Heating Element Bank for Tundish Pre-Heating

Product Specifications

Technical details and manufacturing context for Heating Element Bank

Definition

The Heating Element Bank is a critical component within the Tundish with Pre-Heating system. It consists of an array of individual resistive heating elements arranged in a bank or cluster configuration. Its primary function is to uniformly raise and maintain the temperature of the tundish lining and internal surfaces to a specified setpoint before molten metal is introduced, preventing thermal shock, ensuring proper metal flow characteristics, and reducing energy consumption during the initial casting phase. The bank is engineered for basic metal manufacturing environments, where reliable and precise pre-heating is essential for process stability and product quality. The unit is designed to operate with a three-phase power supply, typically 380–480 V AC, and can be configured for 50 or 60 Hz systems. The heating elements are made from high-resistance alloys such as Nickel-Chromium (NiCr) or Iron-Chromium-Aluminum (FeCrAl), with sheath materials like Incoloy 800 for corrosion and heat resistance. Ceramic insulators (e.g., alumina) and stainless steel mounting hardware ensure electrical isolation and mechanical integrity. The bank's rated power ranges from 15 to 60 kW, depending on tundish size and throughput requirements. Maximum operating temperature is between 900 and 1200 °C, with temperature control accuracy of ±5 °C under steady-state PID control. The unit meets various international standards for electrical safety and performance, including IEC 60038 for voltage, ASTM B344 for heating element material, and IEC 60529 for ingress protection (IP54–IP65). Insulation resistance is at least 100 MΩ at 500 V DC, and dielectric strength is 2000 V AC for one minute without breakdown. Operating pressure is specified at 1.0–1.6 MPa, and the weight ranges from 50 to 200 kg. All values are reference ranges and must be verified for the specific model and application with the legal manufacturer or supplier.

Working Principle

Electrical energy is converted into thermal energy through Joule heating. When an electric current passes through the high-resistance alloy wires or ribbons within each element, the electrical resistance generates heat. The bank of elements is controlled via a power regulation system, often SCR-based, to deliver precise, adjustable heat output to the tundish structure. This ensures uniform temperature distribution and prevents thermal shock.

Common Materials

Nickel-Chromium (NiCr) Alloy (e.g., Inconel), Iron-Chromium-Aluminum (FeCrAl) Alloy (e.g., Kanthal), Ceramic Insulators (e.g., Alumina), Stainless Steel Mounting Hardware

Technical Parameters

Parameter	Typical range	Notes & selection driver
Rated Power	15–60 kW	Total power of the bank; select based on tundish size and throughput.
Supply Voltage	380–480 V AC	Three-phase; other voltages on request.IEC 60038
Frequency	50–60 Hz	Auto-sensing or manual selection.
Max Operating Temperature	900–1200 °C	Sheath temperature; higher for special alloys.
Temperature Control Accuracy	±5 °C	At steady state with PID control.
Heating Element Material	NiCr 80/20	Resistance wire; alternative FeCrAl available.ASTM B344
Sheath Material	Incoloy 800	Corrosion and heat resistant.ASTM B163
Insulation Resistance	≥100 MΩ	At 500 V DC, cold condition.IEC 60364-6
Dielectric Strength	2000 V AC	For 1 minute, no breakdown.IEC 60335-1
IP Rating	IP54–IP65	Dust and splash proof; higher for washdown.IEC 60529
Operating Pressure	1.0–1.6 MPa
Weight	50–200 kg	Depends on power and configuration.

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Heating Element
The core resistive unit that converts electrical energy to heat. Typically a coiled alloy wire or ribbon embedded in ceramic or housed in a metal sheath.

Material: NiCr or FeCrAl Alloy, Magnesium Oxide (MgO) insulation
Terminal Block / Connection Box
Provides secure, insulated electrical connections for power supply cables to the element bank.

Material: Stainless Steel, Ceramic
Mounting Frame / Bracket Part
Structural support that holds the array of heating elements in the correct position relative to the tundish walls.

Material: Heat-resistant Stainless Steel
Thermal Insulation / Reflector Part
Minimizes heat loss to the environment and directs thermal radiation towards the tundish.

Material: Ceramic Fiber, Aluminized Steel
SCR Power Regulation Unit Optional
Chops the mains to set how much power the element bank draws; SCR-controlled banks include it.

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Tundish with Pre-Heating

View system integration details

Manufacturers of Heating Element Bank

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Frequently Asked Questions

What is the primary function of the Heating Element Bank?

The primary function is to uniformly raise and maintain the temperature of the tundish lining and internal surfaces to a specified setpoint before molten metal is introduced, preventing thermal shock and ensuring proper metal flow.

What materials are used in the construction?

Heating elements are made from Nickel-Chromium (NiCr) or Iron-Chromium-Aluminum (FeCrAl) alloys, with sheath material like Incoloy 800. Ceramic insulators (alumina) and stainless steel mounting hardware are also used.

What are the typical electrical specifications?

The bank operates on a three-phase supply of 380–480 V AC, 50–60 Hz, with a rated power of 15–60 kW. Insulation resistance is ≥100 MΩ at 500 V DC, and dielectric strength is 2000 V AC for one minute.

What standards apply to this product?

Relevant standards include IEC 60038 for voltage, ASTM B344 for heating element material, IEC 60529 for IP rating for operating pressure. Always verify compliance with the manufacturer.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification

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pressure:	Atmospheric to 10 bar (gauge), depending on housing design
flow rate:	0.5 to 50 m³/h per module, scalable with bank configuration
temperature:	Ambient to 1200°C (typical), up to 1500°C with special alloys
slurry concentration:	Up to 60% solids by weight, particle size <2 mm

Heating Element Bank

Product Specifications

Applied To / Applications

Industrial Ecosystem & Supply Chain Structure

Application Fit & Sizing Matrix

Reliability & Engineering Risk Analysis

Compliance & Manufacturing Standards