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Alternative Melting Furnace Concepts

   
   

 

Alternative Heating Technologies

The application of alternative heating technologies depends on the requirements for melt quality, productivity and energy efficiency. In principle either electrically or gas-fired furnaces can be used. In this context, with respect to costs the local pricing for the alternative energy play a decisive role.

Gas Heating

Gas-fired furnaces are ideal for melting, particularly if equipped with exhaust gas discharge over the crucible edge. Side exhaust gas discharge is best if a high melt quality is required. However, a higher melt quality means a lower energy efficiency since a fuel-fired furnace with side exhaust gas discharge consumes approx. 20-25 % more energy than a furnace with an exhaust gas discharge over the crucible edge.

Fuel-fired furnaces provide for optimal energy efficiency in combination with highest melt quality due to their burner system that includes heat recovery via recuperator. The hot exhaust gases from the furnace preheat the combustion air for the burner via a heat exchanger. This system leads to savings of up to 25 % compared to conventional fuel-fired furnaces with a side exhaust gas discharge.

Electric Heating

If the melt quality and energy efficiency take priority, an electrically heated furnace is the best choice. The heating is controlled very steadily and precisely. The melt is not polluted through immissions from a fuel-fired heating. Electrically heated furnaces can achieve up to 85 % of the melting performance of fuel-fired furnaces with a side exhaust gas discharge. If the furnaces are used only for holding, we recommend the T…/10 models, which are very energy efficient due to their very good insulation and reduced connected load.

 Informatie aanvragenProcesbesturing en documentatie
 

Alternative Exhaust Gas Systems

   
   

Exhaust gas discharge over the crucible edge

Exhaust Gas Discharge over the Crucible Edge

Exhaust gas discharge over the crucible edge is the standard design for our gas and oil-fired furnaces, except for the TB models for furnace temperatures of 1200 °C, since these furnaces are normally used as holding furnaces. Due to the high melting performance, the furnaces are perfectly suited for melting. This type of exhaust gas discharge is characterised as follows:

  • Very high melting performance, ideal for use as a melting furnace
  • Low power consumption since the crucible is not just heated from the outside but part of the heat also enters the crucible from above. Energy savings of up to 20 % compared to furnaces with a side exhaust gas discharge
  • Limitations on the melt quality due to higher burn-off and increased hydrogen absorption by the melt from the exhaust gases
  • Bath control not recommended
 

Side Exhaust Gas Discharge

   
   

Side exhaust gas discharge

a) without Recuperator Technology

The side exhaust gas discharge is available for all fuel-fired crucible furnaces. Although the melting performance is not as high as with an exhaust gas discharge over the crucible edge, it provides for better melt quality and, in combination with a bath control, is highly recommended for holding operation.

  • High melt quality due to low burn-off and reduced hydrogen inclusions in the melt
  • Swing lid-reduction of power consumption up to 50 % during holding with a closed swing lid
  • Operator exposed to less heat in the area above the crucible
  • Best melt quality if a bath control for precise temperature control is used
  • Lower melting performance compared to furnaces with exhaust gas discharge over the crucible edge
  • Power consumption during melting around 25 % higher compared to furnaces with exhaust gas discharge over the crucible edge
 

 

   
   

 

Side exhaust gas discharge with recuperator technology

b) with Recuperator Technology

Fuel-fired furnaces with burner systems that include heat recovery via a recuperator provide for optimum energy efficiency in connection with a top melt quality. The combustion air for the burner is pre-heated with the hot exhaust gases from the furnace via heat exchanger. The system results in savings of up to 25 % compared to conventional fuel-fired furnaces with side exhaust gas discharge.

Depending on the utilisation the relatively higher acquisition costs pay off already after a short period of time.

  • Burner systems with a recuperator system save around 25 % of the power compared to furnaces with a side exhaust gas discharge
  • High melt quality due to low burn-off and reduced hydrogen absorption in the melt
  • Reduced power consumption by up to 50 % during holding with a closed swing lid
  • Operator exposed to less heat in the area above the crucible
  • Best melt quality if a bath control for a precise temperature control is used
  • Lower melting performance than furnaces with exhaust gas discharge over the crucible edge
  • Power consumption during melting around 20-25 % higher than furnaces with exhaust gas discharge over the crucible edge

Decision Aid for Melting Furnaces 

   
   
 
 UseProductivityMelt QualityEnergy 
Consumption Noise Emissions 
Models TB/KB 
Exhaust gas discharge over the crucible edge  Melting ++ - o -
Models TB/KB 
Side exhaust gas discharge  Melting +
Holding  + + - -
Models TBR 
Side exhaust gas discharge with recuperator  Melting +
Holding  + + + -
Models T/TF/K/KF 
Electrically heated with bath control  Melting +
Holding  o +++ ++ +
Models T/TF/K/KF 
Electrically heated without bath control  Melting +
Holding  o ++ ++ +
Modelle T../10 
Electrically heated with bath control Holding  - +++ +++ +
Models TC/KC 
Electrically heated via SiC rods  Melting +
Holding  + + o +
 Informatie aanvragenProcesbesturing en documentatie
 

Tilting Furnaces KB Gas-Fired, for Melting and Holding 

KB 400/12 Melting furnace plant consisting of two furnaces KB 360/12 with one work platform

 

Hydraulic system with flame resistant hydraulic fluid

Two-stage burner, mounted on furnace frame

KB 240/12 for melting aluminum alloys

Insulated connecting piece for side-wall exhaust gas vent to a connected customer suction system

The gas-fired or oil-heated tilting furnaces in the KB product lines provide for high melting output, making them ideal for melting operations. The use of high-quality insulation materials results in very low energy consumption. The two-stage burner can be configured for either gas or oil operation. Designed with an exhaust vent over the crucible edge, these models achieve very high melting rates and optimum energy efficiency.

  • KB../12 with Tmax of 1200 °C for aluminum and zinc alloys
  • KB../14 with Tmax of 1400 °C, suitable for copper alloys with a maximum melting bath temperature of 1300 °C (appropriate in some cases for aluminum)
  • Fuel heating with gas or oil
  • Two-stage output control: High load for melting operation, low load for holding operation with automatic switching between both modes
  • Modern burner system with optimized flame guide: High efficiency provided by over-pressure operation to keep out entrained air
  • Gas system consisting of pressure regulator, gas filter, manometer and solenoid valves
  • Safe flame monitoring
  • Burner technology with easy-to-service design, e.g. flame head can be removed from the rear when the burner is swung out
  • Burner technology compliant with DIN 746, Part 2
  • Designed for natural gas or liquid natural gas with 8.8 kWh/m3 - 25.9 kWh/m3
  • Required gas input pressure: 50 mbar
  • Operation with other fuels and/or with another gas input pressure possible
  • High melting output powered by high-performance burners and high-quality insulation
  • Crucible made of isostatically pressed clay-graphite
  • Electro-hydraulic tilting system with flame resistant HFC hydraulic fluid
  • Safe, uniform and precise pouring enabled by the optimum pivot point of the furnace and the manual operation of the slider valve
  • Multi-layered insulation with lightweight refractory bricks provide the furnace chamber lining, 1400  °C models come with an additional wear-and-tear layer made of copper-resistant refractory concrete
  • Emergency outlet for safe discharge of the melt in case of a crucible break
  • Exhaust gas discharge over the crucible edge, resulting in approx. 20 % more melting output compared to side exhaust discharge, design without swing lid
  • Over-temperature limiter for the furnace chamber with automatic reset to protect against over-temperature. The limit controller switches off the heating when the pre-set limit temperature has been reached and does not switch it on again until the temperature falls below the setting again.
  • Furnace chamber control with temperature measurement behind the crucible, recommended when using as pre-melt furnace
  • Side-wall exhaust gas vent for KB…/12 models, see additional equipment

