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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-Fired

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.

 

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 cruicible 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 (not for models TB ../12)
Exhaust gas discharge over the crucible edge Melting++-o-
Models TB/KB 
Side exhaust gas discharge Melting +
Holding ++--
Models TBR/KBR 
Side exhaust gas discharge with recuperator Melting +
Holding +++-
Models T/K
Electrically heated with bath control Melting +
Holding o++++++
Models T/K
Electrically heated without bath control Melting +
Holding o+++++
Modelle T../10 
Electrically heated with bath controlHolding -+++++++
Models TC/KC 
Electrically heated via SiC rods Melting +
Holding ++o+
 

Tilting Furnaces KB Gas-Fired, for Melting and Holding

Tilting furnace KB 400/12 with exhaust gas discharge over the crucible edge Melting furnace plant consisting of two tilting furnaces KB 360/12 with side exhaust gas discharge and one work platform

Hydraulic system with flame resistant hydraulic fluid

Two-stage burner, mounted on furnace frame

Tilting furnace KB 240/12 for melting aluminum alloys

The gas-fired or oil-heated tilting furnaces in the KB product lines provide for high melting performance, 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 tilting furnaces achieve very high melting rates and optimum energy efficiency.

Models KB ../12 reach a max. furnace temperature of 1200 °C resulting in melting temperatures of up to 1050 °C. These tilting furnaces are mainly used for aluminum and Zinc alloys.

Models KB ../14 reach a max. furnace temperature of 1400 °C resulting in melting temperatures of up to 1250 °C. These tilting furnaces are mainly used for copper alloys in small foundries.

Standard Design for all Tilting Furnaces

  • 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 min. gas pressure with full load: 50 mbar
  • Operation with other fuels and/or with another gas input pressure possible
  • High melting performance powered by high-performance burners and high-quality insulation
  • Incl. crucible
  • 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
  • Exhaust gas discharge over the crucible edge
  • Emergency outlet for safe discharge of the melt in case of a crucible break
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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
  • Defined application within the constraints of the operating instructions

Standard Design for Tilting Furnaces KB ../14

  • Insulation with an additional wear-and-tear layer made of copper-resistant refractory concrete

Additional Equipment for all Tilting Furnaces

  • Work platform or platform for easier charging
  • Collecting pan under the emergency outlet
  • Process control and documentation via Nabertherm Control Center (NCC) for monitoring, documentation and control

Additional Equipment for Tilting Furnaces KB ../12

  • Side exhaust gas discharge
  • Swing lid (only when equipped with side exhaust gas discharge)
  • Crucible breakage monitoring with optical and acoustic signal
  • Insulated connecting piece (exhaust flue) for side-wall exhaust gas vent to a connected customer suction system
  • SMS-alarm message to one or more mobile phones, e.g. in case of crucible breakage
  • Bath control system (only when equipped with side exhaust gas discharge) see page 28
    • 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
ModelTmax
furnaceTmax
melt bathCrucibleCapacityBurner
outputMelting performance3Consumption
MeltingConsumption
Holding 
Lid closedOuter dimensions4
in mmWeight in
 °C°C kg Alkg CukWkg/h Alkg/h CukWh/kgkWh/hW5DHkg
         Al     
KB 80/1212001050TP 2871805503002201-1,3 - 1,5102730153016802100
KB 150/1212001050TP 4123309703002401-1,0 - 1,3112830163018802600
KB 180/1212001050TP 412 H37012003002601-1,0 - 1,3132830163019802800
KB 240/1212001050TP 587570-3904001-1,0 - 1,3153120184019803100
KB 360/1212001050TBN 800750-4504201-1,0 - 1,3173170189020803300
KB 400/1212001050TBN 11001000-4504501-1,0 - 1,3193170189021503600
         Cu     
KB 40/1414001250R 400/TP 982120400400-33021,0 - 1,3222070144018902300
KB 60/1414001250R 500150500400-36021,0 - 1,3252140144019902500
KB 80/1414001250R 600180600400-38021,0 - 1,3252140144021102650
1At 700 °C 2At 1000 °C
3The stated melting performances are maximum values. Daily operation comes up to roughly 80 %. 5Incl. burner
4External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
 

Tilting Furnaces KBR with Recuperative Burner Gas-Fired, for Melting and Holding of Aluminum

Tilting furnace KBR 240/11

Tilting furnace KBR 240/11 during filling of a transport ladle

The fuel-heated tilting furnaces 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 fuel-heated tilting furnaces is significantly improved. Depending on utilization the exhaust gases from the crucible 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 conventional fuel-heated tilting furnaces with side exhaust gas discharge. The higher purchase costs are amortized within a short time. The KBR series is recommended when both high melt quality requirements and high energy efficiency are required, and the speed of the melting process is of secondary interest. If the fastest possible melting rate is important for the process and a particularly high quality of the melt is of secondary importance, a conventional tilting furnace KB with exhaust ducting over the edge of the crucible (see page 8) is recommended.

