Professional Documents
Culture Documents
HANDBOOK
Resistance Heating Alloys and
Systems for
Industrial Furnaces
This information, which may be subject to change, is offered solely for your
consideration and should not be taken as a warranty or representation for
which we assume legal responsibility. It is not to be understood as permission
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user should determine whether relevant patents exist.
KANTHAL
HANDBOOK
Resistance Heating Alloys and
Systems for
Industrial Furnaces
Contents
Page
KANTHAL or NIKROTHAL?
10
12
15
17
19
KANTHAL AF
20
KANTHAL D
21
NIKROTHAL 80
22
NIKROTHAL 70
23
Terminals
24
Metallic
heating
elements
from Kanthal
This booklet contains technical data for our
resistance heating alloys KANTHAL and
NIKROTHAL.
We also include some instructions for the
calculation and design of heating elements for
industrial furnaces as well as examples of
support systems and insulation. The APM
tubes are described shortly. For more information, ask for the special Tube Handbook.
The latest product- and application information is found on www.kanthal.com.
We can assist you:
in choosing suitable element material, element type, support system and insulation,
by supplying complete heating elements
ready for installation,
to upgrade electric furnaces to latest
heating technology for maximum output and
economy
to replace radiant tubes with Kanthal APM
tubes in both gas- and electrically heated
furnaces and to supply complete recuperative systems (SER).
Our modern workshops have developed considerable experience in manufacturing
heating elements and can manufacture to any
specifications.
Our delivery times are short and our service
objectives are high.
KANTHAL or NIKROTHAL?
There are two main types of electric resistance
alloys. Nickel-chromium (e.g. 80 Ni, 20 Cr) was
developed around the turn of the century and
was soon used as heating element material in
industrial furnaces as well as in electric household appliances.
In the thirties Kanthal introduced a new
resistance heating alloy based on iron-chromium-aluminium with a longer life and a higher
maximum operating temperature than nickelchromium.
The two main types of alloys have their own
specific properties, with advantages and disadvantages, and are supplied in many different
grades and forms. Kanthal manufactures both
types of alloys under the names NIKROTHAL
(nickel-chromium) and KANTHAL (iron-chromium-aluminium).
In general KANTHAL is superior to
NIKROTHAL in respect of performance and
life and is therefore nowadays a standard
material choice when it comes to metallic
heating elements for industrial furnaces. The
most important advantages are:
Table 1. A 120 kW furnace equipped with R.O.B. elements. 3 elements of 40 kW each, 380 V.
Element Data
NiCr 80/20
KANTHAL AF
Furnace temperature, C F
1000
1830
1000
1830
Element temperature, C F
1068
1955
1106
2025
Hot resistance, Rw
3.61
3.61
Temperature factor, Ct
1.05
1.06
3.44
3.41
Wire diameter, mm in
5.5
0.217
5.5
0.217
3.09
19.9
3.98
25.7
224.9
738
174.6
573
44.4
98
29.6
65
Weight saving:
44.429.6
= 33%
44.4
= 33%
9865
= 33%
98
= 33%
3
15
Elongation (%)
FeCrAl
10
APM
Temperature
Time (h)
1000C
1832F
MPa
psi
100
5.6
812
1000
3.4
478
10000
2.2
320
Time (h)
1200C
5
0
100
200
300
500
Time (h)
500
600
Fig. 2 Sagging test dia. 9.5 mm, 1300C, 2370F and 1400C,
2550F, 300 mm between supports.
