Rio Automatic Melting Furnace w/ graphite crucible

What Chris said!
The only place I might suggest a difference is in furnace size. I used a #8 crucible when I was in business. They served my needs perfectly, even for melting silver.

The reason I make mention is the cost of buying crucibles. Unless you feel you'll use the #16, furnace size can be down-sized a little, so construction cost would be reduced, as would operating expense. You also would not be tempted to use a crucible larger than what would be required, taking life out of a very expensive crucible when it isn't necessary. Because of fluxing, you will come to understand that crucible life is relatively short in the refinery. It's a necessary evil, so it can't be avoided. On the positive side, as crucibles grow in capacity, so, too, does the wall thickness. There is a slight offset in that regard, but if you're using a large crucible at less than acceptable capacity, it's still a mistake. So this makes sense, failure of crucibles that are used with flux occurs at the top of the melt---the junction of the charge and air. The crucible is eroded there, and quickly springs a leak. I used to get about 8 heats from a #8 crucible, which would melt a lot of silver.

Tooling up for various sizes isn't exactly a good idea, either, because of the cost of the handling tools. Crucibles must have proper fitting handling tools, otherwise you risk breaking the crucible in use. The consequences of losing a molten charge of metal should not be ignored. It can lead to a burned down facility, or even death.

While small crucibles can be successfully handled by gripping the rim, larger crucibles can't be. They must be removed from the furnace, then transferred to a pouring shank. Two tools to handle the crucible, for each size you may choose to run.

I built a single tool, a pistol grip device with machined jaws (to match the contour of the bilge crucible I used). That tool permitted removing and pouring with the same handling device. I know, from experience, that a #8 is likely the top end of sizes that would permit such a tool. I could pour 200 ounce anodes (of silver), but it required my full attention, and a careful grip. You can see the tool in the picture posted here. You may also get a few ideas of how to build a furnace. Not a big job, really, and a sense of satisfaction when you use it, knowing it exists because of your efforts.

Harold

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