Hydraulic systems in smelting plants operate under some of the harshest industrial conditions.
High temperature, heavy dust, continuous heavy loads, high pressure and long duty cycles combine to challenge both system stability and component durability.

In applications such as tilting furnaces, ladle cars and pouring systems for steel, aluminum and alloy smelting, hydraulic power must deliver precise and controllable motion.
Any loss of pressure, excessive leakage, or pump failure can directly disrupt the production schedule.

Industry Context: The Gap Between Theoretical Performance and Real Conditions

In theory, piston pumps offer high efficiency and strong pressure capability.
However, in real smelting environments where oil cleanliness is difficult to maintain and maintenance access is limited, their sensitivity becomes a limitation.

Common issues include:

Wear and performance degradation under contaminated oil conditions

Increased risk of seizure due to particles entering tight clearances

Higher maintenance requirements and shorter effective service intervals

Conventional external gear pumps, while more tolerant, often struggle under continuous high-pressure operation:

Shorter service life in 30 MPa class duty

Higher noise and flow pulsation under heavy load

These limitations highlight the need for a pump that balances durability, stability and performance.

Core Requirement: Stable High Pressure with Environmental Tolerance

For smelting applications, the hydraulic system must achieve:

Reliable pressure output near 31.5 MPa under continuous heavy load

Stable flow for precise tilting and pouring control

Tolerance to contamination and temperature variation

Long service intervals with minimal unplanned maintenance

Solution Platform: FG Series High-Pressure Internal Gear Pumps

FG internal gear pumps are increasingly selected as the main hydraulic power source in smelting systems.

Key Technical Parameters

Rated pressure: 31.5 MPa
Maximum pressure: up to 35 MPa

FG2 displacement range: 64.7–162.8 mL/r

Speed range: 200–3000 r/min

This configuration supports large cylinders and high-flow requirements typical of tilting furnaces and ladle handling systems.

Structural Advantages

Internal gear design provides low flow and pressure pulsation, improving motion control stability

Robust structure with good wear resistance under contaminated oil conditions

Lower sensitivity to oil cleanliness compared with pumps requiring tight tolerances

With basic filtration and periodic maintenance, FG pumps can maintain long service life in high-temperature, dusty environments.

System Design Approach in Smelting Applications

In typical systems, engineers adopt a structured configuration:

Large-displacement FG2 pumps are used as the main pressure source

Flow is distributed to tilting, clamping and pouring cylinders through valve manifolds

For systems requiring additional functions such as travel drives or auxiliary mechanisms, FG21 dual pumps are used

Front pump supplies the main high-pressure circuit

Rear pump supports auxiliary circuits without requiring additional motors

This approach simplifies system architecture while maintaining flexibility.

Performance Improvements in Field Operation

In practical applications, FG pumps provide noticeable improvements:

Tilting and pouring motions become smoother and more controllable under heavy load

System pressure remains stable during continuous operation

Pump-related failures and emergency maintenance events are reduced

These improvements contribute to a more predictable and stable production rhythm.

Engineering Value: A Balanced Solution for Harsh Environments

FG pumps do not aim to maximize a single performance metric.
Instead, they provide a balanced solution that aligns with real smelting conditions.

They offer:

High-pressure capability for heavy-duty applications

Durability under contaminated and high-temperature environments

Stable output with low pulsation

Reduced maintenance complexity

Summary

In smelting hydraulic systems, pump selection must reflect real operating conditions rather than ideal performance specifications.

FG internal gear pumps provide:

Stable high-pressure output

Tolerance to contamination

Improved motion control

Reduced downtime risk

By aligning hydraulic performance with environmental realities, FG pumps help maintain consistent, reliable operation across demanding smelting processes.