Design and Construction of a Simple Metal Melting Furnace

Abstract

The development of small-scale metal casting technology plays an important role in supporting industrial independence and reducing reliance on imported products. In particular, the use of recyclable metal waste, such as aluminium cans, offers economic and environmental benefits to local communities. However, the high cost and limited accessibility of conventional melting furnaces remain significant challenges for small industries. This study aims to design and develop a simple, efficient, and low-cost metal-melting furnace that uses locally available materials and alternative fuel sources. The research employed a Research and Development (R&D) approach, encompassing design, fabrication, experimental testing, and performance evaluation. The furnace was constructed using readily available materials, with used oil as the primary fuel supplied through a burner system and airflow from a blower. Performance testing included analysis of temperature, melting time, fuel efficiency, and material loss. The results indicate that the developed furnace is capable of melting aluminium efficiently, reaching a maximum temperature of 597°C within 8 minutes and 19 seconds. The combustion system using atomised used oil produced stable, concentrated heat, while the refractory lining effectively retained thermal energy within the furnace. In addition, the melting process resulted in uniform liquid metal with minimal residue, indicating good melting quality. From a performance perspective, using waste oil as fuel demonstrates high efficiency and cost-effectiveness compared to conventional fuels, while also promoting waste utilisation. The furnace design is simple, portable, and easy to construct and maintain, making it suitable for small-scale industries. In conclusion, the developed metal melting furnace successfully meets the requirements of efficiency, affordability, and environmental sustainability. It provides a practical solution for small industries by improving productivity, reducing operational costs, and promoting the use of alternative energy from waste materials.