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Aluminum Holding Furnaces

with Kanthal Electric Heating System

When Efficiency and Environment are in Mind

Experience with Furnaces


up to 100 tons

Kanthal Electric Heating Systems are being used


today in more than 70 holding furnaces within
primary aluminum smelters world-wide.
We can help aluminum producers to reduce
operating costs associated with their holding
furnaces in several ways.
Improved energy efficiency and lower energy
costs.
Reduced metal loss due to 0.51% less dross
formation.
Reduced airborne emissions and zero CO2
emissions from the process supports improved
environment quality and a reduced carbon
footprint.

TUBOTHAL Heaters equipped with Bumper Protection System

Typical furnace rating using Kanthal Electric


Heating Solutions based on TUBOTHAL
R adiant Tube Heating System is from 500 to
1500 kW.
All installations are designed in close cooperation with our customers.

Increase Efficiency

with Energy Balance Calculation


We work closely with our customers to
build up an energy balance model to review
proposed new furnace designs or convertions of existing furnace installations.
The energy balance model helps to optimize
the thermal input requirements in line with the
required process capacity, with additional
reserve power installed
to provide maximum
flexibility for increased
productivity and for safe
and reliable operation.

Conv

Calc

ersio
n fr
om o
n fo
il to
r en
elect
ergy
Cus
d

ulatio

ric h
eatin
g

tome
eman
Furn
r: x
ac
d in
xxxx
Casin e dim.
Al. h
g: le
oldin
ngth
g fu
rnac
with
7,38
es
0
h
E
m
eigh
lectr
6,05
Bath
Furn
t
ic
0
: len
al H
ace
Tonn
m
e
gth
3,55
no: #
a
t
ag
ing C
0
#
apac
Time e
m
with
6,38
ity:
limit
0
.
D
m
dept
e
5
lt
,050
a T
h
6
0
Char
ton
m
0,69
Oil h
ge p
0
ower
ea
1 ho
Powe
m
ur
Heat ting (L
r los
23 g
ing v
ight
s
Linin
C
alue
oil)
Spec
g
powe
435
. we
r
Min.
kwh
ight
Elec
powe
1
tric
2
0,27
8 kw
r
9900
value
cal/g
h
Oil p
Elec
kcal/
513
rice
x K
Acc.
tric
kg
0,89
kwh
H
Oil p
heat
1 07
Heat
kg/li
in
rice
Heat auck +50
g
6 kw
10,2
ing v
ter
%
Effic
S
5 kw
a
lue
El pr
tora
iency
h
g
/
ic
e
l
0,55
e
Effic
/l
Max
iency
0,05
860
imum
kcal/
kr/k
powe
Max
wh
kwh
0,06
r fo
35 %
oil c
/kw
r ma
ons
Add.
h
x bu
96 %
powe ume
rner
r
Effic
capa
city
iency
300
( hou
Usef
r va
ul po
3 07 litre
lues
wer
Ener
4 kw
)
El. c
gy c
onsu
ost h
3
me.
5
A
%
our
dd.
Aver
1 07
p
o
wer
age
6 kw
Effic
p
o
1 12
wer
Avr.
iency
165
fo
1
o
Usef

Add. il consum r holdin


1 12 kwh
ul po
g (
e
1 kw
wer
powe
Ener
hour
r
Effic
= Po
gy c
value
9
wer
iency
o
6
s
t ho
%
s )
ratin
125
Usef
ur
1 07
g
ul po
6 kw
1 28 litre
wer
Ener
1 kw
El. c
7
gy c
1
onsu

ost h
3
5
m
A
e
%
our
dd.
Year
powe .
448
ly en
r
Effic
kw
ergy
Avr.
iency
cost
467
77
oil c
Usef
kw
base
onsu
Add.
u
l
d
467
m
powe
on a
powe
Ener
kw
r
vera
r
Effic
gy c
ge p
1 09
9
o
iency
6%
st h
r. m
5 00
o
o
Usef
u
0
n
r
th
448
ul po
1 28 litre
kw
wer
Ener
1 kw
El. c
29
gy c
on
ost y
35 %
Add. sump.
ear
Inst
p
ower
448
allat
Effic
4 09
kw
ion c
602
Tube
0 13
iency
ost
250
s
5 kw
Usef
1800

h
Tubo
ul po
kw
467
wer
thal
E
kw
n
ergy
elem
Hang
e
c
96 %
nt
ost y
er
e
a
r
Year
El. e
448

ly en
quipm
kw
257
ergy
ent
Oil
Cable
679

cost

Elec
Asse

t
r
mbly
Ener
Tota
602

gy s
l
250
aving

Dros
257

s
s re
679
duct

Year
344

ion
200
ly
571
savin
000

g
450

s
000

Pay
794
off
571
time

Pay Back Calculation


Kanthals Customer Value Calculation
(CVC) tool forms the basis of a cost study
analysis of existing holding furnace installations, and in developing a return on
investment calculation for converting
from gas or oil firing to Tubothal
electric radiant tube heating system.

0,25

Year

Heat Absorption Rate

by Radiation into Low Emissivity Surface

Fig. 1 Temperature distribution (in C) inside


the furnace. Roof surface emissivity = 0.25,
aluminum bath emissivity = 0.1.

Fig. 2 Temperature distribution (in C) inside


the furnace. Roof surface emissivity = 0.55,
aluminum bath emissivity = 0.1.

Heat Transfer Rate


by Radiation

Roof surface characteristics


Fiber block surface: 0.25
Refractory surface: 0.55

146 146

300

1000

139

650

1327

285

Bath surface characteristics


1. Naked liquid Al: 0.1
2. Thin oxide layer: 0.65
3. Solid AI ingots: 0.2

(mm)

Tube surface characteristics


Fully oxidized APM: 0.7
Power density: 4 W/cm2

Heat flux calculation models and CFD


thermal modelling programs assist us
in developing the optimized heating
system design for any specific holding
furnace arrangement.

Simple Replacement
Tubothal electric radiant tube heating systems
are designed for long life and trouble free service.
Along with engineering design service, a full
instruction package is provided covering; storage
and handling, and installation techniques for fast
and simple heater installation and replacement.

APM Tube & TUBOTHAL Installation


(mm)

310

5800

300

Special tooling for installing


and extracting APM tube
and Tubothal is
provided, together with
step by step instructions.

300
880

880
2640

435

Complete Installation
Kanthal supplies all mounting hardware and fixtures needed to make a complete installation,
including: support brackets, fixed position and
swing hangers, hanger installation tools, etc.

Kanthal a Sandvik brand


Kanthal AB, Box 502, 734 27 Hallstahammar, Sweden Phone +46 220 21000 Fax +46 220 21166 www.kanthal.com

6-B-3-3 10-08-1000 www.idebild.com

We also provide specifications for the electrical


power control equipment, or can supply a ready to
install SCR (thyristor) based control system in cabinets for stand alone use, or ready to receive instructions from your existing PLC control system.

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