These include:
• Utilization of load cells to continuously weigh the electrode during the melting process to more accurately measures melt rate

• A PC/ PLC based melt control system that fully automates the melting process, eliminating the older manual operation. The resulting precise process control gives a consistently high quality final product

• Ability to adjust the electrode tip position horizontally at any point in the melt (X-Y axis adjustment) to keep the process electrically and thermally centred in the crucible

• Development of process and equipment for the melting of large round ingots up to 110T and 1800mm diameter and large slab ingots up to 760mm x 2000mm in cross section with weights up to 30T

Other features of a modern Consarc ESR furnace include:
• Inert Gas Melting Systems (IGMS). The use of inert gas (argon) above the melt zone to provide an oxygen and nitrogen free melting environment can improve the cleanliness of remelted steel grades and also greatly assist the control of reactive metal (Al, Si) concentrations to tight tolerance levels.

• PC controlled vibratory Slag Feeders to automate and provide consistency of startup practices during the slag melting phase.

• Fully electromechanical drives systems including single servo motor ram drive for precise control of ram and electrode during the remelt process.