Development of a 6kg Electric Resistance Furnace using Locally Sourced Materials

• Author(s): Olorunmotito Noah Femi ; Omotoso Abiodun Olutola ; Peter Mary ; Yusuf Olatunbosun Tafa
• Paper ID: 1710857
• Page: 1307-1319
• Published Date: 24-09-2025
• Published In: Iconic Research And Engineering Journals
• Publisher: IRE Journals
• e-ISSN: 2456-8880
• Volume/Issue: Volume 9 Issue 3 September-2025

Abstract

This study presents the design, construction, and performance evaluation of a 6-kg-capacity electric resistance furnace (ERF) fabricated from locally sourced materials for melting aluminium and conducting heat-treatment operations. The furnace was specifically developed for use by mechanical engineering students of Kano University of Science and Technology, Wudil, Nigeria, with the aim of bridging the gap between theory and practice through the production of small mechanical components such as automobile propeller couplers, gears, and brake discs. It was designed to achieve a maximum operating temperature of 830 °C, using three 2 kW Nichrome heating elements to provide a total power rating of 6 kW. Fireclay was used as the lining material, supported by fibreglass as a secondary insulator to minimise heat losses, while a mild-steel crucible was employed for charging aluminium scraps into the furnace chamber (240 mm × 240 mm × 300 mm). Performance evaluation, based on a 6 kg aluminium melt test, achieved complete melting within 35 minutes. The estimated thermal efficiency of the furnace was 48.1 %, with a specific energy consumption of 0.58 kWh/kg and a melt rate of 0.17 kg/min. The study demonstrates that locally fabricated furnaces can achieve credible efficiencies while offering a low-cost alternative to imported units. Recommendations for improvement include enhancing insulation and optimising heating-element placement, while future work will explore scaling the design to higher capacities and investigating alternative linings for improved performance.

Keywords

Aluminium Melting; Electric Resistance Furnace; Locally Fabricated Equipment; Heat Treatment; Fireclay and Fibreglass Insulation

Citations

IRE Journals:
Olorunmotito Noah Femi , Omotoso Abiodun Olutola , Peter Mary , Yusuf Olatunbosun Tafa "Development of a 6kg Electric Resistance Furnace using Locally Sourced Materials" Iconic Research And Engineering Journals Volume 9 Issue 3 2025 Page 1307-1319

IEEE:
Olorunmotito Noah Femi , Omotoso Abiodun Olutola , Peter Mary , Yusuf Olatunbosun Tafa "Development of a 6kg Electric Resistance Furnace using Locally Sourced Materials" Iconic Research And Engineering Journals, 9(3)