ESR
ESR
The Electroslag Remelting (ESR) process involves melting the lower end of an electrode through a layer of molten slag into a water-cooled copper mold. The slag, composed of calcium fluoride and other oxides, becomes electrically conductive and superheated, facilitating the melting of the electrode. This process purifies the metal and forms a structurally sound ingot.
Consarc's Generation 7 Automatic Melt Controls use a SCADA system with a PLC, dripshort processor, and PC interface. This system automates the melt process, allowing precise control and data logging of parameters such as vacuum levels, power input, and melt rate.
Innovations include a high fill ratio electrode and a coaxial conductor system, reducing power consumption and improving ingot quality. Their proprietary AC power supply technology, featuring saturable core reactors, offers efficient and reliable current control.
Consarc's ESR furnaces can perform inert gas melting, preventing oxidation and allowing the use of different slags without deoxidants. The system includes an enclosure for the crucible, an inert gas manifold, and an oxygen monitor to maintain low oxygen levels during the melt.
Consarc offers static ESR furnaces in various sizes, with maximum ingot weights ranging from 4,000 kg to 35,000 kg. These furnaces are designed to meet specific customer requirements and include features such as precision electrode drive and fully automated melt control.
Consarc has pioneered ESR technology since the 1960s, significantly improving efficiency and performance with innovations like the high fill ratio electrode and coaxial conductor system.
- Electrode sizes range from 26” (650 mm) to 48” (1200 mm).
- Power capacities range from 15,000 amps to 40,000 amps.
- Ingot weights range from 4,000 kg to 35,000 kg.
Consarc's ESR systems use a proprietary high current AC power supply, including saturable core reactor technology, internally water-cooled systems, and advanced current control.
The ESR process involves melting the lower end of an electrode through a layer of molten slag into a water-cooled copper mold, purifying the metal and resulting in a structurally sound and chemically homogeneous ingot.
Consarc's Generation 7 Automatic Melt Controls feature a full SCADA system, including a PLC for furnace logic, a dripshort processor, and a PC interface for HMI, data logging, and process analysis.
For more information, visit Consarc's website or contact their offices in New Jersey, USA, or North Lanarkshire, UK.
Catalog excerpts
CONSARC CORPORATION 100 Indel Avenue P.O. Box 156 Rancocas, New Jersey 08073 Phone: +1 (609) 267-8000 Fax: +1 (609) 267-1366 E-Mail: [email protected] www.consarc.com CONSARC ENGINEERING LIMITED 9 Woodside Eurocentral Holytown, North Lanarkshire ML14XL Scotland,United Kingdom Telephone : +44 (0)1698 730430 Fax : +44 (0)1698 730431 E-mail : [email protected] www.consarceng.com Electroslag Remelting Furnaces For more information visit www.consarc.com.
Open the catalog to page 1
ESR — The Process G A B H I F D A B C D E F G H I Molten Pool Molten Slag Water Guide Water Cooling Baseplate Clamped Electrode Crucible Ingot The ESR process involves the gradual melting of the lower end of a cast or forged electrode through a layer of molten metallurgically active slag into a water-cooled copper mold. The slag is usually calcium fluoride with the addition of lime, magnesia, and other oxides. Consarc pioneered in Automatic Melt Controls in the early 1970’s. At that time, before personal computers, melt rate was maintained using programmable calculators while operators adjusted...
Open the catalog to page 2
Proprietary High Current AC power supply (Reactor Based) Consarc is the only ESR furnace supplier that designs and builds our own custom designed AC power supplies. These units are specifically designed to meet the demanding requirements of the ESR melting application. This provides Consarc ESR customers with a single source responsibility for the complete ESR and power transmission system. 20,000 amps Consarc offers only Saturable Core Reactor based power supply technology for use in our ESR furnace systems. All systems are internally water cooled by a dedicated, dual pump, closed loop, water...
Open the catalog to page 3
Electroslag Remelting Furnaces Inert Gas Melting A new trend is emerging in ESR melting that involves melting of Oxygen and Nitrogen sensitive alloys under an inert gas enclosure. The major benefits of the inert gas melting system, besides very low oxygen and nitrogen levels, are as follows: Some Features of the Modern Consarc ESR Furnace are: • Fully coaxial • Precision electrode drive • Fully automated melt control • X-Y electrode centering • Inert gas melting capable • Dry air melting capable • Slab ingot capable 900 mm Inert Gas Furnace For inert gas melting the crucible top is sealed by...
Open the catalog to page 4
Electroslag Remelting Furnaces Inert Gas Melting A new trend is emerging in ESR melting that involves melting of Oxygen and Nitrogen sensitive alloys under an inert gas enclosure. The major benefits of the inert gas melting system, besides very low oxygen and nitrogen levels, are as follows: Some Features of the Modern Consarc ESR Furnace are: • Fully coaxial • Precision electrode drive • Fully automated melt control • X-Y electrode centering • Inert gas melting capable • Dry air melting capable • Slab ingot capable 900 mm Inert Gas Furnace For inert gas melting the crucible top is sealed by...
Open the catalog to page 5
Proprietary High Current AC power supply (Reactor Based) Consarc is the only ESR furnace supplier that designs and builds our own custom designed AC power supplies. These units are specifically designed to meet the demanding requirements of the ESR melting application. This provides Consarc ESR customers with a single source responsibility for the complete ESR and power transmission system. 20,000 amps Consarc offers only Saturable Core Reactor based power supply technology for use in our ESR furnace systems. All systems are internally water cooled by a dedicated, dual pump, closed loop, water...
Open the catalog to page 6
ESR — The Process G A B H I F D A B C D E F G H I Molten Pool Molten Slag Water Guide Water Cooling Baseplate Clamped Electrode Crucible Ingot The ESR process involves the gradual melting of the lower end of a cast or forged electrode through a layer of molten metallurgically active slag into a water-cooled copper mold. The slag is usually calcium fluoride with the addition of lime, magnesia, and other oxides. Consarc pioneered in Automatic Melt Controls in the early 1970’s. At that time, before personal computers, melt rate was maintained using programmable calculators while operators adjusted...
Open the catalog to page 7
CONSARC CORPORATION E-Mail: [email protected] CONSARC ENGINEERING LIMITED Holytown, North Lanarkshire ML14XL Scotland,United Kingdom E-mail : [email protected] An inductatherm Croup Company For more information visit www.consarc.com. Leading Manufacturers of Melting, Thermal Processing & Production Systems for the Metals & Materials Industry Worldwide.
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