A quote that says only “500 kg furnace” leaves critical questions unanswered: Is that 500 kg per charge or 500 kg per hour, what fuel and utilities are required, and who pays for the chimney, foundation, and installation? Use the checklist below to separate supplied equipment from options and exclusions, test the technical claims, and compare a complete furnace package on measurable terms.
Key takeaways
- Demand a line-by-line equipment and scope schedule before comparing prices.
- Specify capacity, feed material, temperature, fuel, and hourly melt performance.
- Separate equipment, utilities, emissions control, installation, and commissioning costs.
- Require documented performance tests, warranties, exclusions, and acceptance criteria.
Require a Line-by-Line Equipment and Scope Schedule
Demand a line-by-line schedule, not a single “complete furnace” price. Your melting furnace quotation details must identify the furnace body, crucible or hearth, burner and fuel train, refractory lining, charging system, tilting mechanism, tapping tools, moulds, control panel, PLC/HMI, thermocouples or optical pyrometer, electrical cabling, hood, ducting and filtration.
- Construction: crucible material and grade, lining composition and thickness, furnace dimensions, usable melt volume, batch capacity in kg per charge, and guaranteed throughput in kg/h.
- Controls: sensor number and locations, controller accuracy or control band, over-temperature trip, independent high-limit protection, calibration responsibility, and safety interlocks.
- Accessories: charging and tapping tools, spare refractory, commissioning tools, recommended first-fill consumables, moulds, chimney, induced-draft fan, and dust-collection equipment.
- Emissions: hood capture point, duct diameter or airflow, spark protection, cyclone or pre-separator, baghouse or scrubber, stack, access doors, pressure monitoring, and dust-and-dross disposal method.
- Documents and services: layout and foundation drawings, electrical and fuel schematics, manuals, parts list, installation, commissioning, operator training, emission-test report, and statutory compliance documents.
- Commercial status: mark every line as standard, optional, or excluded; name the price for each option.
List exclusions explicitly, including crane, cooling tower, gas train, transformer, chimney, civil foundation, fire protection, laboratory assay, and upstream dismantling, shredding, drying, separation, and hazardous-fraction handling. State whether the output is molten metal, ingots, or an intermediate alloy, with assay limits and separate copper and aluminium recovery figures.
These are essential copper aluminium melting furnace quote inclusions, not fine print.
Define Capacity, Temperature, Feed, and Melt Performance
A 500 kg furnace rating means one charge, not 500 kg per hour. The quotation must state rated batch capacity in kg per charge, guaranteed melting rate in kg/h, usable melt volume, heat-up time, holding capacity, and expected cycle time.
1. Demand a throughput test basis. State the metal or alloy, charge size, starting temperature, target tapping temperature, furnace utilisation, and maximum allowable melt loss. A guaranteed rate without these conditions cannot be compared between suppliers.
2. Require energy consumption in kWh or fuel quantity per tonne of saleable metal, not just burner or transformer size. The basis must say whether it includes preheating, holding, standby, exhaust treatment, and melting dross or contaminated feed.
3. Define the permitted feed: copper and aluminium grades, alloy families, particle-size range, moisture limit, non-metal content, and contamination limits. Copper melts at about 1,085°C; aluminium melts at about 660°C. Specify operating and maximum bath temperatures, changeover cleaning, refractory compatibility, and atmosphere control.
4. Separate furnace melt loss from metal recovery. For copper-bearing e-waste, require feed assay, sampling method, accounting boundary, product assay limits, and acceptance-test recovery figures for metal, slag, dust, and residues. For mixed copper-aluminium feed, identify whether the output is saleable molten metal, ingots, or an intermediate alloy; melting alone does not produce pure separation.
5. Include thermocouple or optical-pyrometer type, sensor locations, controller accuracy or control band, over-temperature trip, independent high-limit protection, and calibration responsibility. These details belong in the copper aluminium furnace specifications, not in a generic control-panel description.
Price Fuel, Utilities, Safety, Emissions, and Site Installation Separately
A furnace quote is incomplete unless it separates purchase price from operating services and site work. Price each line against site assumptions: floor area, foundation load, roof height, utility connection points, delivery access, and required permissions.
- Utilities: fuel train and gas pipeline, electrical cabling, transformer, cooling water or cooling tower, compressed air, recurring fuel, refractory, crucible, and filter-bag consumables.
- Safety: charging and tapping tools, temperature instruments, PLC/HMI interlocks, emergency shutdown, gas-leak detection, fire protection, spark or ember protection, and operator training.
