There are distinct advantages of a DRH kiln:

• Yields are much higher (typically doubled) due to the inert atmosphere attainable as a result of electrical firing.
• Equipment size for a given through-put is greatly reduced because the live load is an order of magnitude greater than that of conventional furnace technologies.
• Thermal losses are greatly reduced due to the size reduction of the kiln and the +99% conversion of electrical energy into useful heat.
• Utilizing the resistive properties of the product to provide the heating energy allows the refractory lining to operate at a lower temperature than in conventional equipment.

The DRH kiln technology allows itself to any reaction requiring a controlled atmosphere providing that the constituents of reaction are electrically conductive at high temperatures.

Thermopower Furnaces is continuously running tests in developing the technology for further applications.

These kilns are custom sized according to production requirements. There is no standard size and the maximum size is limited to the lifting capabilities of available or supplied lifting equipment. The primary advantage of the electrically fired “Top Hat” kiln is that the “kiln moves to the load”, and not “the load to the kiln”.

Added to this are:

• Temperature uniformity, accurate and constant
• Clean firing
• Ease of operation
• No shift work
• Low maintenance costs
• Fast insulation
• Economic firings

Included along with the standard design “top hat” range are these two specialized designs:

L.T.M. Top Hat (Low thermal mass)

This range combines an old concept with modern technology, utilizing lightweight insulation material and molybdenum di-silicide or silicon carbide elements. The units’ size can range from lab-scale up to 22 cubic meters, and fire as high as 1700ºC.

Tempo Top Hat Furnace

The tempo furnace makes use of both convection and radiation firing, eliminating thermal shock and improving repeatable batch consistency. The design of the tempo ensures that the load experiences uniform heat treatment. By modifying the firing cycle, the tempo unit can be used as a dryer, evenly desiccating damp ware when ambient conditions are unfavorable.

The tempo is no more costly to maintain than any convectional top hat furnace. In fact, as low temperature soaking (as in pre-firing cycle) is supported by forced convection, the build-up of moisture which could turn into structurally damaging acids is reduced, considerably increasing steelwork life.

Common usages include:

• Drying
• Calcining
• Devolitising
• Roasting
• Refining
• Re-generation
• Incinerating aggregates and waste

The advantages of using rotary tube furnaces are many fold, with this list being a few of the main advantages:

• Continuous operation
• Ease of operation and maintenance
• No shift work
• Low maintenance costs
• Fast installation
• Comprehensive material handling systems, custom designed to suit the material and function, allow for ease of handling and reduced input costs.
• Can be fired under controlled atmospheres.
• Can operate with co-current or counter current gas flow
• Controlled firing zones

These kilns are capable of reaching temperatures of up to 1600°c under specific conditions, and operate comfortably up to temperatures of 1150°c. Designs include small scale test equipment for lab use, up to 12t/hour coal devol units.

Should the process require it, Thermopower can design and manufacture, all in-house, oxidizers, scrubbers and stacks to mate up easily to the rotary for the effective control of volatiles, fines and harmful off-gases, Thermopower prides itself on turn-around times especially with our rotary units which we consider to be our specialty, as was the case when we built a 2t/h rotary drier in two weeks.

Our electric ladle heaters have successfully been used in the industry, both in drying/curing refractories and preheating ladles. The massive savings in OPEX with our units have proven themselves time and time again. The units range in size from small compact candle-element fired units for the refineries, to larger 40t ladle pre-heaters in foundries and heavy-metal sands operations.

The advantages of using our Ladle Heaters are many fold, with this list being a few of the main advantages:

• Precise temprature control
• Cost effective
• Energy efficient
• No fumes
• No noise
• Easy to opperate
• Better quality end product

Continues kilns or lehrs are designed for the fast firing of product on a continuous basis and can reach temperatures of 1050ºC, fired with individually controlled temperature zones along its length. Mesh belt kilns can be designed around an automated material handling system. We manufacture continues kilns and lehrs up to a maximum belt width of 7meters wide.

Applications vary, from controlled atmospheres to applications of the unit.

Our most popular range is definitely in the decorative glass and ceramic industry.

Ideal for small factories, these kilns are very convenient, easy to load and unload. We will custom build the unit to your requirements.

They are used for a wide range of products and applications.

When circumstances require a shuttle option, which combines the compact lower cost of a batch oven with the productivity and economy of a continuous furnace, shuttle kilns seem to be the preferred option. We have a number of standard designs available, but once again will custom design a unit for your unique requirements. The shuttle kiln is defined by its separate charging and discharging doors.

Thermopower Furnaces’ unique design in high temperature lab kilns allows for more efficient heating, as well as ensuring a hermetic seal keeping heat losses to a minimum at high temperatures.

Our lab kilns can operate at temperatures from 100°C to 1700°C, depending on the size of the load area and function required.

Custom designed specifically for industrial purposes to suit your individual needs, from desk top to free standing, single or double door. Firing temperatures in our chamber kilns range from 100ºC to 1200°c, with specialty kilns firing up to 1600ºC.

Designed by Thermopower for saving energy by reducing turn around time ……………

Custom designed air heating systems complete with forced draught fans are a popular option when gas flow is a critical component of a process. Thermopower has built many variations to this theme, from low range temperatures with sheathed elements, through the intermediate range with coiled elements, right up to 1400°c by means of silicon-carbide heating systems. We will manufacture a unit to suit your individual needs.

In our 40 years we have built convection ovens of all sizes and shapes, for many different purposes, from low temperature tempering units for the metal industry, to custom designed units for the aviation industry, and large 20-30m³ homogenous firing ovens for the PVC industry.

Convection ovens ensure that your load is heated up homogenously, with various heating cycles possible.

These continuous units reduce firing cycles and are extremely energy efficient. Capable of reaching temperatures up to 1100ºC they are ideally suited for the continuous production of tiles, tableware and advanced ceramics. The higher production levels achievable in these units far out-weigh the relatively high CAPEX at the initiation of the project.

Thermopower has manufactured various melting pot units, for copper, tin, lead and zinc, of various load sizes or melting capacities. Innovative design concepts have successfully been implemented into the industry, and while the standard units are the most popular, specialized units are regularly ordered and manufactured at Thermopower.