Temperature
2192F
psi
3.3
478
1000
1.6
232
10000
0.7
100
Time (h)
1400C
2552F
MPa
psi
1.3
189
1000
0.5
72
10000
0.2
30
Temperature
100
MPa
100
30
20
10
50
100
Time (h)
150
KANTHAL
A-1
KANTHAL
AF
KANTHAL
D
NIKROTHAL
80
NIKROTHAL
70
NIKROTHAL
60
NIKROTHAL
40
Max continuous
operating temp., C
operating temp., F
Nominal composition, % Cr
Nominal composition, % Al
Nominal composition, % Fe
Nominal composition, % Ni
Resistivity at 20C, mm-2m-1
Resistivity at 68F, /cmf
Density, g/cm3
Ib/in3
Coefficient of thermal
expansion, K-1
20-750C, 681380F
20-1000C, 681838F
Thermal conductivity at 20C
W m-1 K-1
68F, Btu in ft2 h1 F1
Specific heat capacity
KJ kg-1 K-1, 20C
Btu Ib1 F1, 68F
Melting point, C
Melting point, F
Mechanical properties (approx.)*
Tensile strength, N mm-2
Tensile strength, psi
Yield point, N mm-2
Yield point, psi
Hardness, Hv
Elongation at rupture, %
Tensile strength at 900C, Nmm-2
Tensile strength at 1650F, psi
Creep strength at 800C, N mm-2
Creep strength at 1000C, N mm-2
Creep strength at 1470F, psi
Creep strength at 1830F, psi
Magnetic properties
Emissivity, fully oxidized condition
KANTHAL
APM
1425
2600
22
5.8
Rest
1.45
872
7.10
0.256
1400
2550
22
5.8
Rest
1.45
872
7.10
0.256
1300
2370
22
5.3
Rest
1.39
836
7.15
0.259
1300
2370
22
4.8
Rest
1.35
812
7.25
0.262
1200
2190
20
1250
2280
30
1150
2100
15
1100
2010
20
80
1.09
655
8.3
0.300
70
1.18
704
8.1
0.296
60
1.11
668
8.2
0.296
35
1.04
626
7.9
0.285
14.10-6
15.10-6
14.10-6
15.10-6
14.10-6
15.10-6
14.10-6
15.10-6
17.10-6
18.10-6
16.10-6
17.10-6
16.10-6
17.10-6
18.10-6
19.10-6
13
90
13
90
13
90
13
90
15
104
13
90
13
90
13
90
0.46
0.110
1500
2730
0.46
0.110
1500
2730
0.46
0.110
1500
2730
0.46
0.110
1500
2730
0.46
0.110
1400
2550
0.46
0.110
1380
2515
0.46
0.110
1390
2535
0.50
0.119
1390
2535
875
127000
450
65000
185
30
120
17400
15
4
2160
580
Non
0.88
750
109000
450
65000
180
30
100
14500
15
4
2160
580
Slightly
0.88
750
109000
450
65000
180
30
120
17400
20
4
2160
580
Non
0.88
680
680
680
680
750
99000
99000
99000
99000
109000
445
445
445
445
450
65000 65000 65000 65000 65000
230
230
230
230
180
19
19
19
19
30
40
34
37
34
100
5800
5000
5400
5000
14500
14
6
8
6
15
1.8
1
1.5
1
4
2000
870
1160
870
2160
260
145
215
145
580
Magnetic (Curie point 600C 1100F)Non
0.70
0.70
0.70
0.70
0.88
*) The values given apply for sizes of 4 mm, 0.16 in diameter for the KANTHAL alloys and of 1 mm, 0.04 in for the NIKROTHAL alloys.
kW/m2
kW/ft 2
100 _____
______ 9.3
90 _____
______ 8.36
80 _____
______ 7.4
70 _____
______ 6.5
60 _____
______ 5.6
50 _____
______ 4.6
40 _____
______ 3.7
30 _____
______ 2.8
20 _____
______ 1.9
10 _____
Furnace
temperature
______ 0.93
KANTHAL
A-1/AF/APM
700
1290
800
1470
900
1650
1000
1830
1100
2010
1200
2190
1300C
2370F
Element a
Wire and strip element in grooves. Wire diameter min. 3 mm, 0.12 in, strip thickness min. 2
mm, 0.08 in.
Element b
Wire element on ceramic tube
Wire diameter min. 3 mm 0.12 in.
Fig. 4 Maximum
recommended surface loads
for KANTHAL and
NIKROTHAL alloys in
industrial funaces.
