Can you achieve higher efficiency
in your melting furnace?
Case story · Minimized maintenance in melting and holding furnaces · Tubothal®
STG, Svensk Tryckgjutning AB, located in southern Sweden, specializes in die-casting products in alu-
minum and zinc for customers in the automotive, electronics, engineering, transport and construction
industries.The company is certified according to ISO 9000, and has recently moved into new premises
with a factory floor space of 6000 m2 (7176 yd2).
The challenge
Melting was previously done in crucible and induction furnaces,
but before moving to the new factory, it was decided to invest in
modern melting furnaces. The objective was to improve product
quality, yield and economy.
New gas/electric multi-chamber furnaces
SMUAB, a furnace builder specializing in installations for alu-
minum, re­commended a combined gas-electric, tiltable melting
furnace type and two such furnaces were ordered.
The melting process takes place in a separate chamber with an
open gas burner using propane with a power of 190 kW.
Tubothal electric heating elements are made of heavy Kanthal APM
wire rod and rated at 48.2 kW at 220 V, corresponding to a load-
ing of 3.7 W/cm2 (24 W/in2).
The Sandvik solution
The holding chamber uses overhead heating provided by a
Tubothal® – Kanthal APM™ radiant tube system. The molten
aluminum, with a temperature of 720°C (1330°F), is circulated
in the furnace by a pump, thereby speeding up the melting pro-
cess and improving quality.
The maximum capacity is 600 kg (1323 lb) of molten aluminum
per hour.
The electric heating system comprises three high power, multi-
shank, heavy gauge Tubothal wire elements combined with
Kanthal APM metallic radiant tubes. This system allows a higher
power rating than any other metallic system available. Tubothal
elements are rated at 48.2 kW each at 220 V, totally 145 kW,
designed to connect directly to a mains voltage supply of 380 V.
The maximum element temperature is 1100°C (2010°F). The
temperature is controlled by thermocouples in the furnace
chamber, and also in one of the radiant tubes. The Kanthal APM
tubes have a total length of 2400 mm (94 in) and are supported
by hangers and half-shells made from Kanthal APM material to
avoid sagging. The outer tube temperature is 965°C (1770°F)
and the loading is 4.1 W/cm2 (26 W/in2).
Today, Tubothal system is used in a vast number of melting
and holding furnaces. A primary advantage of these tubes is the
formation of a thin cohesive oxide film on both the inner and
outer surface. This oxide does not spall off and, consequently,
the molten aluminum is not contaminated. The oxide also func-
tions as a barrier against atmospheric attack and prolongs the
life of the tubes.
The two SMUAB melting furnaces at STG have each a capacity
of 600 kg/h (1323 lb/h) aluminum. The size is 2520 × 4320 × 1800
(height) mm (99 × 170 × 71 in). Total power is 190 kW (gas) +
145 kW (electric).
The result

Results beyond expectations

The first furnace was installed in the autumn of 1994, and the
next a year later. Production runs in three-shifts with production
stoppage at weekends. The results so far have exceed expecta-
tions – the furnaces are very efficient and provide a substantial
increase in productivity and economy. Maintenance has been
minimized to the regular cleaning of slag. Tubothal® system
shows no sign of ageing and could have a lifetime of several
years.

STG are now planning to upgrade their old Westomat furnaces

with Tubothal system to achieve a higher power output, better
insulation and less maintenance.

The three Kanthal APM™ tubes in the fiber-insulated lid. The tubes
are 198 mm (diam.) × 2400 mm (length) (7.8 × 94 in). The hangers
and half-shells are made of Kanthal APM material. Each tube is
fitted with a Tubothal electric heating element.

Sandvik Group
The Sandvik Group is a global high technology enterprise with 47,000 employees in 130 countries. Sandvik’s
operations are concentrated on three core businesses: Sandvik Tooling, Sandvik Mining and Construction and
Sandvik Materials Technology – areas in which the group holds leading global positions in selected niches.

Sandvik Materials Technology

Sandvik Materials Technology is a world-leading manufacturer of high value-added products in advanced stainless
S-KA034-SS-ENG, 6-D-4-3, 09.2011. Printed in Sweden

steels and special alloys, and of medical implants, steel belt-based systems and industrial heating solutions.
Kanthal is a Sandvik owned brand, under which world class heating technology products and solutions are offered.
Sandvik, Kanthal,Tubothal and Kanthal APM are trademarks owned by Sandvik Intellectual Property AB.

Challenge
   your expectations

Sandvik Materials Technology

Sandvik Heating Technology AB · Box 502 · 734 27 Hallstahammar, Sweden
Phone +46 220 210 00 · Fax +46 220 211 66
www.kanthal.com · www.smt.sandvik.com