Induction Melting lead ingots

Melting lead ingots

Objective Melting 30 lb(13.6 kg) & 60 lb(27.2 kg) lead ingots to form
battery posts & connectors
Material 30 lb(13.6 kg) & 60 lb(27.2 kg) lead ingots and 5” (12.7cm) ID
Zircar Ceramic Alumina tube
Temperature 620 ºF
Frequency 10 kHz
Equipment • Power of 90 kW induction heating system, equipped with a remote workhead containing three 26μF capacitors for a total of 80μF
• An induction heating coil designed and developed specifically for this application.
Process A five turn helical coil is used for this application. Lead ingots are placed inside the ceramic tube which is inside the coil. Different size ingots are melted at specified power, voltage and frequencies, see table below. As the lead melts and flows out of the tube the coil coupling decreases, a constant feed of lead is required for a consistent flow and coil coupling.

melting lead

WeightPower (kW)VoltageFrequency (kHz)Time (Secs)60 lb26375930030 lb455009980

Results/Benefits Induction heating provides:
• Faster startup/shutdown time saves energy
• Cleaner process than furnace melting
• Safer and more cost effective
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating