Crane Selection for the Non-Ferrous Metal Smelting Industry—Lifting Solutions for Four Types of Smelting: Electrolytic Aluminum, Copper, Lead-Zinc, and Rare Earths
In a nutshell:Krud Heavy Industry provides crane configuration solutions for non-ferrous metal smelting enterprises covering four major categories: electrolytic aluminum, copper smelting, lead-zinc smelting, and rare earth smelting. These solutions are designed for lifting capacities of 5–100 metric tons and spans of 12–40 meters, with total investment in plant-wide lifting equipment ranging from approximately 400,000 to 6,000,000 yuan. Electrolytic aluminum workshops are equipped with high-temperature-resistant, corrosion-resistant, multi-functional units (15–32 metric tons), while copper smelting areas use high-capacity double-girder overhead cranes (20–50 metric tons), lead-zinc smelting areas are equipped with corrosion- and acid-resistant overhead cranes (10–30 metric tons), and rare earth smelting areas use stainless steel clean-room cranes (5–20 metric tons), meeting the special lifting requirements of non-ferrous metal smelting operations involving high-temperature molten materials, strong acid and alkali corrosion, and electrolytic magnetic fields.
💡 Non-ferrous metal smelting (2000A-class electrolytic aluminum shops, 50–200-metric-ton copper smelting converters, lead-zinc roasting furnaces, and rare earth extraction) involves high-temperature, corrosive, and heavy-duty environments. We recommend the QD double-girder 20–50 t heat-insulated model combined with a corrosion-resistant MH overhead crane and an explosion-proof KBK system. Krude Heavy Industry’s full range of non-ferrous smelting solutions features temperature-resistant and corrosion-resistant designs.
The four major non-ferrous metal smelting processes—aluminum electrolysis, copper pyrometallurgy, lead-zinc roasting, and rare earth extraction and separation—all operate in high-temperature, highly corrosive, and high-current environments, placing special demands on the temperature resistance, corrosion resistance, and insulation performance of lifting equipment. This article provides tailored crane solutions based on these four types of smelting processes.
I. Primary Aluminum Production Shop—Cranes for Anode Replacement and Electrolytic Cell Maintenance
The core lifting requirements in an electrolytic aluminum plant are anode replacement (15–25 metric tons per set of anodes; 20–40 sets per electrolytic cell; replacement cycle of 28–32 days) and major overhauls of electrolytic cells (hoisting the cell body out for repair). The workshop temperature ranges from 50 to 80°C, with magnetic field strengths of 10 to 50 mT and high concentrations of corrosive gases (HF).
Recommended Models:QD-type double-girder bridge crane, 50 t/span 22–28 m, heat-insulated model (motor with Class F insulation, double-glazed insulated operator’s cab, cables rated for 200°C). Anod replacement is performed using a dedicated anode lifting device (with anti-disengagement hook protection and current isolation); major overhauls of the electrolytic cell are performed using a dedicated C-type lifting device. Hoisting speed: ≤2 m/min under heavy load; 12 m/min under no load.
Price Guide:The QD double-girder 50t/25m model costs approximately 350,000–550,000 yuan per unit; the heat-insulated version costs an additional 20%%. Krude Heavy Industry’s electrolytic aluminum solution comes standard with protection against magnetic field interference and an HF-corrosion-resistant coating.
II. Copper Smelting Using the Fire Method—Relining and Hoisting of Converter/Anode Furnaces
The core equipment for copper smelting using the fire-furnace process consists of a converter (weighing 100–200 metric tons, with refractory brick linings that require periodic replacement) and an anode furnace (50–100 metric tons). The process of relining a converter involves lifting the furnace body off its base → laying the refractory bricks → and reinstalling it. Each refractory brick weighs 5–20 kg, and a single furnace requires 500–3,000 bricks.
Recommended Models:QD-type double-girder bridge crane, 100 metric tons, span 20–26 meters, equipped with a forced-air cooling fan (motor cooled via a separate air duct). Converter lining work is performed using a masonry platform (3-metric-ton capacity, liftable); the crane is responsible for lifting the converter body and handling the refractory brick pallets.
Price Guide:A QD double-girder crane with a capacity of 100 metric tons and a span of 24 meters costs approximately 600,000 to 1,000,000 yuan per unit; forced cooling incurs an additional charge of approximately 15%%. Krude Heavy Industry’s copper smelting solution includes high-temperature-resistant steel wire ropes (galvanized and oil-impregnated, with a temperature resistance of 300°C).
