Preheating transport and bath ladles with electric heating

For aluminum producers, using electric heating to preheat transport and bath ladles will result in increased energy efficiency and lower costs, as well as reduced emissions and improved workplace safety.

Daniel Burton, Business Development Manager, KanthalGas burners have long been the traditional choice of heating solution for ladle preheating. This is despite their poor thermal efficiency since most of the heat generated is lost through exhaust gasses rather than used to heat the actual ladle. Not only does this increase energy costs, but also results in high emissions.

“With gas burners, you’re releasing all these poisonous gasses into the factory and into the atmospheres, such as carbon dioxide, monoxide and nitrous oxides,” says Daniel Burton, Business Development Manager, Kanthal. “This is not only harmful for the environment but also creates a potentially hazardous working environment inside the factory.”

A cleaner, more efficient alternative

By replacing gas burners with electric heating, such as Kanthal’s Tubothal® and Kanthal® Flow Heater, aluminum producers can benefit from a huge improvement in thermal efficiency.

By replacing gas burners with electric heating, such as Kanthal’s Tubothal® and Kanthal® Flow Heater, aluminum producers can benefit from a huge improvement in thermal efficiency – from around 40 per cent up to over 95 per cent. This translates into an energy saving of around 60 per cent. Furthermore, all exhaust gasses and emissions are reduced to virtually zero.

“There are a whole host of environmental benefits to electric heating, namely the elimination of carbon dioxide emissions. But it also makes the factory a much safer, cleaner and quieter work environment,” adds Daniel. “You’re removing all the harmful gasses as well as reducing the noise levels significantly. On top of that, you can also free up a lot of space on the factory floor as you no longer need to reroute gas pipes and so on.”

Four benefits to using electric heating to preheat transport and bath ladles in primary aluminum production

  1. Improved efficiency. Since far less heat is lost through exhaust gasses, electric heating offers far greater efficiency than conventional gas heaters.
  2. Zero emissions. Electric heating generates no carbon dioxide emissions, significantly improving its environmental impact.
  3. Cleaner, quieter factory. By replacing gas burners with electric heating, you remove all harmful exhaust gasses, reduce noise levels, eliminate risks of explosion caused by gas and can contribute to a less cluttered working environment.
  4. Safer factory. Electric heating requires no combustion and offers an improved and repeatable process. Because no water vapor is produced in the process, the potential for water vapor explosions is greatly reduced.

Connected products

Here you can find the Kanthal product offering

Tubothal® heating element

Metallic heating elements of cartridge element type designed for long life and trouble-free service. Tubothal® elements can be used inside all types of radiant tubes or as stand-alone elements.

See product details

Learn from our experts

Our latest articles

Decarbonizing the aluminum industry requires technology, investment and policy change

Decarbonizing the aluminum industry requires technology, investment and policy change

Aluminum is essential to modern society and stands to play an important part in future sustainable applications. As the industry seeks to reduce its climate impact, electrification is one solution that could help reduce emissions and dependence on fossil fuels. So says Pernelle Nunez, Deputy Secretary General and Sustainability Director at the International Aluminium Institute.

Read more
Industry outlook: The way forward is electrification

Industry outlook: The way forward is electrification

Electric heating in industrial processes is central to meet ambitious climate targets set globally . K ey to success is increased access to green power.

Read more
Busting the myths about electric heating

Busting the myths about electric heating

If you are thinking about making the switch from gas to electric heating, you need to know all the facts. Here we debunk some of the popular myths associated with electric heating solutions to help you make an informed decision.

Read more