The Hybrid Induction–Indirect Plasma Powder Smelting System is designed as a containerized, plug-and-play solution, enabling rapid deployment and flexible operation without the need for large-scale smelter infrastructure. Built within standard shipping containers, the system integrates six indirect plasma torches (80 kW each, totaling 480 kW), a 480 kW induction furnace, a cone-type water-cooled condenser, and a complete gas handling unit including cyclones and a dust collector. The process operates in alternating modes to maintain a maximum load of 480 kW: in plasma mode, finely ground ore powder (150–250 mesh) is injected into a 2,500–4,000°C plasma zone where volatile metals vaporize and non-volatile components form molten droplets; these are rapidly cooled in a copper-lined cone condenser positioned directly below the plasma jet, allowing metal powder and droplets to fall into the crucible. In induction mode, the collected material is melted and separated into metal and slag, with slag removed through a skimming outlet. The system’s stainless steel casing with refractory lining and external cooling coils ensures durability under high thermal conditions. Designed for minimal installation requirements, the containerized unit only needs power, water, and exhaust connections to begin operation, making it ideal for remote mining sites, recycling facilities, and modular industrial clusters. This plug-and-play architecture significantly reduces capital expenditure, installation time, and operational complexity while maintaining high recovery efficiency for both volatile and non-volatile metals.