Additional equipment

  • Side exhaust gas discharge for melt and holding operation 
    • Low burn-off provides for high quality melt
    • Low hydrogen absorption by the melt
    • Low heat exposure for the operator in the area above the crucible
    • Swing lid which, when closed during holding operation, saves up to 50 % energy
    • Approx. 20 % lower melting output than for exhaust gas venting over the crucible edge
  • Insulated connecting piece (exhaust flue) for side-wall exhaust gas vent to a connected customer suction system
  • Exhaust gas collection hood for furnaces featuring exhaust gas venting over the crucible edge
  • Work platform or platform for easier charging
  • Crucible breakage monitoring with optical and acoustic signal (only for models KB ../12)
  • SMS-message to one or more mobile phones in case of crucible breakage. One or more furnaces can be connected to the messaging device in parallel
  • Bath control system 
    • Furnace control via the bath temperature
    • Thermocouples in the furnace chamber and the melt
    • Improved melt quality ensured by a reduction in temperature overshoots
    • Integrated safety controller system that, in case of bath thermocouple breakage, continues to operate the furnace at a reduced output to prevent the melt from solidifying
ModelTmaxCrucibleCapacityMelting output3Consumption
holding lidConsumption
meltingBurner
outputOuter dimensions
in mmWeight in
 °C Kg AlKg CuKg Al/hKg Cu/hclosed KWh/hKWh/kgkWWDHkg
                AL          
KB 80/12 1200 TP 287 180 550 2201 - 10 1.3 - 1.5 300 2030 1700 1510 1800
KB 150/12 1200 TP 412 330 970 2401 - 11 1.3 - 1.5 300 2140 1900 1710 2200
KB 180/12 1200 TP 412 H 370 1200 2601 - 13 1.3 - 1.5 300 2140 1900 1810 2400
KB 240/12 1200 TP 587 570 - 4001 - 15 1.3 - 1.5 390 2650 2030 1810 2600
KB 360/12 1200 TBN 800 750 - 4201 - 17 1.3 - 1.5 450 2650 2080 1910 2900
KB 400/12 1200 TBN 1100 1000 - 4501 - 19 1.3 - 1.5 450 2650 2080 2080 3300
                           
KB 40/14 1400 R 400/TP 982 120 400 - 3302 22 1.0 - 1.3 400 2070 1700 1770 2300
KB 60/14 1400 R 500 150 500 - 3602 25 1.0 - 1.3 400 2070 1900 1810 2500
KB 80/14 1400 R 600 180 600 - 3802 25 1.0 - 1.3 400 2070 1900 1910 2650
1At 700 °C 2At 1000 °C
3The stated melting outputs are maximum values. Daily operation comes up to roughly 80 %.

Tilting Furnaces K (Brick Insulation) and KF (Fiber Insulation) Electrically Heated, for Melting and Holding

 
K 150/12 KF 240/12  

Side wall insulation with fiber materials in KF models

Charging of transport ladle with K 360/12

3 x K 300/12 with work platform for melting of aluminum

The electrically heated tilting furnaces of the K and KF product lines are characterized by high melting performance with very temperature uniformity in the melt. Aluminum and brass can be melted in the 1200 °C version. The 1300 °C version can also be used to melt bronze alloys. For faster heating-up cycles in batch operation furnaces can be insulated with fiber resulting in lower heat storage (KF models).

  • K, KF../12 with maximum furnace chamber temperature of 1200 °C for aluminum or brass. Maximum bath temperature, depending on the condition of the crucible, between 1050 °C and 1100 °C
  • K, KF../13 with maximum furnace chamber temperature of 1300 °C also suitable for bronze alloys or brass, with a maximum melt temperature of 1200 °C
  • Heating from three sides using electric heating elements, radiating freely on carrier tubes, simple exchange of individual heating elements
  • Multi-step wiring of the heating elements for furnaces with more than 50 kW electrical rating
  • Heating of furnaces up to 24 kW power rating controlled using long-lasting, noiseless solid-state-relays
  • Heating of furnaces beyond 24 kW with contactors
  • High melting performance with temperature uniformity in the melt
  • Insulation constructed in multiple layers with lightweight refractory bricks on the hot face (K models)
  • Insulation constructed in multiple layers with fiber material in the side walls and corner bricks to support heating elements (KF models)
  • Crucible of clay-graphite up to K 240, isostatically pressed clay-graphite or SiC from K, KF 360 and up
  • Electro-hydraulic tilting system with flame resistant HFC hydraulic fluid
  • Safe, even, and precise pouring thanks to optimum pivot point in the furnace and manual throttling valve operation
  • Emergency outlet for safe draining of the melt in case of crucible breakage
  • No exhaust gas discharge needed
  • Integrated safety system which continues to operate the furnace at reduced power in case of malfunction in the bath thermocouple, in order to prevent the freezing of the melt
  • Over-temperature limiter in furnace chamber for protection against overheating. The limiter switches the heating off when the set limit temperature is reached, and only switches it back on after the temperature has fallen again
  • Furnace chamber control with temperature measurement behind the crucible, recommended for melting

Additional equipment

  • Work platform for easy charging
  • Crucible breakage monitor with visual and audible signal (only for models K, KF ../12)
  • SMS-message to one or more mobile phones in case of crucible breakage. One or more furnaces can be connected to the messaging device in parallel
  • Bath control with thermocouples in the furnace chamber and in the melt. The furnace temperature is controlled through the melt. Temperature overshoots are reduced, thus the quality of the melt is improved
  • Heating system operated through thyristors in phase-angle mode provides for even load on the heating elements and results in longer service life
  • Multi-step switching of the furnace heat (see page 23). In holding mode, a switch or the controller is used to turn off one heating section in order to reduce the electrical rating
  • Higher electrical ratings to increase melting performance
ModelTmaxCrucibleCapacityOuter dimensions
in mmHeating power Weight inMelting performance3Holding
lid closed/open
 °C Kg AlKg CuWDHin kW4kgkg/hr Alkg/h CukW
K, KF 10/12 1200 A 70 20 70 1510 1240 1040 16 750 32¹ 472 3/7¹
K, KF 20/12 1200 A 150 45 150 1660 1360 1060 20 940 42¹ 632 3/7¹
K, KF 40/12 1200 A 300 90 300 1740 1470 1140 26 1270 58¹ 842 3/7¹
K, KF 80/12 1200 TP 287 180 550 1800 1700 1180 50 1430 126¹ 1902 4/10¹
K, KF 150/12 1200 TP 412 330 970 1870 1900 1460 60 1800 147¹ 2202 5/12¹
K, KF 240/12 1200 TP 587 570 - 2010 2000 1460 80 2290 210¹ - 8/17¹
K, KF 300/12 1200 TP 587H 650 - 2010 2000 1560 80 2400 210¹ - 9/18¹
K, KF 360/12 1200 BUK 800 750 - 2120 2100 1550 100 2780 260¹ - 11/20¹
K, KF 400/12 1200 TBN 1100 1050 - 2120 2100 1700 126 3030 295¹ - 12/22¹
                         