III. Lead-Zinc Roasting—Roasting Furnace Maintenance and Material Handling
Roasting furnaces (fluidized bed furnaces/rotary kilns) used in lead-zinc smelting have a furnace body capacity of ≤30 metric tons and are lined with refractory materials. Lead-zinc smelting produces SO₂ and lead dust, which are highly corrosive and toxic. The workshop must be designed as a sealed, negative-pressure facility, and cranes must be acid-resistant and corrosion-resistant.
Recommended Models:MH-type gantry cranes, 10–30 t, span 12–18 m, with acid-resistant coating (zinc-rich epoxy primer + chlorinated rubber topcoat, total thickness ≥ 200 μm). Electric hoists have an IP55 protection rating, and the control cabinet is designed for positive-pressure explosion protection. Specialized supports for the kiln body are provided for rotary kiln maintenance.
Price Guide:The MH gantry crane (20 t/16 m) costs approximately 150,000–250,000 yuan per unit; an acid-resistant coating adds approximately 10%% to the price. Krude Heavy Industry’s lead-zinc solution includes an acid-resistant protective cover and a negative pressure interlock shutdown system.
IV. Rare Earth Extraction and Separation—Transportation of Extraction Tanks and Calcination Kilns
Transportation of extraction tanks (weight ≤ 10 metric tons) and calcination kilns (5–15 metric tons) used in rare earth extraction and separation. Since rare earth extractants are mostly organic solvents (such as P507 and TBP, which are flammable), the workshop must be designed to be explosion-proof. Rare earth products are highly valuable (praseodymium-neodymium oxide ≥ 500,000 yuan/t), so measures must be taken to prevent spillage during lifting operations.
Recommended Models:A 5-metric-ton KBK flexible modular crane equipped with an explosion-proof electric hoist (Exd IIB T4) covers the extraction tank installation and maintenance area. The calcination kiln area is equipped with a small jib crane (2 metric tons, made of corrosion-resistant stainless steel). The finished product packaging area is equipped with an electric stacker.
Price Guide:The KBK explosion-proof 5-metric-ton model costs approximately 80,000 to 150,000 yuan per set, while the 2-metric-ton jib crane costs approximately 10,000 to 20,000 yuan per unit. Krude Heavy Industry’s rare-earth solution includes a full range of explosion-proof electrical components and leak-proof, sealed lifting attachments.
Comparison of Lifting Equipment Configurations for Non-Ferrous Metal Smelting
| Process | Recommended Models | Tonnage | Special Requirements | Suggested Price |
|---|---|---|---|---|
| Electrolytic Aluminum | QD Double-Girder Insulated Type | 50 metric tons | Class F Insulation/HF-Resistant | 350,000–550,000 |
| Copper Smelting | QD Double-Girder Forced Cooling | 100 metric tons | Temperature-resistant up to 300°C | 600,000–1,000,000 |
| Lead-Zinc Smelting | MH Acid-Resistant Overhead Crane | 10–30 metric tons | Epoxy coating ≥ 200 μm | 150,000–250,000 |
| Rare Earth Extraction | KBK Explosion-Proof Type | 5t | Exd IIB T4/Stainless Steel | 80,000–150,000 |
Key Parameters in Nonferrous Metal Smelting
Krude's Competitive Advantages in the Non-Ferrous Metal Smelting Industry
Krude Heavy Industry has been deeply involved in the non-ferrous metal smelting industry for many years. With a 50,000-square-meter production facility and an ISO 9001-certified quality management system, the company provides high-temperature, corrosion-resistant crane solutions for customers in four sectors: electrolytic aluminum, copper smelting, lead-zinc smelting, and rare earth extraction.
High-Temperature Corrosion Protection Solutions
Centered around a combination of QD double-girder insulated/forced-cooling cranes, MH acid-resistant overhead cranes, and explosion-proof KBK systems, this solution covers all lifting requirements throughout the entire smelting process for aluminum, copper, lead-zinc, and rare earth metals.
Materials and Workmanship Guarantee
Comes standard with a high-temperature-resistant motor (Class F/Class H insulation) + acid-resistant and corrosion-resistant coating (epoxy ≥ 200 μm) + HF-resistant sealing treatment, making it suitable for various corrosive smelting environments.
Complete Line Planning Services
Provide a comprehensive layout plan for the non-ferrous metal smelting workshop—including the crane types, lifting capacities, temperature resistance ratings, corrosion protection requirements, and explosion-proof configurations for each workstation—to ensure safety and efficiency.
