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EVENTS & NEWS
Plasma Induction Furnaces – Working Principles & Metallurgy
Release time:
May 19,2026
source:
Plasma Induction Furnaces
The plasma induction furnace is a novel type of smelting equipment that has emerged in recent years. It is a hybrid metallurgical system combining a conventional induction furnace with a plasma arc heating device.
By integrating these two heating methods, it successfully avoids the typical drawbacks of standard induction furnaces—namely, cold slags and the inability to maintain protective atmospheres—thereby significantly enhancing the furnace’s refining capabilities.
Development of this technology began internationally in the 1960s. By the 1970s, production capacities reached $2\text{ tons}$. Domestically, a $500\text{ kg}$ plasma induction furnace has been successfully constructed, and larger capacity furnace units are currently under development.
1. Core Applications in High-Purity Metallurgy
Plasma induction furnaces are predominantly utilized for the production of specialized, high-value alloys:
Ultra-low carbon and ultra-low carbon stainless steel.
Precision alloys.
High-temperature alloys containing easily oxidizable elements such as aluminum ($\text{Al}$) and titanium ($\text{Ti}$).
Due to its high refining efficiency, the quality of the metallurgical products processed in a plasma induction furnace matches or closely approaches the standards achieved via Vacuum Induction Melting (VIM). It represents a highly promising branch of specialized smelting technology that is currently undergoing rapid development.
2. Working Principle of the DC Transferred Arc Plasma Induction Furnace
The structural layout and functional diagram of a DC transferred arc plasma induction furnace are illustrated below:
System Components
A direct current (DC) plasma induction furnace is comprised of four primary sub-systems:
Furnace Body Assembly (including the crucible and shell)
Induction Furnace Power Supply
Plasma Gun Assembly
Plasma Arc Power Supply
The Frequency Conversion and Arc Initiation Process
The working principle of the plasma arc generating device operates as follows:
Power Conditioning: The DC power supply of the plasma gun routes the incoming electricity through a transformer, reactor, and rectifier, converting high-voltage AC into low-voltage, high-current DC.
Voltage Application: This regulated DC voltage is applied across the cathode (6) and the auxiliary anode (7).
Gas Ionization: A working gas—typically argon ($\text{Ar}$)—is manually introduced into the gap between the two electrodes. As the gas flow passes through the electrode tips, a high-frequency spark generator (10) discharges a high-voltage spark. This spark ionizes the argon gas molecules, creating a stable plasma arc between the cathode tip and the auxiliary anode.
The Transferred Arc Mechanism
Once initiated, the plasma gun is gradually lowered toward the furnace charge.
As the tip of the plasma gun approaches the metallic raw material, the plasma arc automatically transfers from the auxiliary anode to the furnace charge itself (utilizing an anode embedded in the furnace bottom).
Once this transferred arc stabilizes, the DC contactor (5) disconnects the auxiliary anode circuit. The plasma arc is now fully sustained between the gun and the charge, providing intensive thermal energy to melt the raw materials.
3. Combined Heating Advantages
Simultaneously, the induction furnace power supply is energized to initiate induction heating. Because thermal energy is applied from two directions at once (arc heating from above and induction heating within the crucible), the melting rate is drastically accelerated.
Furthermore, this dual action effectively eliminates the "bridging" phenomenon (where an upper layer of solid scrap forms a crust over molten metal below). Once the furnace charge is completely liquefied, the metallurgical process transitions into normal operations, allowing the operator to reduce the power inputs of both the plasma gun and the induction coils accordingly before tapping the steel.
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