K, KF 10/13 1300 A 70 20 70 1510 1240 1040 16 800 32¹ 472 5/82
K, KF 20/13 1300 A 150 45 150 1660 1360 1060 20 1040 42¹ 632 5/82
K, KF 40/13 1300 A 300 90 300 1740 1470 1140 26 1350 58¹ 842 5/82
K, KF 80/13 1300 TP 287 180 550 1800 1700 1180 50 1600 126¹ 1902 6/112
¹At 700 °C 2At 1000 °C
3The specified melting performances are maximum values. In practice, approx. 80 % are achieved.
4Depending on furnace design connected load might be higher
 

Bale-Out Furnaces TB Gas-Fired, for Melting and Holding

 
TB 20/14 TB 240/12  

 

Thermocouple for melting bath control

Emergency outlet for safe melt discharge in case of crucible break

TB 40/14 with crucible pulling device

Insulated connecting piece for side exhaust gas discharge for connection to an exhaust gas system

The gas-fired or oil-heated bale-out furnaces of the TB product lines provide for high melting output. The use of modern burner systems, optimized pressures and flame guide in the furnace as well as the processing of high-quality insulation materials result in very low energy consumption.

The TB ../12 models are largely used for melting and holding of aluminum and zinc alloys, for example in die-cast foundries. The side exhaust gas discharge provides for a high quality melt. The TB 10/14 to TB 40/14 models are mostly used for melting copper alloys in small foundries. This is why these furnaces are equipped with an exhaust gas vent over the crucible edge for high melting output and with a collar plate as a standard which can be swung to the side for pulling the crucible.

  • TB../12 with maximum furnace chamber temperature of 1200 °C for aluminum and zinc alloys
  • TB../14 with maximum furnace chamber temperature of 1400 °C, suitable for copper alloys with a maximum melting bath temperature of 1300 °C (appropriate in some cases for aluminum)
  • Fuel heating with gas or oil
  • Two-stage output control: High load for melting operation, low load for holding operation with automatic switching between both modes
  • Modern burner system with optimized flame guide: High efficiency provided by over-pressure operation to keep out entrained air
  • Gas system consisting of pressure regulator, gas filter, manometer and solenoid valves
  • Safe flame monitoring
  • Burner technology with easy-to-service design, e.g. flame head can be removed from the rear when the burner is swung out
  • Burner technology compliant with DIN 746, Part 2
  • Designed for natural gas or liquid natural gas with 8.8 kWh/m3 - 25.9 kWh/m3
  • Required gas input pressure 50 mbar
  • Operation with other fuels and/or with another gas input pressure possible
  • High melting output powered by high-performance burners and high-quality insulation
  • Multi-layered insulation with lightweight refractory bricks provide the furnace chamber lining, 1400 °C models come with an additional wear-and-tear layer made of copper-resistant refractory concrete
  • Emergency outlet for safe discharge of the melt in case of a crucible break
  • Exhaust gas discharge Exhaust gas discharge options see page 6
    • Exhaust gas discharge over the crucible edge TB…/14 models, resulting in approx. 20% more melting output compared side exhaust discharge, design without swing lid
    • Side-wall exhaust gas vent for TB…/12 models (for description, see additional equipment)
  • Crucible pulling device with swinging collar plate for models to TB 10/14 - TB 40/14
  • Over-temperature limiter for the furnace chamber with automatic reset to protect against over-temperature. The limit controller switches off the heating when the pre-set limit temperature has been reached and does not switch it on again until the temperature falls below the setting again.
  • Furnace chamber control with temperature measurement behind the crucible, recommended when using as pre-melt furnace

Additional equipment

  • Side exhaust gas discharge (for 1400 °C models) 
    • Low burn-off provides for high quality melt
    • Low hydrogen absorption by the melt
    • Low heat exposure for the operator in the area above the crucible
    • Swing lid which saves energy when closed
    • Approx. 20% lower melting output than for exhaust gas venting over the crucible edge
  • Insulated connecting piece (exhaust flue) for side-wall exhaust gas vent to a connected customer suction system
  • Exhaust gas collection hood for furnaces featuring exhaust gas venting over the crucible edge
  • Work platform or platform for easier charging
  • Crucible breakage monitoring with optical and acoustic signal (only for models KB ../12)
  • SMS-message to one or more mobile phones in case of crucible breakage. One or more furnaces can be connected to the messaging device in parallel
  • Bath control system (only for 1200 °C models) 
    • Furnace control via the bath temperature
    • Thermocouples in the furnace chamber and the melt
    • Improved melt quality ensured by a reduction in temperature overshoots
    • Integrated safety controller system that, in case of bath thermocouple breakage, continues to operate the furnace at a reduced output to prevent the melt from solidifying
  • Crucible pulling device with swinging collar plate for models to TB 20
ModelTmaxCrucibleCapacityMelting output3Consumption
holding lid Consumption
meltingBurner
outputOuter dimensions
in mmWeight
in 
 °C Kg AlKg CuKg Al/hKg Cu/hclosed kWh/hkWh/kgkWWDHkg
                AL          
TB 80/12 1200 BU 200 200 650 1401 - 10 1.3 - 1.5 180 1200 1870 1240 900
TB 100/12 1200 BU 250 250 830 1401 - 11 1.3 - 1.5 180 1310 1980 1380 1000
TB 110/12 1200 BU 300 300 1000 1501 - 13 1.3 - 1.5 210 1310 1980 1510 1200
TB 150/12 1200 BU 350 350 1150 2201 - 15 1.3 - 1.5 300 1310 1980 1550 1400
TB 180/12 1200 BU 500 500 1650 2701 - 17 1.3 - 1.5 300 1450 2140 1560 1700
TB 240/12 1200 BU 600 600 2000 3301 - 19 1.3 - 1.5 390 1490 2180 1700 1900
TB 360/12 1200 BN 800 800 - 3501 - 20 1.3 - 1.5 400 1590 2280 1800 2000
TB 400/12 1200 BN 900 900 - 3501 - 22 1.3 - 1.5 400 1590 2280 1900 2100
TB 500/12 1200 BU 1210 1200 - 3501 - 23 1.3 - 1.5 400 1690 2380 1850 2300
TB 600/12 1200 BU 1310 1300 - 4201 - 25 1.3 - 1.5 500 1690 2380 2000 2400
TB 650/12 1200 BU 1810 1400 - 4201 - 26 1.3 - 1.5 500 1760 2450 1630 2300
TB 700/12 1200 BU 1510 1500 - 4201 - 28 1.3 - 1.5 500 1690 2380 2120 2600
TB 800/12 1200 BU 1810 1800 - 4401 - 30 1.3 - 1.5 500 1760 2450 2100 2800
                Cu          
TB 10/14 1400 A 100 30 100 - 902 22 1.0 - 1.3 210 980 1590 1190 1000
TB 20/14 1400 A 150 45 150 - 1002 22 1.0 - 1.3 210 1080 1870 1310 1250
TB 40/14 1400 A 400 120 400 - 3002 25 1.0 - 1.3 300 1210 2000 1460 1500
TB 60/14 1400 A 500 150 500 - 3202 25 1.0 - 1.3 320 1210 2000 1510 1600
TB 80/14 1400 A 600 180 600 - 3202 25 1.0 - 1.3 320 1260 2050 1540 1750
1At 700 °C 2At 1000 °C
3The stated melting outputs are maximum values. Daily operation comes up to roughly 80 %.
 