Technical Design as Models KB (See Page 8) but with the Following Features

  • 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
  • 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
  • Max. furnace temperature of 1100 °C for melt bath temperatures up to 950 °C
  • Required minimum gas pressure at full load: 80 mbar
ModelTmax
furnaceTmax
melt bathCrucibleCapacityBurner
outputMelting performance2Consumption
MeltingConsumption
Holding 
Lid closedOuter dimensions3
in mmWeight in
 °C°C kg AlkWkg/h Al1kWh/kgkWh/hW4DHkg
       
Al     KBR 240/111100950TP 587570390320
1,1 - 1,4132580230019803600KBR 360/111100950TBN 800750450340
1,1 - 1,4152580235020803800KBR 400/111100950TBN 11001000450360
1,1 - 1,4162580235021504100
1At 700 °C 4Incl. burner
2The stated melting performances are maximum values. Daily operation comes up to roughly 80 %.
3External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
 

Tilting Furnaces K Electrically Heated, for Melting and Holding

Tilting furnace K 150/12 Tilting furnace K 150/12 and bale-out furnace T 180/11 as premelting and holding system

Charging of transport ladle with tilting furnace K 360/12

Tilting furnace K 40/13 with extended spout (sculpture foundry Knaak)

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

Filling a mould with liquid bronze (photographer Andrea Künstle)

The electrically heated tilting furnaces 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.

  • K ../12 with Tmax of 1200 °C also suitable for aluminum or brass, with a maximum melt bath temperature, depending on the condition of the crucible, of 1050 °C
  • K ../13 with Tmax of 1300 °C also suitable for bronze alloys or brass, with a maximum melt bath temperature of 1150 °C
  • Heating from three sides using electric heating elements, radiating freely on support 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 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
  • Incl. crucible
  • 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
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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
  • Defined application within the constraints of the operating instructions

Additional equipment

  • Work platform for easy charging
  • Collecting pan under the emergency outlet
  • Crucible breakage monitor with visual and audible signal (only for models K ../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 27). 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
  • Process control and documentation via Nabertherm Control Center (NCC) for monitoring, documentation and control
ModelTmax
furnaceTmax
melt bathCrucibleCapacityHeating power Melting performance3Consumption 
Holding 
Lid closed/openOuter dimensions3
in mmWeight in
 °C°C kg Alkg Cuin kW4kg/h Alkg/h CukWh/hWDHkg
K 10/1212001050A 7020701632¹4723/7¹189012401390950
K 20/1212001050A 150451502042¹6323/7¹1890140014101400
K 40/1212001050A 300903002658¹8423/7¹2000145014901550
K 80/1212001050TP 28718055050126¹19024/10¹2050152015801750
K 150/1212001050TP 41233097060147¹22025/12¹2120160018602350
K 180/1212001050TP 412H370120060160¹24025/12¹2120160018602450
K 240/1212001050TP 587570-80180¹-8/17¹2260176018602800
K 300/1212001050TP 587H650-80210¹-9/18¹2260176019603200
K 360/1212001050BUK 800750-100260¹-11/20¹2370181019503500
K 400/1212001050TBN 11001050-126295¹-12/22¹2370193021003700
              
K 10/1313001150A 7020701632¹4725/821890124014401000
K 20/1313001150A 150451502042¹6325/821890140014601300
K 40/1313001150A 300903002658¹8425/822000145015401650
K 80/1313001150TP 28718055050126¹19026/1122050152015801950
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
5External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
 

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

Bale-Out Furnace TB 20/14

Thermocouple for melt bath control

Emergency outlet for safe melt discharge in case of crucible break

Bale-out furnace TB 20/14 for bronze melting with side exhaust gas discharge and swiveling collar plate for crucible pulling