D = (58)d
W/cm2
10 _________
9 _________
8 _________
s = (23)d
D = (1014)d
s = (36)d
W/in2
________ 65
________ 58
________ 52
7 _________
________ 45
6 _________
________ 39
5 _________
________ 32
4 _________
________ 26
3 _________
________ 19
2 _________
________ 13
1 _________
Furnace
temperature
KANTHAL
A-1/AF/APM
800 900 1000 1100 1200 1300C
1470 1650 1830 2010 2190 2370F
NIKROTHAL
________
Note: The diagram is valid for thyristor control. For on-off control lower surface loads should be chosen. (About 20%).
In such cases a KANTHAL alloy is recommended, provided the heating elements are preoxidized in air at 1050C 1920F for 710 hours.
Reoxidation of the heating elements should be
carried out at regular intervals.
e) NIKROTHAL 80
f) NIKROTHAL 60
g) NIKROTHAL 40
400
400
300
300
200
200
100
100
1000
1830
1100
2010
1200
2190
Element temperature
8
1300
2370
1400C
2550F
KANTHAL
A-1 and APM
C
F
KANTHAL
AF
C
F
KANTHAL
D
C
F
NIKROTHAL
80 and 70
C
F
NIKROTHAL NIKROTHAL
60
40
C
F
C
F
Oxidizing:
Air, dry
Air, moist
1400* 2550
1200 2190
Neutral:
N2, Nitrogen**
1200 2190
2280
Ar, Argon
Exothermic:
10 CO, 15 H2
5 CO2, 70 N2
1400* 2550
2280
1150 2100
Reducing:
Endothermic:
20 CO, 40 H2
40 N2
H2, Hydrogen
1050 1920
1400* 2550
Cracked ammonia:
75 H2, 25 N2
Vacuum:
10-3 torr
1150 2100
1250
2280
1830
1650
Wire Elements
Element systems
Spiral
Spiral
Porcupine
Rod over
Bend
Supports
Ceramic
tubes
Grooves
Ceramic
tubes
Metallic
rods
Material
Sillimanite
Chamotte or
Grade 28
Sillimanite
Kanthal APM
1300
2370
1250
2280
800
1470
1300
2370
40
3.7
35
3.3
50
4.6
34
1926
34
1926
56
3239
2.06,5
0.080.26
2.05.0
0.080.2
1.06.5
0.040.26
5.0
0.2
(1214) d
(56) d
250
9.8
3d
2d
3d
40
1.6
Strip Elements
Corrugated
Looped
DeepCorrugated
DeepCorrugated
DeepCorrugated
Corrugated
Metallic
staples
Ceramic
tubes
Ceramic
cup locks
Ceramic
bushes
Ceramic
tubes
Grooves
U-shaped
KANTHALnails
Sillimanite
Cordierite
Mullite
Cordierite or
Mullite
Sillimanite
Chamotte or
Grade 28
1300
2370
1300
2370
1300
2370
1300
2370
1300
2370
1300
2370
50
4.6
60
5.6
60
5.6
60
5.6
60
5.6
2040
1.93.7
36
1939
56
3239
56
3239
56
3239
56
3239
34
3239
2,05,0
0.080.2
5,0
0.2
2.03.0
0.080.12
2,03,0
0.080.12
2,03,0
0.080.12
1,53,0
0.060.12
(812) t
(812) t
(812) t
(812) t
100
3.9
250
9.8
250
9.8
250
9.8
250
9.8
(23) w
40
1.6
40
1.6
50
2.0
50
2.0
50
2.0
1.5 w
11
Long life
The use of APM wire is the reason for the high
performance of TUBOTHAL elements. The life
at 1000C 1830F furnance temperature is
more than double that of NiCr wire.
Another major advantage of the Tubothal
system is the possibility to adjust the element
to existing power supply. Typically no transformer is needed.
Element
Diameter
130 150
70
60
90 120 140
80
100
70
Power Output (kW)
50
30
90
50
40
30
80
154 (6.06)
110
80
60
70
50
60
40
124 (4.88)
90
70
20
110 (4.33)
50
80 (3.15)
40
20
10
120
100
60
40
170 (6.69)
110 130
30
20
10
10
30
68 (2.68)
20
10
0.5
1.0
1.5
2.0
2.5
3.0
Kanthal AB, Head office and main production unit at Hallstahammar, Sweden.