Crucible Furnaces TBR with Recuperative Burner Gas-Fired, for Melting and Holding 

 
TBR 110/11  

 

2 x TBR 100/11 in production

Production with 16 x TBR 100/11 and 2 x TBR 180/11

Heat exchanger in the exhaust gas duct

Burner with gas supply system 

The fuel-heated melting furnaces in the TBR product line fitted with the side exhaust gas discharge provide for optimum energy utilization combined with highest quality melt. Fitted with a burner system including heat-recovery system using a recuperative burner, the energy efficiency of ordinary fuel-heated melting furnaces is significantly improved.

Depending on utilization the hot exhaust gases from the furnace are guided through a heat exchanger in order to preheat the combustion air for the burner. The system provides for energy savings of up to 25 % compared to ordinary fuel-heated furnaces with side exhaust gas discharge. The higher purchase costs are amortized within a short time.

  • Tmax 1100 °C for aluminum and zinc alloys
  • Two-stage output control: High load for melting operation, low load for holding operation with automatic switching between both modes
  • Modern burner system with optimized flame guide: High efficiency provided by over-pressure operation to keep out entrained air
  • Heat exchanger in the exhaust gas duct to preheat the combustion air for the burners
  • Energy savings of up to 25 % in comparison to other fuel-heated melting furnaces featuring side-wall exhaust gas vents
  • Gas system consisting of pressure regulator, gas filter, manometer and solenoid valves
  • Safe flame monitoring
  • Burner technology with easy-to-service design, compliant with DIN 746, Part 2
  • Designed for natural gas or liquid natural gas with 8.8 kWh/m3 - 25.9 kWh/m3
  • Required gas input pressure 70 mbar
  • Operation with other fuels and/or with another gas input pressure possible
  • High melting output powered by high-performance burners and high-quality insulation
  • Multi-layered insulation with lightweight refractory bricks provide the furnace chamber lining
  • Emergency outlet for safe discharge of the melt in case of a crucible break
  • Side exhaust gas discharge 
    • Low burn-off provides for high quality melt
    • Low hydrogen absorption by the melt
    • Low heat exposure for the operator in the area above the crucible
  • Over-temperature limiter for the furnace chamber with automatic reset to protect against over-temperature. The limit controller switches off the heating when the pre-set limit temperature has been reached and does not switch it on again until the temperature falls below the setting again.
  • Furnace chamber control with temperature measurement behind the crucible

Additional equipment

  • Crucible made of clay graphite or SiC with higher heat conductivity
  • Work platform or platform for easier charging
  • Crucible break monitoring with optical and acoustic signal
  • Bath control system 
    • Furnace control via the bath temperature
    • Thermocouples in the furnace chamber and the melt
    • Improved melt quality ensured by a reduction in temperature overshoots
    • Integrated safety controller system that, in case of bath thermocouple breakage, continues to operate the furnace at a reduced output to prevent the melt from solidifying
ModelTmaxCrucibleCapacityMelting output2Consumption
holding
lid closedConsumption
melting
Burner
output
 °C Kg AlKg CuKg Al/hKg Cu/hkWh/hkWh/kg ALkW
TBR 80/11 1100 BU 200 200 650 1401 - 8.0 1.0 - 1.1 180
TBR 100/11 1100 BU 250 250 830 1401 - 8.8 1.0 - 1.1 180
TBR 110/11 1100 BU 300 300 1000 1501 - 10.4 1.0 - 1.1 210
TBR 150/11 1100 BU 350 350 1150 2201 - 12.0 1.0 - 1.1 240
TBR 180/11 1100 BU 500 500 1650 2701 - 13.6 1.0 - 1.1 300
TBR 240/11 1100 BU 600 600 2000 3301 - 15.2 1.0 - 1.1 320
TBR 360/11 1100 BU 800 800 - 3501 - 16.0 1.0 - 1.1 320
1At 700 °C
2The stated melting outputs are maximum values. Daily operation comes up to roughly 80 %.
 

Bale-Out Furnaces T (Brick Insulation) and TF (Fiber Insulation) Electrically Heated, for Melting and Holding 

 
T 110/11 TF 150/11  

T 800/11

Four side heating for excellent temperature uniformity

Manual ladling from a T 80/10

K 150/12 and T 180/11 as premelting and holding system

Side-wall insulation made of fiber material for TF models

Emergency outlet for the safe draining of melt in case of crucible breakage

Due to their high-grade insulation and optimized connected loads the models T and TF can be used both for melting and holding. They feature good melting output together with outstanding temperature uniformity in the melt. The 1100 °C version can be used for melting aluminum, the 1200 °C version for brass as well. The 1300 °C version can also be used for melting bronze alloys.

The T models are fitted with multi-layer insulation. The furnace chamber insulation with high-quality lightweight refractory bricks is recommended for holding operation. For rapid heat-up times in non-continuous operation, the TF models can also be used, which are lined with a fiber insulation with low heat retention capacity.