The gas-fired or oil-heated bale-out furnaces of the TB product lines provide for high melting performance. 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 reach a max. furnace chamber temperature of 1200 °C resulting in melting temperatures up to 1050 °C. These bale-out furnaces are mainly 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../14 models reach a max. furnace chamber temperature of 1400 °C resulting in max. melting temperatures of up to 1250 °C. These bale-out furnaces are mostly used for melting copper alloys in small foundries. This is why these bale-out furnaces are standardly equipped with an exhaust gas vent over the crucible edge for high melting rates. Models TB 10/14 and TB 20/14 are standardly equipped with a collar plate that can be swung aside for crucible pulling.

Standard Design for all Bale-Out Furnaces

  • 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 min. gas pressure with full load: 50 mbar
  • Operation with other fuels and/or with another gas input pressure possible
  • High melting performance powered by high-performance burners and high-quality insulation
  • Multi-layered insulation with lightweight refractory bricks
  • Emergency outlet for safe discharge of the melt in case of a crucible break
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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
  • Defined application within the constraints of the operating instructions

Standard Design for Bale-Out Furnaces TB ../12

  • Side exhaust gas discharge
  • Swing lid

Standard Design for Bale-Out Furnaces TB ../14

  • Insulation with an additional wear-and-tear layer made of copper-resistant refractory concrete
  • Exhaust gas discharge over the crucible edge
  • Swinging collar plate for crucible pulling for bale-out furnaces to TB 10/14 - TB 20/14 (not possible for larger models)

Additional Equipment for All Bale-Out Furnaces

  • Work platform or platform for easier charging
  • Collecting pan under the emergency outlet
  • Process control and documentation via Nabertherm Control Center (NCC) for monitoring, documentation and control

Additional Equipment for Bale-Out Furnaces TB ../12

  • Crucible breakage monitoring with optical and acoustic signal
  • SMS-alarm message to one or more mobile phones, e.g. in case of crucible breakage
  • Equipped with recuperator technology
  • Bath control system see page 28
    • 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
ModelTmax
furnaceTmax
melt bathCrucibleCapacityBurner
outputMelting performance3Consumption
meltingConsumption
HoldingOuter dimensions4
in mmWeight
in
 °C°C kg Alkg CukWkg/h Alkg/h CukWh/kgkWh/hWDHkg
 
        AlLid closed    TB 80/12
12001050BU 2002006501801401-1.3 - 1.510120018701240900TB 100/12
12001050BU 2502508301801401-1.3 - 1.5111310198013801000TB 110/12
12001050BU 30030010002101501-1.3 - 1.5131310198015101200TB 150/12
12001050BU 35035011503002201-1.3 - 1.5151310198015501400TB 180/12
12001050BU 50050016503002701-1.3 - 1.5171450214015601700TB 240/12
12001050BU 60060020003903301-1.3 - 1.5191490218017001900TB 360/12
12001050BN 800800-4003501-1.3 - 1.5201590228018002000TB 400/12
12001050BN 900900-4003501-1.3 - 1.5221590228019002100TB 500/12
12001050BU 12101200-4003501-1.3 - 1.5231690238018502300TB 600/12
12001050BU 13101300-5004201-1.3 - 1.5251690238020002400TB 650/12
12001050BP 10001400-5004201-1.3 - 1.5261760245016302300TB 700/12
12001050BU 15101500-5004201-1.3 - 1.5281690238021202600TB 800/12
12001050BU 18001800-5004401-1.3 - 1.5301760245021002800 
        CuWithout lid    TB 10/14
14001250A 10030100210-9021.0 - 1.316980159011901000TB 20/14
14001250A 15045150210-10021.0 - 1.3171080187013101250TB 40/14
14001250A 400120400300-30021.0 - 1.3231210200014601500TB 60/14
14001250A 500150500320-32021.0 - 1.3261210200015101600TB 80/14
14001250A 600180600320-32021.0 - 1.3291260205015401750
1At 700 °C 2At 1000 °C
3The stated melting performances are maximum values. Daily operation comes up to roughly 80 %.
4External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
 

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

Crucible furnace TBR 110/11

Heat exchanger in the exhaust gas duct

2 crucible furmaces TBR 100/11 in production

Production with 16 crucible furnaces TBR 100/11 and 2 crucible furnaces TBR 180/11

