Pilot-Scale High-Temperature Molten Salt Electrolysis Furnace for Metal Refining and Smelting

ZYLAB Pilot-Scale High-Temperature Molten Salt Electrolysis Furnace

Introduction

The ZYLAB Pilot-Scale High-Temperature Molten Salt Electrolysis Furnace is specifically designed for advanced metal processing, smelting, and purification applications. This furnace is widely used in the molten salt electrolysis of various metals, including tungsten (W), aluminum (Al), lithium (Li), lead (Pb), tin (Sn), cobalt (Co), nickel (Ni), and titanium (Ti). Among these, aluminum production is one of the most common and successful applications, as molten salt electrolysis remains one of the most effective methods for producing high-purity aluminum.

This pilot-scale system bridges the gap between laboratory research and industrial production. It provides a reliable solution for validating experimental results at a pre-production scale, offering a solid theoretical and practical foundation for future continuous production processes.

By using PLC automatic control and a user-friendly touchscreen interface, the furnace ensures precise temperature management, stable operation, and simplified process control. The high thermal efficiency, low energy consumption, and environmentally friendly design help reduce resource waste and environmental impact, while maintaining a cost-effective and highly efficient electrolysis process.

Key Features

• High-Quality Vacuum Chamber Construction

  • All vacuum chambers are made from corrosion-resistant 316L stainless steel using automated welding techniques.
  • Each chamber undergoes rigorous helium leak testing to ensure high safety and reliability.

• Advanced Pressure Monitoring and Intelligent Vacuum Control

  • Equipped with multiple pressure sensors for real-time monitoring of each chamber’s internal pressure.
  • Automated vacuum pumping and gas replacement functions enhance process automation and safety.

• Real-Time Water and Oxygen Content Detection

  • Internal sensors monitor water and oxygen levels continuously, ensuring maximum operational safety.
  • Designed to prevent hazardous reactions between high-temperature molten salts and moisture.

• Manual Spiral Feeders for Semi-Continuous Operation

  • Features four manual spiral feeding tanks for convenient material addition.
  • Supports semi-continuous production processes, ideal for scaling from lab research to pilot production.

• Automatic Scraping Mechanism

  • Minimizes manual intervention to reduce potential contamination and operational errors.
  • Ensures sample purity and improves process consistency.

• Uniform Heating Design for Precise Temperature Control

  • Combines bottom and circumferential ring heating for superior temperature uniformity.
  • Achieves highly accurate temperature distribution across the heating zone.

• Multiple Observation and Maintenance Ports

  • User-friendly design with multiple observation windows and maintenance ports for ease of operation and maintenance.

• Reliable Control System with Intuitive Operation

  • Stable and user-friendly control interface for reliable operation.
  • Advanced PID self-learning fuzzy logic control for high-precision temperature regulation (±1°C).

• High-Purity Alumina Fiber Insulation Lining

  • The furnace chamber is lined with lightweight, high-purity alumina fiber insulation for excellent thermal retention and energy efficiency.

• Data Logging and Recipe Management Functions

  • Capable of storing important sintering parameters for up to 30 days (based on 8-hour daily operation).
  • Supports more than 100 pre-set process recipes for enhanced flexibility in various experimental protocols.

• Multiple Safety Interlock Systems

  • Comprehensive fail-safe mechanisms to ensure operator and equipment safety during operation.

• Network Connectivity and Remote Monitoring

  • Features an RJ45 interface with TCP/IP protocol, allowing the system to connect with upper-level computers for remote monitoring and control (software required on the upper computer).

Technical Specifications of Molten Salt Electroplating Furnace

Model	G1200-600
Power Supply	380V 50Hz
Temperature Control Accuracy	±1°C
Rated Power	40KW
Heating Rate	1°C/hour – 20°C/min
Temperature Measurement	Dual Control with K-type Thermocouples, 500mm length
Maximum Temperature (Tmax)	1100°C
Heating Method	Bottom + Circumferential Resistance Wire Ring Heating
Heating Zone Size	Ø600mm × 350mm
DC Power Supply Specification	5V 1000A
Cathode Titanium Size	Ø130mm × 200mm
Feeding Tank Volume	4L per tank, total 4 tanks
Installation Dimensions	L 5.5m × H 2.6m × D 2.1m
Gas Inlet Control	Mass Flow Controller, 30SLM (Single Channel)
Ultimate Vacuum	5Pa
Moisture Detection Range	0 – Saturation ppm (minimum detection <10ppm)
Oxygen Detection Range	0 – 25% (Supports both regular and trace oxygen detection, minimum detection <10ppm)
Control System		1. Programmable Sintering Process Curve：Dynamic display of settings and process curves. Supports storing and editing multiple sintering process curves. 2. Scheduled Sintering Function：Enables unmanned operation with automated process execution. 3. Real-Time Data Display and Recording：Displays power, voltage, and other data in real time.Records and exports sintering data for paperless logging. 4. Remote Operation Capability：Supports remote monitoring and control of system status. 5. Temperature Calibration：Automatically corrects the temperature difference between the control point and the sample, ensuring nonlinear correction throughout the process.
Heating Element		Mo-doped Fe-Cr-Al Alloy Heating Wire
Equipment Details		Knife Gate Valve
System Interface		Process Control
Net Weight	Approx. 1300kg
Service & Support	1-year limited warranty.Lifetime technical support (Excludes consumable parts such as processing tubes and O-rings; replacement parts can be ordered from related product sections).

Applications

Key Application Areas:

• Metal Extraction and Refining

  • Suitable for the electrochemical extraction and refining of non-ferrous and rare metals, such as aluminum, magnesium, lithium, titanium, tungsten, niobium, tantalum, nickel, cobalt, lead, and tin.
  • Commonly used in the production of high-purity aluminum and titanium, which are essential in aerospace and electronics industries.

• Rare and Refractory Metals Processing

  • Supports high-efficiency production processes for refractory metals that require high temperatures and stable molten salt environments, ensuring superior material quality.

• High-Purity Material Preparation

  • Enables the purification of metals and alloys by reducing impurities through controlled molten salt electrolysis, ideal for semiconductors, battery materials, and advanced electronic components.

• Research and Development (R&D)

  • Facilitates pilot-scale studies to bridge the gap between laboratory research and industrial-scale production.
  • Provides reliable data and validation for the development of new materials and innovative electrolysis technologies.

Industries Served:

• Aerospace and Aviation
• New Energy and Battery Manufacturing
• Metallurgical and Mining Industries
• Chemical and Material Science Research Institutes
• Electronic and Semiconductor Industry

Why Choose ZYLAB Pilot-Scale Molten Salt Electrolysis Furnace?

• Proven technology for efficient metal extraction and purification
• Customizable designs to meet specific process requirements
• Comprehensive support for laboratory research and industrial applications
• Energy-efficient and environmentally friendly operation

Click Here to View：How Laboratory Molten Salt Electric Heating Furnaces Are Transforming the Aluminum Electrolysis Industry

In addition, we offer high-performance molten salt electroplating furnaces for laboratory applications. For more tube furnaces, box furnaces, vacuum furnaces, and other high-temperature furnaces, click here to view!