  • T, TF../11 with maximum furnace chamber temperature of 1100 °C for aluminum or zinc. Maximum melt temperatures, depending on the condition of the crucible, between 950 °C and 980 °C
  • T, TF../12 with maximum furnace chamber temperature of 1200 °C also suitable for brass. Maximum melt temperatures, depending on the condition of the crucible, between 1050 °C and 1100 °C
  • T, TF../13 with maximum furnace chamber temperature of 1300 °C, also suitable for bronze alloys. Maximum melt temperatures, depending on the condition of the crucible, between 1150 °C and 1200 °C
  • Four-side heating using electric heating elements, freely radiating on carrier tubes
  • Simple replacement of individual heating elements. In case of crucible breakage, only the defective heating elements on each level need to be replaced
  • Heating of furnaces up to 60 kW power rating controlled using long-lasting, noiseless solid-state-relays
  • Heating of furnaces beyond 60 kW with contactors
  • High melting performance with temperature uniformity in the melt
  • Insulation constructed in multiple layers with lightweight refractory bricks on the hot face (T models)
  • Insulation constructed in multiple layers with fiber material in the side walls and corner bricks to support heating elements (TF models)
  • Emergency outlet for safe draining of the melt in case of crucible breakage
  • No exhaust gas discharge needed
  • Integrated safety system which continues to operate the furnace at reduced power in case of malfunction in the bath thermocouple, in order to prevent the freezing of the melt
  • Over-temperature limiter in furnace chamber for protection against overheating. The limiter switches the heating off when the set limit temperature is reached, and only switches it back on after the temperature has fallen again
  • Furnace chamber control with temperature measurement behind the crucible, recommended for melting
  • Crucible not included in the standard version

Additional equipment

  • Crucible of clay-graphite or SiC
  • Work platform
  • Crucible breakage monitor with visual and audible signal (not for 1300 °C models
  • SMS-message to one or more mobile phones in case of crucible breakage. One or more furnaces can be connected to the messaging device in parallel
  • Bath control with thermocouples in the furnace chamber and in the melt (not for 1300 °C models). The furnace temperature is controlled through the melt. Temperature overshoots are reduced, thus the quality of the melt is improved
  • Heating system operated through thyristors in phase-angle mode assures an even charging of heating elements
  • Multi-step switching of the furnace heat (see page 23). In holding mode, a switch or the controller is used to turn off one heating section in order to reduce the electrical rating
  • Higher electrical ratings to increase melting performance
ModelTmaxCrucibleCapacityOuter dimensions in mmHeating powerWeight 
inMelting performance3Holding
lid closed/open
 °C Kg AlKg CuWDHin kW4kgkg/hr Alkg/h CukW
T, TF 10/11 1100 A 70 20 - 860 860 790 16 400 321 - 3/51
T, TF 20/11 1100 A 150 45 - 940 940 790 20 460 421 - 3/61
T, TF 40/11 1100 A 300 90 - 1010 1010 880 26 580 581 - 3/71
T, TF 80/11 1100 BU 200 200   1110 1110 940 50 650 1261 - 4/91
T, TF 110/11 1100 BU 300 300 - 1200 1200 1040 60 880 1361 - 5/101
T, TF 150/11 1100 BU 350 350 - 1200 1200 1250 60 900 1471 - 5/101
T, TF 180/11 1100 BU 500 500 - 1370 1370 1250 70 1080 1681 - 7/151
T, TF 240/11 1100 BU 600 600 - 1370 1370 1350 80 1200 2101 - 7/151
T, TF 360/11 1100 BN 800 800 - 1510 1510 1490 110 2000 2001 - 8/171
T, TF 400/11 1100 BN 900 900 - 1510 1510 1590 110 2100 2001 - 10/201
T, TF 500/11 1100 BN 1200 1200 - 1510 1510 1640 110 2450 2001 - 11/211
T, TF 600/11 1100 BU 1310 1300 - 1615 1615 1730 110 2550 2001 - 13/231
T, TF 650/11 1100 BP 1000 1400 - 1685 1685 1360 110 2400 2401 - 13/201
T, TF 700/11 1100 BU 1510 1500 - 1615 1615 1850 140 2750 2401 - 13/231
T, TF 800/11 1100 BU 1800 1800 - 1685 1685 1830 140 2800 2401 - 15/251
                         
T, TF 10/12 1200 A 70 20 70 860 860 770 16 440 321 472 5/82
T, TF 20/12 1200 A 150 45 150 940 940 770 20 520 421 632 5/102
T, TF 40/12 1200 A 300 90 300 1010 1010 860 26 600 581 842 5/122
T, TF 80/12 1200 BU 200 200 650 1110 1110 930 50 760 1261 1902 5/152
                         
T, TF 10/13 1300 A 70 20 70 900 900 890 16 600 321 472 5/82
T, TF 20/13 1300 A 150 45 150 980 980 890 20 640 421 632 5/102
T, TF 40/13 1300 A 300 90 300 1050 1050 970 26 760 581 842 5/122
T, TF 80/13 1300 BU 200 200 650 1150 1150 1030 50 960 1261 1902 5/152
1At 700 °C 2At 1000 °C
3The specified melting performances are maximum values. In practice, approx. 80 % are achieved.
4Depending on furnace design connected load might be higher
 

 

 
KC 180/14 TC 80/14  

KC 150/14

Heated on both sides by high performance SiC rods

Swing lid with good sealing to collar plate to avoid heat loss over the crucible opening 

Switchgear with thyristors in phase angle operation for economic power consumption

The electrically heated tilting and bale-out furnaces of the KC and TC product lines are characterized by a higher melting performance than achievable with wire heated melting furnaces. These furnaces are designed for permanent operation at working temperatures.

  • Tmax 1450 °C, also suitable for bronze alloys with a maximum melt temperature of up to 1320 °C, subject to the condition of crucible
  • Heating from two sides by generously dimensioned SiC rods, temperature uniformity
  • Simple exchange of individual heating elements
  • Heat operation by thyistors in phase-angle mode with performance control: The resistance of the SiC rods changes with temperature and age. Performance control ensures constant power of heating irrespective to the condition of the heating elements.
  • High melting performance with temperature uniformity
  • Insulation constructed in multiple layers with lightweight refractory bricks on the hot face
  • SiC-Crucible
  • Electro-hydraulic tilting system with flame resistant HFC hydraulic fluid (KC models)
  • Safe, even, and precise pouring thanks to optimum pivot point in the furnace and manual throttling valve operation (KC models)
  • Emergency outlet for safe draining of the melt in case of crucible breakage
  • No exhaust gas discharge needed
  • Over-temperature limiter in furnace chamber for protection against overheating. The limiter switches the heating off when the set limit temperature is reached, and only switches it back on after the temperature has fallen again
  • Furnace chamber control with temperature measurement behind the crucible

Additional equipment

  • Work platform for simplified loading
ModelTmaxCrucibleCapacityOuter dimensions in mmHeatingWeight Melting performance3
 °C Kg AlKg CuWDHpower in kW4in kgkg/h Alkg/h Cu
KC 20/14 1450 A 150 45 150 1710 1900 1050 36 1500 - 1202
KC 40/14 1450 A 300 90 300 1770 1900 1100 36 1600 - 1202
KC 80/14 1450 TCP 287 200 650 1880 1970 1160 48 1900 - 1802
KC 150/14 1450 TCP 412 300 1000 2000 2070 1300 66 2700 - 2202
KC 180/14 1450 TCP 412H - 1000 2000 2070 1500 99 3000 - 2302
                       
TC 20/14 1450 A 150 45 150 1200 1250 930 36 830 801 1202
TC 40/14 1450 A 300 90 300 1260 1250 1020 36 950 801 1202
TC 80/14 1450 BU 200 200 650 1360 1350 1080 48 1050 1201 1802
TC 150/14 1450 BU 300 300 1000 1450 1320 1300 66 1300 1401 2202
1At 700 °C 2At 1000 °C
3The specified melting performances are maximum values. In practice, approx. 80 % are achieved.
4Depending on furnace design connected load might be higher
 

Bale-Out Furnaces T ../10 Electrically Heated, for Holding

 
T 150/10    

Bale-out of T 650/10 with robot

Design of a holding furnace with bath control system containing thermocouples for the melt, the furnace chamber and the over-temperature limiter

The perfect insulation and the reduced electric connected loads provide for perfect energy efficiency and make the T ../10 models optimally suitable for holding operation. Due to the reduced connected load these furnaces are only suitable for melting to a limited extent. This is why they are mostly used in foundries with central pre-melting furnaces followed by transportation of the melt to the holding furnace. 