Burner with gas supply system

The fuel-heated crucible 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 crucible 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 min. gas pressure with full load: 70 mbar
  • Operation with other fuels and/or with another gas input pressure possible
  • High melting performance 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
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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
  • Defined application within the constraints of the operating instructions

Additional equipment

  • Crucible made of clay graphite or SiC with higher heat conductivity
  • Collecting pan under the emergency outlet
  • Work platform or platform for easier charging
  • Crucible break monitoring with optical and acoustic signal
  • SMS-alarm message to one or more mobile phones, e.g. in case of crucible breakage
  • 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
  • Process control and documentation via Nabertherm Control Center (NCC) for monitoring, documentation and control
ModelTmax
furnaceTmax
melt bathCrucibleCapacityBurner
outputMelting performance2Consumption
Melting
Consumption
holding
lid closed
 °C°C kg Alkg CukWkg/h Alkg/h CukWh/kg AlkWh/h
TBR 80/111100950BU 2002006501801401-1.0 - 1.18.0
TBR 100/111100950BU 2502508301801401-1.0 - 1.18.8
TBR 110/111100950BU 30030010002101501-1.0 - 1.110.4
TBR 150/111100950BU 35035011502402201-1.0 - 1.112.0
TBR 180/111100950BU 50050016503002701-1.0 - 1.113.6
TBR 240/111100950BU 60060020003203301-1.0 - 1.115.2
TBR 360/111100950BU 800800-3203501-1.0 - 1.116.0
1At 700 °C
2The stated melting performances are maximum values. Daily operation comes up to roughly 80 %.
 

Bale-Out Furnaces T Electrically Heated, for Melting and Holding

Bale-out furnace T 110/11

Bale-out furnace T 800/11

Four side heating for excellent temperature uniformity

Manual ladling from a bale-out furnace T 80/10

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

Due to their high-grade insulation and optimized connected loads the bale-out furnaces can be used both for melting and holding. They feature good melting performance 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 bale-out furnaces are fitted with multi-layer insulation.

  • T ../11 with Tmax of 1100 °C for aluminum or zinc, with a maximum melt bath temperature, depending on the condition of the crucible, of 950 °C
  • T ../12 with Tmax of 1200 °C also suitable for brass, with a maximum melt bath temperature, depending on the condition of the crucible, of 1050 °C
  • T ../13 with Tmax of 1300 °C, also suitable for bronze alloys, with a maximum melt bath temperature, depending on the condition of the crucible, of 1150 °C
  • Four-side heating using electric heating elements, freely radiating on support 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
  • Emergency outlet for safe draining of the melt in case of crucible breakage
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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
  • Defined application within the constraints of the operating instructions

Additional equipment

  • Crucible of clay-graphite or SiC
  • Work platform
  • Collecting pan under the emergency outlet
  • Crucible breakage monitor with visual and audible signal (not for 1300 °C models
  • SMS-alarm message to one or more mobile phones, e.g. in case of crucible breakage
  • 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 27). 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
  • Process control and documentation via Nabertherm Control Center (NCC) for monitoring, documentation and control
ModelTmax
furnaceTmax
melt bathCrucibleCapacityHeating powerMelting performance3Consumption
Holding 
Lid closed/openOuter dimensions5 in mmWeight 
in
 °C°C kg Alkg Cuin kW4kg/h Alkg/h CukWh/hWDHkg
T 10/111100950A 7020-16321-3/51860860790400
T 20/111100950A 15045-20421-3/61940940790460
T 40/111100950A 30090-26581-3/7110101010880580
T 80/111100950BU 200200 501261-4/9111101110940650
T 110/111100950BU 300300-601361-5/101120012001040880
T 150/111100950BU 350350-601471-5/101120012001250900
T 180/111100950BU 500500-701681-7/1511370137012501080
T 240/111100950BU 600600-801801-7/1511370137013501200
T 360/111100950BN 800800-1102001-8/1711510151014902000
T 400/111100950BN 900900-1102001-10/2011510151015902100
T 500/111100950BN 12001200-1102001-11/2111510151016402450
T 600/111100950BU 13101300-1102001-13/2311615161517302550
T 650/111100950BP 10001400-1102401-13/2011685168513602400
T 700/111100950BU 15101500-1402401-13/2311615161518502750
T 800/111100950BU 18001800-1402401-15/2511685168518302800
              