14
* High loading potential. At a furnace temperature of 1000C (1830F) the loading can
be more than double that of a NiCr tube.
* APM tubes are extruded so there are no
welded seams thus eliminating a source of
potential failure.
* APM tubes weight less than equivalent NiCr
tubes of the same dimension.
* Ready to install. Supplied flanged, with or
without inner tube and gas burner or suitable electric heating element.
* Can operate at a maximum tube temperature of 1250C (2280F).
Comparison between NiCr and Kanthal APM tubes after 1000 hours at
1150C 2100F.
The NiCr tubes are severely contaminated with oxide flakes while the
Kanthal APM tubes are completely clean.
15
Gas fired
U-type, straight through or SER
systems with inner- and outer tubes
and gas burner
Electrically heated
Kanthal Silicon Carbide elements
Kanthal Super elements
Kanthal AF
Tubothal
16
Nominal
Size
Sch 40S
Sch 40S
2 1/2
4
5
6
Sch 40S
OD
Weight
OD
mm
Wall
thickness
mm
kg/m
26.67
33.7
33.4
40
50.8
60.33
64
73
75
83
87
88.9
100
109
115
128
146
154
164
178
198
220
260
2.87
6.0
3.38
3.0
6.35
3.91
4.0
4.5
4.5
5.0
5.0
5.49
5.0
5.0
5.5
5.5
6.0
6.0
6.0
8.0
9.0
8.5
12.0
1.52
3.71
2.26
2.48
6.35
4.92
5.35
6.88
7.08
8.70
9.15
10.2
10.6
11.6
13.4
15.0
18.7
19.8
21.2
30.3
37.9
40.1
55.8
Tubothal elements
1.
2.
3.
4.
5.
6.
Suits Tubothal
Suits Tubothal
Suits Tubothal
Suits Tubothal
Suits Tubothal
Suits Tubothal
element
element
element
element
element
element
Weight
in
Wall
thickness
in
1.05
1.33
1.31
1.57
2.00
2.38
2.52
2.87
2.95
3.27
3.43
3.50
3.94
4.29
4.53
5.04
5.75
6.06
6.46
7.01
7.80
8.66
10.2
0.11
0.24
0.13
0.12
0.25
0.15
0.16
0.18
0.18
0.20
0.20
0.22
0.20
0.20
0.22
0.22
0.24
0.24
0.24
0.31
0.35
0.33
0.47
1.02
2.49
1.52
1.67
4.27
3.31
3.60
4.62
4.76
5.85
6.15
6.88
7.12
7.79
9.02
10.1
12.6
13.3
14.2
20.4
25.5
26.9
37.5
Remarks
ib/ft
6
5
4
3
2
1
**
**
**
**
**
**
***
***
***
***
***
***
***
*
*
*
*
*
*
*
170
154
124
110
80
68
17
20
100
200
300
400
500
600
700
800
1.00 1.00 1.00 1.00 1.00 1.01 1.02 1.02 1.03 1.03 1.04 1.04 1.04 1.04 1.05
Wire
dia mm
Resistance
/m 20C
Weight
g/m
cm2/
20C
Strip*)
WxT mm
Resistance
/m 20C
Weight
g/m
35.5.........
49.7.........
107............
142............
102............
128............
107............
128............
160............
213............
266............
320............
213............
284............
355............
426............
355............
444............
533............
426............
533............
639............
cm2/
20C
414
1520
3310
5790
2620
4020
2380
3350
5120
8900
13700
19600
7040
12100
18600
26500
15500
23700
33600
19008
26200
41000
*) only A-1
19
KANTHAL AF
Wire and strip. Standard stock items.
Resistivity 1.39 mm2 m-1. Density 7.15 g cm-3. To obtain resistivity at working
temperature, multiply by factor Ct in following table.
