials

Indicative industry ranges for design and RFQ preparation. Confirm the exact figures and applicable standard with the manufacturer before specifying.

Compliance & Manufacturing Standards

Applicable Standards
ASTM A604/A604M - Standard Practice for Macroetch Testing of Consumable Electrode Remelted Steel Bars and Billets CE Marking - Machinery Directive 2006/42/EC

Quoted from the published standard.

Manufacturing Precision
  • Electrode alignment: +/- 0.5mm
  • Mold concentricity: 0.2mm total indicator runout
Quality Inspection
  • Ultrasonic Testing (UT) for internal defects
  • Chemical Composition Analysis via Optical Emission Spectrometry
Technical documentation
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Manufacturing capability
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Inspection readiness
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Supplier transparency
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Manufacturers of Electroslag Remelting Furnace

3 companies list this product among what they make. Company figures are quoted from each company's own website; every card states where the relationship came from.

CHNZBTECH
Xian, Shaanxi, CN
Also makes: Continuous Casting Machine, Electric Arc Furnace, Water-Cooled Panels and 8 more
Listed on the company's own website · profile compiled by CNFX from public sources
Listed there as: “ESR Electroslag Remelting Furnace”
View source page ↗ zbmetaltech.com · recorded 2026-08-22
View profile Send enquiry
Hani Metallurgy Equipment Co., Ltd.
Shaanxi, CN
Also makes: Continuous Casting Machine, Induction Melting Furnace, Electric Arc Furnace and 3 more
Listed on the company's own website · profile compiled by CNFX from public sources
Listed there as: “Electroslag furnace 2”
View source page ↗ hanmetallurgy.com · recorded 2026-09-03
View profile Send enquiry
Inductotherm Industries (Shanghai) Ltd.
Shanghai, CN
Listed on the company's own website · profile compiled by CNFX from public sources
Listed there as: “Consarc ElectroSlag Remelting Furnace”
View source page ↗ inductotherm.com.cn · recorded 2026-09-05
View profile Send enquiry

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Frequently Asked Questions

What is the typical ingot diameter range for an ESR furnace?

According to directory data, the maximum ingot diameter ranges from 200 to 1200 mm. However, the actual range depends on the specific furnace model and configuration. Always confirm with the manufacturer.

What is the power consumption per ton of metal produced?

The directory lists power consumption between 1200 and 1800 kWh per ton. This is a reference range; actual consumption varies with operating conditions and material. Verify with the supplier.

What standards apply to the electrical supply?

The voltage and frequency are listed as 380–660 V and 50/60 Hz, referencing IEC 60038. The protection class for electrical enclosures is IP54–IP65 per IEC 60529. These are procurement references, not certifications.

What are the cooling water requirements?

Cooling water flow rate is typically 20–80 m³/h at a pressure of 0.3–0.6 MPa. These values ensure proper cooling of the mold and furnace. Confirm exact requirements for your installation.

Data basis: editorial classification, named public sources where available, and source-reviewed manufacturer records. See the editorial policy.

Related equipment

Industrial Ecosystem & Supply Chain Structure

Industry Taxonomies & Aliases

Commonly used trade names and technical identifiers for Electroslag Remelting Furnace.

ESR furnace electroslag furnace

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification
This page supports structured research, RFQ preparation, and supplier evaluation. It does not replace buyer-led supplier qualification, standards review, or technical approval.

Compiled and source-reviewed by the CNFX editorial team. Each manufacturer above links to the page on that company's own website where the product is listed, with the date we checked it. How we source and review · Page last updated 11 October 2026

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