T 10/1212001050A 702070163214725/82860860770440
T 20/1212001050A 15045150204216325/102940940770520
T 40/1212001050A 30090300265818425/12210101010860600
T 80/1212001050BU 20020065050126119025/15211101110930760
              
T 10/1313001150A 702070163214725/82900900890600
T 20/1313001150A 15045150204216325/102980980890640
T 40/1313001150A 30090300265818425/12210501050970760
T 80/1313001150BU 20020065050126119025/152115011501030960
1At 700 °C 3The specified melting performances are maximum values. In practice, approx. 80 % are achieved.
2At 1000 °C 4Depending on furnace design connected load might be higher
5External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
 

Tilting Furnace KC and Bale-Out Furnace TC SiC-Rod-Heated, for Melting

Tilting furnace KC 180/14 Bale-out furnace TC 80/14

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

Tilting furnace KC 150/14

Switchgear with thyristors in phase angle operation for economic power consumption

The electrically heated tilting furnaces 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 melting of 1320 °C, depending on the crucible condition
  • 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
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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
  • Defined application within the constraints of the operating instructions

Additional equipment

  • Work platform for simplified loading
  • Process control and documentation via Nabertherm Control Center (NCC) for monitoring, documentation and control
ModelTmax
furnaceTmax
melt bathCrucibleCapacityHeatingConnectedMelting performance3Outer dimensions5 in mmWeight
 °C°C kg Alkg Cupower in kW4load in kWkg/h Alkg/h CuWDHin kg
KC 20/1414501320A 150451503669-12021710190010501500
KC 40/1414501320A 300903003669-12021770190011001600
KC 80/1414501320TPC 2872006504894-18021880197011601900
KC 150/1414501320TPC 412300100066112-22022000207013002700
KC 180/1414501320TPC 412H-115099187-23022000207015003000
              
TC 20/1414501320A 150451503669801120212001250930830
TC 40/1414501320A 3009030036698011202126012501020950
TC 80/1414501320BU 2002006504894120118021360135010801050
TC 150/1414501320BU 300300100066112140122021450132013001300
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 higher5External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
 

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

Bale-out furnace 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 bale-out furnaces T ../10 optimally suitable for holding operation. Due to the reduced connected load these bale-out 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 support 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
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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
  • Defined application within the constraints of the operating instructions
ModelTmax
furnaceTmax
melt bathCrucibleCapacityHeating
powerConsumption
Holding 
Lid closed/openOuter dimensions3 in mmWeight in
 °C°C kg Alkg Cuin kW2kWh/hWDHkg
T 80/101000800BU 200200-204/91115011501030660
T 110/101000800BU 300300-265/101124012401130890
T 150/101000800BU 350350-385/101124012401290920
T 180/101000800BU 500500-427/1511410141012901120
T 240/101000800BU 600600-507/1511410141013901240
T 360/101000800BN 800800-508/1711510151014902000
T 400/101000800BN 900900-5010/2011510151015902100
T 500/101000800BU 12101200-5011/2111615161515802450
T 600/101000800BU 13101300-5013/2311615161517302550
T 650/101000800BP 10001400-6013/2011685168513602400
T 700/101000800BU 15101500-6013/2311615161518502750
T 800/101000800BU 18001800-7015/2511685168518302800
1At 700 °C 3External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
2Depending 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

Forklift entry with dampers

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 bale-out furnace can also be optionally used at different pouring locations.

  • Tmax 1000 °C, ideal for holding of aluminum
  • Cylindrical, highly stable furnace housing
  • Damper 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
  • Insulation constructed in multiple layers with lightweight refractory bricks on the hot face
  • Emergency outlet for safe discharge of the melt in case of a crucible break
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • 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.
  • Defined application within the constraints of the operating instructions
ModelTmax
furnaceTmax
melt bathCrucibleCapacityHeating powerConsumption
Holding
Lid closed/openOuter dimensions3
in mm
 °C°CØHkg Alkg Cuin kW2kWh/h1WDH
TM 80/101000800BU 200200-214/9100011001150
TM 150/101000800875600350-365/10132014401150
TM 240/101000800BU 600600-427/15122013401450
TM 310/1010008001170580770-428/17165017301200
1At 700 °C 3External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
2Depending on furnace design connected load might be higher
 

Bath Furnaces B Electrically Heated, for Holding of Aluminum

Bath furnace B 500 Bath furnace B 120

Inlet opening for filling with liquid aluminum

Melting thermocouple in the bath of the outlet opening

Heating mounted in the lid, simple replacement of the heating elements

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 bath furnaces 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 bale-out furnaces.