  • Tmax 1000 °C, ideally suited for the holding of aluminum
  • Four-side heating using electric heating elements, freely radiating on carrier tubes
  • Simple replacement of individual heating elements. In case of crucible breakage, only the defective heating elements on each level need to be replaced
  • Heating of furnaces up to 60 kW power rating controlled using long-lasting, noiseless solid-state-relays
  • Heating of furnaces beyond 60 kW with contactors
  • Particularly good insulation constructed in multiple layers with lightweight refractory bricks on the hot face Emergency outlet for safe draining of the melt in case of crucible breakage
  • No exhaust gas discharge needed
  • Crucible not included in the standard version
  • Integrated safety system which continues to operate the furnace at reduced power in case of malfunction in the bath thermocouple, in order to prevent the freezing of the melt
  • Over-temperature limiter in furnace chamber for protection against overheating. The limiter switches the heating off when the set limit temperature is reached, and only switches it back on after the temperature has fallen again.
  • Furnace chamber control with temperature measurement behind the crucible, recommended for melting
  • Additional equipment, see T, TF furnaces
ModelTmaxCrucibleCapacityOuter dimensions in mmHeating
powerWeight inMelting performance2Holding
lid closed/open
 °C Kg AlKg CuWDHin kW3kgkg/hr Alkg/h CukW
T 80/10 1000 BU 200 200 - 1150 1150 1030 20 660 holding only 4/91
T 110/10 1000 BU 300 300 - 1240 1240 1130 26 890 5/101
T 150/10 1000 BU 350 350 - 1240 1240 1290 38 920 5/101
T 180/10 1000 BU 500 500 - 1410 1410 1290 42 1120 7/151
T 240/10 1000 BU 600 600 - 1410 1410 1390 50 1240 7/151
T 360/10 1000 BN 800 800 - 1510 1510 1490 50 2000 8/171
T 400/10 1000 BN 900 900 - 1510 1510 1590 50 2100 10/201
T 500/10 1000 BU 1210 1200 - 1615 1615 1580 50 2450 11/211
T 600/10 1000 BU 1310 1300 - 1615 1615 1730 50 2550 13/231
T 650/10 1000 BP 1000 1400 - 1685 1685 1360 60 2400 13/201
T 700/10 1000 BU 1510 1500 - 1615 1615 1850 60 2750 13/231
T 800/10 1000 BU 1800 1800 - 1685 1685 1830 70 2800 15/251
1At 700 °C
2The specified melting performances are maximum values. In practice, approx. 80 % are achieved.
3Depending on furnace design connected load might be higher

Transportable Bale-Out Furnaces TM Electrically Heated, for Holding Aluminum

  Transportable holding furnace TM 80/10 Meander heating elements

Slots under the furnace for the forklift forks

Plug socket on the furnace for the cable connection to the switchgear and control box

The bale-out furnaces of the TM product lines were developed especially for use at different pouring locations. The cylindrical, very stable furnace housing, the very high-quality insulation and the meandering heating elements are the special features of this furnace family. The furnaces are designed to be transported by forklift truck and come with a plug-in connection to the control gear. With a forklift truck the furnace can be transported to the pre-melt furnace for filling. When additional switchgear and control boxes are used, the furnace can also be optionally used at different pouring locations.

  • Tmax 1000 °C, ideal for holding of aluminum
  • Cylindrical, highly stable furnace housing
  • Slots under the furnace for safe forklift transportation of the furnace inside the foundry
  • All-round heating provided by resistant meandering heating elements
  • Switchgear and control box for plug-in connection
  • Heating of furnaces up to 60 kW power rating controlled using long-lasting, noiseless solid-state-relays
  • Heating of furnaces beyond 60 kW with contactors
  • Especially good insulation, multi-layered with fiber material in the furnace chamber
  • Emergency outlet for safe discharge of the melt in case of a crucible break
  • No exhaust gas vent necessary
  • Crucible in standard design not included
  • Furnace chamber control with temperature measurement behind the crucible
  • Over-temperature limiter in the furnace chamber to protect against over-temperature The limit controller switches off the heating when the pre-set limit temperature setting has been reached and does not switch it on again until the temperature falls below the setting again.
ModelTmaxCrucibleCapacityOuter dimensions
in mmHeating powerMelting output2Holding
Lid closed/open
 °CØHKg AlKg CuWDHin kW3kg/h Alkg/h CukW
TM 80/10 1000 BU 200 200 - 1000 1100 950 21 only for holding 4/91
TM 150/10 1000 875 600 350 - 1320 1440 1000 36 5/101
TM 240/10 1000 BU 600 600 - 1220 1340 1300 42 7/151
1At 700 °C 
2The specified melting performances are maximum values. In practice, approx. 80 % are achieved.
3Depending on furnace design connected load might be higher
 

Accessories for Bale-Out and Tilting Furnaces 

   
   

Crucible Pulling Feature with swinging collar plate

Pneumatic lid opener

Charging funnel for ingots

Work platform for K 240/12

Crucible breakage alarm device under the emergency outlet of a melting furnace

Crucible Pulling Feature with Swinging Collar Plate

In standard version, Nabertherm crucible furnaces are built with a collar plate fixed to the furnace. The bale-out is done manually or by robot. As additional equipment, the smaller models up to T 40 can be equipped with a swinging collar plate which allows crucible pulling. To pull the crucible, the collar plate is swung to the side, so that the operator has free access to the crucible from above.

Pneumatic Lid Opener for Bale-Out Furnaces for Holding

The Crucible furnaces of the T.. product lines can be equipped with an optional pneumatic lid opener. The pneumatic lid opener is activated by depressing a foot pedal. Optionally, the pneumatic lid opener can be controlled and triggered by an external signal to fully automate the ladling process. The furnace lid swings to the side and the operator has free access to the crucible. This practical feature increases energy efficiency because the furnace is only open during charging and bale-out. Over 50 % energy savings can be realized with the pneumatic lid opener vs. an always open furnace (see tables for energy consumption for each model of melting furnace, page 7).

Charging Funnel for Ingots

The charging funnel made of stainless steel 1.4301 (304) makes charging the furnace much easier, especially when melting ingots. Long ingots can also be charged extending over the crucible edge, and then sink, guided, into the crucible. Furnaces which are designed with a control system with night-time reduction can, for example, be filled in the evening and, on the following morning a complete melt is ready for use. The funnel is suitable for all melting furnaces, electrically heated or gas- with a side exhaust gas discharge.

