New Induction Furnace Increases Melt Capability
We have increased our range of furnaces following the recent £500,000 investment in a self-contained 1 tonne induction furnace and ancillary equipment. This new furnace, which has been installed our Green Steel Centre, incorporates the latest fast melt technology and means that the Institute now has furnaces with melt capability ranging from laboratory scale through to 3.5 tonnes using our Electric Arc Furnace (EAF).
This furnace is a key addition to our capability to support ferrous and non-ferrous metals research, typically for metal recovery and recycling industries direct, or as part of collaborative research programmes, and for commercial melts of up to 1t. This new furnace increases the range of our melting capability and makes scale up research and development more cost effective. Research activities that this furnace will be used for includes steel grade development, and low carbon slag development. Melting services for clients includes assay melts and consolidation melts.
The 4-month project to install the furnace started in December 2024 with groundworks and building of the concrete plinth enabling our existing 400kg induction furnace to sit alongside the new furnace. Installation and commissioning of the furnace took place in March 2025, with this work being led by the furnace manufacturer, Meltec.
Safety is integral to the furnace operation with in-built features including its self-contained design which significantly reduces the need for access while the furnace is running. Processes have been automated wherever possible meaning that minimal access to high temperature zones is required by the furnace operators. Safety skirting has also been added around the void for additional protection when furnace tapping is taking place.
Real time data capture has been integrated to help operators understand and manage the power requirements, temperature, water flows, to make live adjustments to optimise furnace performance and to minimise melt time, making the whole process more cost-effective and delivering environmental benefits through reduced energy use.
An additional feature is the detachable hydraulic lining removal system which improves safety and enables the rapid ejection of the furnace lining. This hydraulic system means that the lining can be removed in 1 hour when previously the process could take up to 2 days, resulting in massive savings in time and use of other resources, including manpower.
Commercial melts are now being carried out and the furnace is already being used to support collaborative research.
If you want to know more about how we can support your research or commercial melt requirements, contact us at enquiries@mpiuk.com
Video Link - https://www.youtube.com/watch?v=vvh4Wj61Drg
This investment has been undertaken with support from the Innovate UK funded Foundation Industries Sustainability Consortium (FISC) EconoMISER programme. FISC brings together global leaders in innovation, research, and technology to revolutionise sustainability across the Foundation Industries – the Materials Processing Institute is a member of the FISC consortium along with CPI, Glass Futures, Henry Royce Institute and Lucideon.
23 April 2025