  • Tmax 1000  °C, perfectly suited for holding of aluminum at about 720 °C
  • Heating mounted in the lid, freely radiating from carrier tubes
  • Particularly low energy consumption due to generously dimensioned, multi-layer insulation
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • High melt quality due to very low corundum formation on the surface
  • Heating switched by solid-state-relays
  • No exhaust gas discharge needed
  • Temperature control with measurement in the melt and in the furnace chamber
  • Plug for connection with separate switchgear cabinet
  • For information on temperature control
  • Useful only for holding, not for melting
  • Defined application within the constraints of the operating instructions

Additional Equipment

  • Adaptation to dosing pump
  • Automated lid opening for ladling operation
  • Ladle opening adapted to size of ladle
ModelTmax
furnaceTmax
melt bath °C°C
B 1201000750300112300 x 3001900115011601900
B 2501000750600143380 x 3802030128012002450
B 50010007501200205430 x 4302350145012403700
1Depending on furnace design connected load might be higher 2External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.
 

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

Collecting pan under the emergency outlet

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.

Collecting Pan under the Emergency Outlet

The bale-out furnaces are standardly euipped with an inclined bottom and an emergency outlet for liquid metal in case of a crucible breakage. To collect the liquid melt in case of an emergancy the models T…, TB…, K… and KB… can be delivered with a small base frame and a collecting pan. The pan can safely receive full crucible volume and is equipped with a pull-out handle. Unncecessary foundation works can be avoided.

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 °C to 1300 °C, and can be delivered with different dip pipe lengths (200 mm, 380 mm, 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.

 

Tilting Furnaces with Electrohydraulic Lifting Platforms

Tilting furnace 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.

 

Melting Furnaces for Heavy Metals

Tilting furnace K 240/11 for melting of lead

Steel crucible with special suspension brackets for high charge weight

Our melting furnaces in the K and T product lines can be upgraded with adapted electrical heating for melting of heavy metals like lead and zinc. The melting 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 melting 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.

 

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 gas supply systems. We are capable of implementing furnace systems to provide for a crucible volume of 1500 liters of magnesium.

 

Laboratory Melting Furnaces

Melting furnace K 4/10 Melting furnace KC 2/15

Melting furnace 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 melting furnaces are available for furnace chamber temperatures of 1000, 1300, or 1500 °C. This corresponds to melt temperatures of about 80 °C - 110 °C lower.

  • Tmax 1000 °C, 1300 °C, or 1500 °C
  • Crucible sizes of 0,75, 1,5 or 3 liters
  • Crucible with integrated pouring spout of iso-graphite included with delivery
  • Additional spout (not for KC), mounted at the furnace for exact pouring
  • Only fiber materials are used which are not classified as carcinogenic according to TRGS 905, class 1 or 2
  • Compact bench-top design, simple emptying of crucible by tiltiing system with gas damper
  • Crucible for heating up of melting furnace insulated with a hinged lid, lid opened when pouring
  • Defined application within the constraints of the operating instructions

Additional equipment

  • Other crucible types available, e.g. steel
  • Design as bale-out furnace without tilting device, e.g. for lead melting
  • Over-temperature limiter for the furnace chamber with automatic reset to protect against overtemperature. 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
ModelTmax
furnaceTmax
melt bathCrucibleVolumeOuter dimensions4 in mmHeatingWeight
 °C°C in lWDHpower in kW3in kg
K 1/101000850A 60.755206806603.085
K 2/101000850A101.505206806603.090
K 4/101000850A253.005707557053.6110
          
K 1/13113001150A 60.755206806603.0120
K 2/13113001150A101.505206806603.0125
K 4/13113001150A253.005707557055.5170
          
KC 1/15215001320A60.7558063058010.5170
KC 2/15215001320A101.5058063058010.5170
1Outer dimensions of furnace, transformer in separate housing (500 x 570 x 300 mm)
2Switchgear and controller mounted in a floor standing cabinet
3Depending on furnace design connected load might be higher
4External dimensions vary when furnace is equipped with additional equipment. Dimensions on request.