Work Platform for Loading for Bale-Out and Tilting Furnaces

For bale-out and tilting furnaces, customized work platforms for charging and servicing can be provided as additional equipment. This feature is used to simplify access to the furnace, particularly for larger furnace models. The operator has access to the top of the furnace to charge ingots or clean the melt.

Crucible Breakage Alarm Device (up to T(B)../12)

Nabertherm melting furnaces are equipped with emergency outlet. In case of crucible breakage or leaking melt the crucible breakage alarm device will provide for a warning as soon as fluid metal emerges from the emergency outlet. The warning signal of the alarm is both optical, with an signal lamp, and acoustic, using a horn. As additional equipment it is possible to send an alarm as SMS-message to one or more mobile phones. One or more furnaces can be connected to the messaging device in parallel.

Filling Level Measurement by means of Optical Detection or Weight Loss

When crucible furnaces are used in continuous operation, it can be necessary to monitor the filling level of the crucible and provide for a signal when defined levels are reached. The signal can be either optical, acoustic, or a signal for automatic filling of the crucible. When the minimum level is reached, a signal to fill a crucible is given. On reaching the maximum level this process is stopped. The measurement of fill level can either be done by using a scale under the furnace or by using a measurement probe to detect the fill level and which records the data very precisely independent from external influences.

Separate Bath Temperature Measurement Device

For melting furnaces with only furnace chamber temperature control, a separate bath temperature measurement device can be used to check the bath temperature. The measurement device is suitable for a temperature range from 0 to 1300 °C, and can be delivered with different dip pipe lengths (200, 380, 610 mm). Temperature measurement is carried out using a NiCr-Ni thermocouple. The submersion length of the pipe whould be 2/3 of the element length to achieve the most ideal reaction time. The average reaction time is 40 seconds. The thermocouple is suitable for all nonferrous metals except phosphor bronze.

 

Additional Equipment for All Electrically Heated Melting Furnaces

   
   

Multi-Step Switch

Multi-Step Switch for Reduction of Connected Rating

A multi-step switch switches off a part of the heating depending on the power of the corresponding furnace model. Generally, the furnace can be operated at full load for melting. If the furnace is only used in holding mode the connected rating of the furnace can be reduced by turning off a defined part of the heating capacity, resulting in a significant cost advantage. As an option, this function can be automatically switched depending on temperature.

Power Management for Reduction of the Electrical Connection Value

If several crucible furnaces are used the installation of an intelligent power management can be the right choice. Monitoring all furnaces the power management is continuously reconciling the switch-on times of the heating. This effectively prevents all furnaces from switching-on at the same time. The positive impact is that the total connected rating provided by the energy provider can be significantly reduced.

Switchgear Cooling with Fans or Air-Conditioning

The switchgear of our furnaces is designed for environment temperatures of up to 40 °C. To secure a failure-free and long lasting operation of the switchgear in case of higher temperatures they can be equipped with active fan cooling or even with an air-conditioner.

 

Control and Documentation Alternatives for Melting Furnaces

   
   

 

Eurotherm 3208 controller

Work platform of K 360/12

Bath control with thermocouple in the melt

Compact controller Eurotherm 3504

Furnace Control with the Eurotherm 3208

In the basic model, Nabertherm melting furnaces are equipped with furnace chamber control using the Eurotherm 3208 controller. The temperature is measured in the furnace chamber behind the crucible. Two set values and a heat-up ramp rate may be entered. For example, the set values could be the pouring temperature and the lower idle temperature. Optionally, a 7-day digital timer can be fitted to automatically switch between the two temperatures and different switching times can be selected for each working day.

Bath Control for Bale-Out and Tilting Crucible Furnaces (Cascade Control)

In the basic version, the bale-out and tilting crucible furnaces of the T.. and K.. product lines are equipped with with a thermocouple in the furnace chamber behind the crucible. To achieve fast heat-up times the temperature is set significantly higher than the desired bath temperature. Therefore, this control allows very fast heating-up times, but results in considerable temperature overshoots in the melt due to the indirect temperature measurement.

As an option these furnaces can be equipped with a bath control system, which is particularly well-suited for holding operations. A second thermocouple in the bath is used in addition to the furnace chamber thermocouple to measure the bath temperature. Both temperatures are reconciled by the controller. The bath temperature is the target parameter and the chamber temperature is the working tool. This control system significantly improves the melt quality because overshoots can be effectively prevented. As an alternative to the thermocouple in the melt, a thermocouple in a special pocket in the crucible wall can be used (a special crucible with pocket is required) which measures the temperature of the crucible wall. Of course, this indirect control is not as precise as a measurement in the melt. However, the thermocouple is positioned in a protected location.

Bath Control with Controller Eurotherm 3504

All melting furnaces can be fitted with an optional bath control system. Instead of only being monitored by a thermocouple behind the crucible, the temperature is also measured in the melt, respectively in the pocket of the crucible wall, (see also description on page 23). Furnaces already in use can also be upgraded with a bath control system. An optional digital seven-day timer which automatically switches between two temperatures can also be added. The two alternate times can be selected for each working day. This allows the bath temperature, for example, to be lowered at night to save energy.

  • Alternative operation modes with furnace chamber control of bath control via cascade
  • Multi-line and plain text display
  • Data entering by using function keys
  • Programming the furnace operation with two set values (second temperature, e.g. for night-time temperature reduction)
  • A separate, freely programmable preparation program, e.g. to dry the crucible. An external switch is used to switch over to the preparation program.

Additional equipment

  • Seven-day timer for switching between two temperatures (e.g. night-time reduction). Switching times can be separately selected for each working day.
 

 

   
   

H 700

Seven-day timer for switching between melting temperature and lowered temperature

Multi-Step Switch

Bath Controls with PLC and Touch Panel

The H 700 PLC features state-of-the-art bath control. It provides a combination of precise control, ease of operation and a wide variety of user applications and professional documentation. A touch panel using plain text provides a simple and clean user interface for programming and control.

  • Furnace chamber control or alternatively bath control via cascade applicable
  • Colored graphic display of all temperatures
  • Touch panel provides a simple and clean user interface
  • Seven day timer for temperature switching
  • For each weekday, a program can be configured with 12 segments
  • A separate, user-entered furnace preparation program that can be used to dry the crucible, etc. Access to the program is controlled by a key switch
  • Customer can switch between different languages

Addtional equipment for H 700

  • Manual Overriding of automatic control 
    • If a running program needs to be extended (for example, when working overtime to meet a customer‘s schedule), a key switch can be used to put the programmer into Manual mode in order to continue working at the present temperature. In the background, the original program is continued, and when the key switch is turned back to Program mode, the furnace resumes its currently scheduled set point.
  • Documentation of melting process 
    • The H 700 controls can be upgraded with the Nabertherm Control Center package (NCC) on a personal computer. NCC controls provide for a professional documentation of the melting process among others, with the following features:
    • All relevant data, such as furnace chamber temperature, bath temperature, messages, etc. are always automatically stored as a daily file.
    • The switchgear is equipped with start and stop buttons. By pressing these buttons, the bath temperature is documented and stored as a file. For instance, customer batches can be monitored and archived separately.