- Emissions: hood and capture point, duct diameter or design airflow, cyclone or pre-separator, baghouse or wet scrubber, induced-draft fan, stack, access doors, differential-pressure gauge, dust and dross disposal, emission testing, and compliance documents.
| Cost item | State separately in the offer |
|---|---|
| Ex-works scope | Furnace, crucible or hearth, burners or power supply, refractory, controls, charging system, tapping tools, moulds, and spare parts |
| Site installation | Packing, freight, unloading, local transport, lifting equipment, civil foundation, structural supports, erection, chimney, ducting, cabling, and commissioning |
| Excluded services | Crane, transformer, gas pipeline, cooling tower, fire system, laboratory assay, permits, GST, and hazardous-fraction handling |
| Acceptance work | Factory acceptance test, site acceptance test, heat-up time, charge size, melting rate, fuel use, tapping temperature, interlock operation, emissions, and melt-loss result |
Keep FAT and SAT separate: an empty furnace can pass FAT yet fail on contaminated e-waste. A furnace installation quote in Ghaziabad should also identify who supplies depollution, sorting, drying, and safe handling of batteries, capacitors, plastics, and moisture before charging.
Make the Commercial Offer Testable Before You Sign
A price is comparable only after every supplier quotes the same duty: kg per charge, guaranteed kg/h, feed assay, charge size, starting temperature, tapping temperature, utilisation, and permitted melt loss. Treat copper aluminium melting furnace quote inclusions as a commercial checklist, not marketing copy.
- Demand a witnessed acceptance test with weighed feed and product, energy or fuel records, cycle time, metal temperature, melt loss, and product assay. State separate recovery figures for copper and aluminium, plus the accounting boundary for metal, slag, dross, dust, and residues. “Recovery” without these records proves nothing.
- Put warranty duration, covered parts, response time, labour, refractory exclusions, and the remedy for failed capacity or temperature control in the contract. Specify who pays travel and freight.
- Require a maintenance schedule with refractory inspection intervals, burner or coil service, calibration frequency, recommended spares, training hours, remote support, and guaranteed parts availability. Name the thermocouple or optical pyrometer, sensor locations, control band, independent high-limit trip, and calibration responsibility.
- Make the melting furnace quotation details identify whether the output is molten metal, ingots, or an intermediate alloy. Require the supplier to state how copper and aluminium separation occurs; melting alone does not produce pure metals.
| Technology | Compare | Evidence to demand |
|---|---|---|
| Induction | Electrical load, coil life, alloy changeover | Power curve, refractory grade, control test |
| Gas-fired crucible | Fuel consumption, emissions, burner turndown | Fuel basis, combustion test, flue scope |
| Resistance furnace | Heat-up, holding stability, element life | Temperature map, element warranty, cycle record |
Check Upstream Separation Before Choosing a Melting Furnace
Melting is the wrong purchase when your feed is mixed, wet, plastic-rich, or still contains batteries, capacitors, sealed items, and pressurised parts. A furnace does not separate copper from aluminium into pure metals; it can turn poor sorting into contaminated alloy, hazardous fumes, dross, and unrecoverable residues.
Demand separate recovery figures for metal, slag, dust, and residue.
Before comparing copper aluminium furnace specifications, require the upstream scope in writing:
- Manual depollution and dismantling for batteries, capacitors, cables, plastics, and brominated fractions
- Shredder, screens, magnetic separation, and eddy-current or sensor sorting for copper and aluminium fractions
- Drying and moisture control, with limits stated at the furnace charge point
- Dust extraction, spark protection, and hazardous-fraction storage
- Sampling and assay of particle size, moisture, non-metal content, and copper-aluminium proportions
Use the metal recovery furnace equipment list to check whether the proposal includes these machines or excludes them. A proposal from Privi is worth comparing only after its furnace boundary is separated from the complete sorting and depollution line.
| Feed condition | Furnace purchase | Proposal test |
|---|---|---|
| Clean, sorted metal | Furnace may be appropriate | State alloy, melt loss, kg/charge, and kg/h |
| Mixed e-waste shred | Furnace alone is inadequate | Include sorting, depollution, and representative-feed testing |
| Copper-aluminium concentrate | Furnace plus separation or refining | Specify product assay, slag accounting, and separate recovery |
| Contaminated or wet feed | Do not charge directly | State rejection limits and safe handling equipment |
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Frequently asked questions
What should a copper aluminium melting furnace quote include?
Request separate line items for the furnace body, crucible or hearth, burner and fuel train, refractory lining, charging system, tilting mechanism, tapping tools, moulds, controls, sensors, cabling, hood, ducting, and filtration.
Which copper aluminium furnace specifications should you define?
State rated batch capacity, hourly melt output, metal grades, feed size and contamination, operating and maximum temperatures, fuel or electrical supply, heat-up time, melt cycle, metal recovery, and power or fuel consumption.
Which costs should a furnace installation quote show separately?
Separate the furnace price from freight, foundations, erection, utilities, fuel storage, electrical work, exhaust ducting, filtration, safety equipment, civil work, commissioning, operator training, taxes, and permits.
Why check upstream separation before selecting a melting furnace?
Remove plastics, batteries, steel, glass, and other contaminants before melting. Cleaner copper or aluminium feed improves recovery, reduces emissions, protects refractory materials, and prevents a furnace from masking separation problems.
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