C
Ct
Wire
dia mm
20
100
200
300
400
500
600
800
1.00 1.00 1.01 1.01 1.02 1.03 1.04 1.04 1.05 1.05 1.06 1.06 1.06 1.06 1.07
Resistance
/m 20C
Weight
g/m
cm2/
20C
20
700
Strip*)
WxT mm
Resistance
/m 20C
Weight
g/m
cm2/
20C
KANTHAL D
Wire and strip. Standard stock items.
Resistivity 1.35 mm2 m-1. Density 7.25 g cm-3. To obtain resistivity at working
temperature, multiply by factor Ct in following table.
C
Ct
Wire
dia mm
20
100
200
300
400
500
600
700
800
1.00 1.00 1.01 1.01 1.02 1.03 1.04 1.05 1.06 1.06 1.07 1.07 1.08 1.08
Resistance
/m 20C
Weight
g/m
cm2/
20C
Strip*)
WxT mm
Resistance
/m 20C
Weight
g/m
cm2/
20C
21
NIKROTHAL 80
Wire and Strip. Standard stock items.
Resistivity 1.09 mm2 m-1. Density 8.30 g cm-3. To obtain resistivity at working
temperature, multiply by factor Ct in following table.
C
Ct
Wire
dia mm
20
100
200
300
400
500
600
800
1.00 1.01 1.02 1.03 1.04 1.05 1.04 1.04 1.04 1.04 1.05 1.06 1.07
Resistance
/m 20C
Weight
g/m
cm2/
20C
22
700
Strip*)
WxT mm
Resistance
/m 20C
Weight
g/m
cm2/
20C
NIKROTHAL 70
Wire. No standard stock items
on special order only.
Resistivity 1.18 mm2 m-1. Density 8.10 g cm-3. To obtain resistivity at working
temperature, multiply by factor Ct in following table.
C
Ct
Wire
dia mm
20
100
200
300
400
500
600
700
800
1.00 1.01 1.02 1.03 1.04 1.05 1.05 1.04 1.04 1.04 1.05 1.05 1.06
Resistance
/m 20C
Weight
g/m
cm2/
20C
23
Terminals
Resistance and Weight Data
Material
Material
Resistivity
mm2 m1
..................1.45......................
..................1.35......................
..................1.45......................
..................1.09......................
..................1.04......................
Resistance
/m
Density
g/cm3
...............
...............
...............
...............
...............
7.10
7.25
7.10
8.30
7.90
Weight
g/m
KANTHAL D
8 ..............................................................................
10 ..............................................................................
12 ..............................................................................
16 ..............................................................................
20 ..............................................................................
..................0.0269..................
..................0.0172..................
..................0.0119..................
..................0.0067..................
..................0.0043..................
............... 364
............... 569
............... 820
...............1460
...............2280
..................0.0288..................
..................0.0185..................
..................0.0128..................
..................0.0072..................
..................0.0046..................
..................0.0021..................
..................0.0012..................
............... 357
............... 558
............... 803
...............1428
...............2231
...............5019
...............8922
..................0.0217..................
..................0.0172..................
..................0.0119..................
..................0.0067..................
..................0.0043..................
............... 417
............... 652
............... 939
...............1670
...............2610
..................0.0207..................
..................0.0132..................
..................0.0092..................
..................0.0033..................
..................0.0015..................
............... 397
............... 620
............... 893
...............2482
...............5584
NIKROTHAL 80
8 ..............................................................................
10 ..............................................................................
12 ..............................................................................
16 ..............................................................................
20 ..............................................................................
NIKROTHAL 40
8 ..............................................................................
10 ..............................................................................
12 ..............................................................................
20 ..............................................................................
30 ..............................................................................
24
Tubothal
Metallic Elements
Wire and Strip
Kanthal Super,
Superthal
Ready-made metallic
elements manufactured by
Kanthal workshops.
Silicon Carbide
FIBROTHAL
Heating elements
Extruded Tubes
Kanthal extruded radiant
tubes for gas or electriceally
heating furnaces.
KANTHAL
Box 502
SE-734 27 Hallstahammar, Sweden
Phone: +46 220 210 00
Telefax: +46 220 163 50
E-mail: info@kanthal.com
www.kanthal.com
A complete modular
building system for heating
and insulation.