Additional Equipment for all Controllers

  • Temporary overriding of bath control to increase melting performance 
    • When an empty crucible is recharged, the values measured by the bath thermocouple do not correspond to the actual temperature of the solid metal. Using melt bath regulation in this case would reduce the power available to melt the metal. A pushbutton on the panel allows the operator to temporarily bypass normal control, and have the controller maintain a higher than normal chamber temperature to melt the metal faster. A user-set timer (up to 120 minutes) and set point allows the operator to optimize the time it takes to melt. When the timer elapses, the controller resumes its normal control mode.
 

Tilting Furnaces with Electrohydraulic Lifting Platforms 

 
  K 240/12 with lifting platform for charging and pouring at different levels
 

Depending on the material flow and space requirements in a foundry, the charging height and pouring height may need to be different for a tilting furnace. For instance, if loading is performed at ground level and the metal is poured into a machine at a higher level, then an optional electro-hydraulic lifting platform can adjust for the difference. The operation of the lifting platform is by means of a 2 hand operation with a manual throttling valve. It can also be interlocked with other machinery and be motor driven operated.

 

Combi Transport Ladle for Melting, Holding, and Transporting 

 
  Electrically heated combi transport ladle TRP 240/S for melting, holding, and transport
 

Especially in smaller foundries or in foundries with narrow space availability, our TRP 240/S combi transport pan is available. It combines a melting furnace and a transport ladle in one unit. Its electrical connected rating allows the furnace to be used for melting.

  • Tmax 900 °C for melting and holding of aluminum
  • Electrically heated
  • Connection between switchgear and furnace pluggable
  • Customer must provide plant crane
  • Comfortable planetary gearbox
  • Simple handling and precise pouring
  • Optimally arranged heating modules resulting in very long crucible standing times
ModelTmaxCrucibleMelting performanceOuter dimensions in mmHeating
 °C kg Al/hrWDHpower in kW1
TRP 240/S 900 TP 587/TP 587 SF 200 2230 1430 1210 69
1Depending on furnace design connected load might be higher
 

Melting Furnaces for Heavy Metals 

 
  K 240/11 for melting of lead

Steel crucible with special suspension brackets for high charge weight

Our melting furnaces in the K, KF, T, and TF product lines can be upgraded with adapted electrical heating for melting of heavy metals like lead and zinc. The furnace is equipped with a special crucible, in most cases a steel crucible. The melting power is tailored to the type of metal to ensure optimum utilization of the furnace.

 

Rotary Table System for Continuous Pouring 

 
  Rotary table system with 3 x T 150/11
 

For continuous processes, multiple crucible furnaces can be combined on a rotary table system. For example, when using three furnaces with a rotation in 120° steps, loading takes place at the first space, de-gassing at the second space, and bale-out at the third. This ensures a continuous supply of liquid metal at the pouring location. The rotary table is designed with an emergency drain below in case of crucible breakage.

 

Bath Furnaces, Electrically Heated, for Holding

 
B 500  

 

The B 120 - B 500 bath furnaces (without crucibles) have been especially developed for stationary holding operation in die-cast foundries with removal of the melt by a bale-out robot. The tub of the furnace is lined with special long-life brick. The multi-layered backing insulation is designed for lowest electric connected load. The furnace tub is divided into three interconnected chambers. The heating proceeds from the lid into the center chamber. The bale-out openings are dimensioned to enable the robot to be optimally used. In holding operation bath furnaces, when used properly, provide better energy efficiency than crucible bale-out furnaces.

ModelTmaxCapacityOuter dimensions in mmWeight inBale-out opening HeatingHolding/ 
 °CKg AlWDHkgmmpower in kW1kW
B 120 1000 300 1900 1150 1160 1900 300 x 300 11 2
B 250 1000 600 2030 1280 1200 2450 380 x 380 14 3
B 500 1000 1200 2350 1450 1240 3700 430 x 430 20 5
1Depending on furnace design connected load might be higher
 

Magnesium Melting Furnaces

 
  Tilting furnaces for magnesium K 1500/75 S with 1500 liters crucible volume
 

For a variety of projects, Nabertherm has supplied melting furnaces to be upgraded by the customer for the melting of magnesium. Nabertherm supplied the furnace with all necessary control systems and the steel crucible. The furnaces were completed by the customer with the safety devices, pump systems for bale-out, and protective-gas systems. We are capable of implementing furnace systems to provide for a crucible volume of 1500 liters of magnesium.

Laboratory Melting Furnaces Electrically Heated

KC 2/15 K2/10 as crucible furnace with steel crucible for lead melting

KC 2/15

K 1/10 - K 4/13, KC 1/15 + KC 2/15

These compact melting furnaces for the melting of non-ferrous metals and alloys are one of a kind and have a number of technical advantages. Designed as tabletop models, they can be used for many laboratory applications. The practical counter balanced hinge with shock absorbers and the spout (not for KC) on the front of the furnace make exact dosing easy when pouring the melt. The furnaces are available for furnace chamber temperatures of 1000, 1300, or 1500 °C. This corresponds to melt temperatures of about 80-110 °C lower.

  • Tmax 1000 °C, 1300 °C, or 1500 °C, with melt temperature about 80 - 110 °C lower
  • Crucible sizes of 1, 2, or 4 liters
  • Crucible with integrated pouring spout of iso-graphite included with delivery
  • Spout (not for KC), mounted at the furnace for exact pouring
  • Compact bench-top design, simple emptying of crucible by tiltiing system with gas damper
  • Crucible for heating of furnace insulated with a hinged lid, lid opened when pouring

Additional equipment

  • Other crucible types available, e.g. steel
  • Design as crucible furnace without tilting device, e.g. for lead melting
  • Over-temperature limiter for the furnace chamber with automatic reset to protect against over-temperature. The limit controller switches off the heating when the pre-set limit temperature has been reached and does not switch it on again until the temperature falls below the setting again.
  • Observation hole for melt
ModelTmaxCrucibleVolumeOuter dimensions in mmHeatingElectricalWeight
 °C in lWDHpower in kW4connectionin kg
K 1/10 1000 A 6 1.0 520 680 660 3.0 single-phase 85
K 2/10 1000 A10 2.0 520 680 660 3.0 single-phase 90
K 4/10 1000 A25 4.0 570 755 705 3.6 single-phase 110
                   
K 1/132 1300 A 6 1.0 520 680 660 3.0 single-phase 120
K 2/132 1300 A10 2.0 520 680 660 3.0 single-phase 125
K 4/132 1300 A25 4.0 570 755 705 5.5 3-phase1 170
                   
KC 1/153 1500 A6 1.0 580 630 580 10.5 3-phase 170
KC 2/153 1500 A10 2.0 580 630 580 10.5 3-phase 170
1Heating only between two phases
2Outer dimensions of furnace, transformer in separate housing (500 x 570 x 300 mm)
3Switchgear and controller mounted in a floor standing cabinet
4Depending on furnace design connected load might be higher

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