From gas to electric in anode preheating

Transitioning from fossil fuels to electric heating in furnaces significantly improves workplace safety and creates a more sustainable and efficient production process.

A move to electric heating elements in furnaces can have significant positive impacts on the cost of production, the reliability of heating furnaces and safety within the factory, according to Daniel Burton, Business Development Manager, Kanthal. “Gas, or in worst-case oil burners, have historically been integral to anode preheating. But gas burners are typically quite loud and generate high decibel-levels in the workshop.”

For a safer and quieter workplace

Daniel Burton, Business Development Manager, KanthalThis is not the case with solutions such as Kanthal® Super heating elements and Superthal® heating modules. “Electric heating,” Daniel goes on to say, “is almost silent, making a better working atmosphere and environment. It is also much easier to transport around the workshop and removes the need for the rerouting of gas pipes.”

But a quieter workplace is by no means the only benefit. Electricity also provides a reliable solution for drying out anodes and reducing explosion risks in the workplace. “Kanthal® Super heating elements radiate down and ensure they're completely dry. The heat is significantly more controllable,” says Daniel.

The use of electricity can also promote and provide major improvements in the levels of safety within the factory environment and processes. “The first thing to note with electricity,” continues Daniel “is that the systems do not require monitoring from the workforce. A typical gas process, especially with open burners, requires a workforce available for constant supervision.”

Electric heating elements are clean. They do not produce any of the carbon dioxide, carbon monoxide or nitrous oxides that can be emitted by gas burners and linger in the factory environment.

Removing the need for human presence during the anode preheating process is also supported by the environmental improvements from electric heating elements. “Electric heating elements are clean. They do not produce any of the carbon dioxide, carbon monoxide or nitrous oxides that can be emitted by gas burners and linger in the factory environment.”

Four benefits to using Kanthal® Super and Superthal® for anode stub hole preheating

  1. A safer workplace. In contrast to gas heaters, electric heating does not produce water vapor and therefore reduces the risk of explosion. They also remove all harmful exhaust gasses and significantly reduce noise levels.
  2. Better for the environment. Switching to electric heating will eliminate all CO2 emissions that come with gas heaters.
  3. Reduced energy consumption. The improved thermal efficiency of electric heating means energy consumption can be reduced by up to 60 percent compared to gas heating.
  4. Improved welding quality. Dry and preheated stub holes reduce the voltage drop over the cast iron thimble and reduce the risk of ‘burning anodes’

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