Hydraulic Furnace Upender: 10-Ton 90-Degree Flipper for Relining

Country / Destination: Changsha, Hunan Province, China
End-User Client: Metso Metallurgical Engineering Technology Co., Ltd.
Equipment Model: FZPT-10000 Customized Heavy-Duty Hydraulic Furnace Upender
Rated Load Capacity: 10,000 kg (22,046 lbs) continuous tilting payload
L-Shape Platform Dimensions: $2, 000 mm \times 1, 700 mm$ (flat support plate) + $1, 700 mm \times 1, 700 mm$ (V-support plate)
Lifting Cylinder Configuration: Quad-cylinder hydraulic system (Four $Φ160 mm$ double-acting cylinders)
Compatible Vessel Geometry: Heavy cylindrical furnace bodies with an outer diameter of $Φ1, 430 mm$ ( $Φ4.69 ft$ ) and height of $1, 938 mm$ ( $6.36 ft$ )
Operating Environment: High-temperature foundry area (Operating range -20°C to 60°C)

This newly developed 10-ton Hydraulic Furnace Upender has been custom-designed by our team to automate the vertical handling of heavy smelting vessels. Our client, a prominent multinational contractor specializing in mining and mineral process engineering, needed an exceptionally stable and robust system to maintain their large industrial furnaces.

Inside metallurgical smelting foundries, the internal refractory brick lining of melting pots and gas-fired furnaces must be replaced periodically due to high-temperature erosion. Safely swapping out these heavy firebricks requires tilting the cylindrical furnace vessel 90 degrees from an upright operating position to a flat horizontal maintenance position.

To handle this massive and unevenly balanced load safely, we engineered a specialized electro-hydraulic L-cradle upender. The entire heavy-duty structure was built to withstand high radiant temperatures, conforming directly with European EN 1570-1 safety requirements and ISO 13577 industrial furnace safety standards to ensure complete workplace security in foundry zones. This custom solution is a part of our premium engineering catalog of upenders and tilters.

Challenge

The primary engineering challenge of this metallurgical project was securing the cylindrical $Φ1, 430 mm$ furnace during high-vibration brick replacement. Under horizontal maintenance conditions, workers use heavy pneumatic hammers to chip away worn firebricks, creating continuous impact forces. If the furnace shifts or slides during this process, it presents catastrophic safety hazards for the maintenance crew.

To guarantee complete positional stability, we built three specialized mechanical features into the L-cradle deck:

Integrated Steel V-Saddles: We welded heavy-duty circular-arc steel V-saddles directly onto the $1, 700 mm$ platform face. These saddles are geometrically configured to securely cradle and self-center the $Φ1, 430 mm$ furnace cylinder, preventing lateral rolling.
Dual-Active Hydraulic Locking Clamps: On both outer sides of the V-saddle, we integrated two heavy-duty hydraulic clamp claws. Once the furnace is lowered into the saddle via the overhead crane, these two claws close hydraulically, locking the furnace body firmly to the steel cradle frame.
Adjustable Furnace-Mouth End Stopper: To completely prevent longitudinal sliding under pneumatic impact forces, we engineered an adjustable mechanical clamp stopper at the furnace mouth end. This ensures the furnace remains locked in position regardless of vibration.
Projecting Lifting Lug Clearances: We cut dedicated clearances into the steel frame to accommodate the furnace’s protruding lifting lugs. This ensures the vessel sits perfectly flush on the V-saddles with zero point-load stress on its external accessories.

Solution

Operating inside active smelting foundries means the upender is exposed to intense radiant heat, slag splatter, and high humidity. To guarantee maximum service life, we performed Sa2.5 grade grit-blasting on the entire steel structure, followed by a premium multi-layer high-temperature protective coating system. We applied a silicone zinc silicate primer (DFT

 $45 μ m$ ) followed by intermediate and topcoats of specialized heat-resistant aluminum-silicon paint (DFT  $35 μ m$ ). The final RAL 9006 metallic silver finish has a total dry film thickness exceeding  $115 μ m$ , providing robust protection against dynamic thermal stress and oxidation.

The mechanical frame is built for extreme rigidity, constructed using heavy $200 \times 100 \times 8 mm$ Q235B rectangular structural steel tubes and an 8mm thick solid steel faceplate. The hydraulic motion is powered by a high-torque 11 kW Wannan motor (Class II efficiency, AC 400V 50Hz) coupled to four robust $Φ160 mm$ Hengyu Group cylinders.

To eliminate dynamic pressure spikes, the hydraulic manifold is fitted with integrated counterbalance valves and Japan-imported NOK cylinder seals. Safety electronics are managed via an IP55 Siemens PLC system with a 10-inch HMI touchscreen console, providing automated overload power-cut protection and a handheld wireless pendant.

If your metallurgical plant requires a custom engineered Hydraulic Furnace Upender, please contact our engineering team to receive a free, factory-direct technical layout and design consultation.

Parameter	Delivered Specification / Value (FZPT-10000)
Model Designation	FZPT-10000 Customized Heavy-Duty Hydraulic Furnace Upender
Rated Load Capacity	10,000 kg (22,046 lbs) continuous operating payload
Flipping Angle Range	0° to 90° (Driven by quad-cylinder hydraulic system)
Cradle Table Dimensions	$2, 000 mm \times 1, 700 mm$ (flat support) + $1, 700 mm \times 1, 700 mm$ (V-support)
Compatible Furnace Diameter	$Φ1, 430 mm$ ( $Φ4.69 ft$ ) cylindrical smelting vessels
Heavy-Duty Scissor Cylinders	4 Units, Bore diameter: $Φ160 mm$ with hard-chrome plated rods
Hydraulic Seals Brand	NOK brand (Imported from Japan)
Platform Structural Steel	Q235B Grade high-strength rectangular tube ( $200 \times 100 \times 8 mm$ )
Platform Plate Thickness	8 mm (0.31 in) Solid Q235B Steel Plate
Hydraulic Clamp Outriggers	Dual active hydraulic clamp claws mounted on V-saddle side frames
Longitudinal Stop Fixture	Adjustable bolt-tensioned mechanical furnace-mouth stopper
Drive Pump Motor Power	11.0 kW Wannan Motor (Class II efficiency, AC 400V, 50Hz)
Tilting Operational Speed	Approximately 30 seconds for full 90-degree transition cycle
Surface Coating Specification	Sa2.5 sandblast + Zinc silicate + high-temp aluminum-silicon paint ( $\geq 115 μ m$ )
Automation Control System	Siemens PLC with 10-inch HMI touch screen & wireless remote
Finish Color Aesthetics	RAL 9006 Aluminum Silver Metallic Gloss Finish

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Hydraulic Furnace Upender: 10-Ton 90-Degree Flipper for Relining

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