Large ElectroSlag Remelting Furnaces - Consarc

Large ElectroSlag Remelting Furnaces

Consarc has built the world’s largest single electrode static ESR with a final ingot weight of 150,000 kg.  This furnace is also capable of using multiple electrodes to melt that same 150,000 kg ingot via electrode exchange into a static crucible.

Consarc’s ESR furnaces are available in custom sizes to meet any customer requirements for both round and slab electrodes.


Consarc Corporation

100 Indel Ave, P.O. Box 156 Rancocas, NJ 08073-0156


  • Fully coaxial
  • Precision electrode drive
  • Fully automated melt control
  • X-Y electrode centering
  • Inert gas melting capable
  • Dry air melting capable
  • Slab ingot capable
  • Dry slag starting capable
  • Liquid slag starting available
  • Purpose designed AC power supplies

Tech Specs

Product sizing:
Large ESR furnaces are tailored by Consarc engineering to the customer’s desired final ingot size and electrode supply.

Dry or Liquid Slag Start Capable:
Most ESR furnaces today are started “cold” with dry prefused slag.  Consarc can also provide a slag melting furnace with the ESR system that gives “hot” (liquid) slag start capability.  This is most useful in situations where humidity and moisture are concerns, as well as in locations where sourcing of prefused slag is problematic.

Purpose Designed AC Power Supplies:
Consarc is the only ESR furnace supplier that designs and builds our own 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.

Some of Consarc’s large ESR furnaces utilize a Consarc-designed Cycloconvertor power supply, which utilizes a three phase line frequency input to produce a single phase low frequency output.

Inert Gas Melting System:
Today many Oxygen and Nitrogen sensitive alloys are melted under an inert gas atmosphere.  The major benefits of the Inert Gas Melting System are:

  • Helps improve control Oxygen and Nitrogen levels in the final ingot compared to melting in air or dry air
  • The system is fully enclosed, preventing the possibility of contamination from the melt shop during melting
  • Different slags can be used because the oxidation of the slag is no longer a concern
  • Minimal to no deoxidant is required; deoxidant can be a principal source of inclusions in ESR ingots.

Alloys requiring higher nitrogen levels can be remelted in an inert gas atmosphere that includes a higher percentage of nitrogen, reducing the outgassing of that element from the alloy