The Market Demand and Kanthal's Vision

Industries, particularly in the iron and steel sector, require highly efficient and reliable MW-scale electric process gas heaters to significantly reduce their carbon footprint. As a process like Direct Reduction of Iron (DRI) is gradually transitioning from natural gas to hydrogen, the demand for electric process gas heating solutions for industrial and pressurized applications is on the rise. However, the MW scale lacks proven robust and safe electric solutions for heating various process gases to high temperatures (800-1,100°C or 1,472-2,012°F).

To address this challenge, in 2021, Kanthal and Nycast AB entered into an exclusive license agreement for gas heating technology to develop high-efficiency MW-scale electric heaters.

Successful Test at Swerim

Thomas Helander, R&D specialist, Kanthal.These solutions, which will go under the name Prothal® TH, cater to diverse industries, offering versatility to accommodate varying process parameters such as gas compositions, operating pressure, and flow rates.

A recent test at Swerim AB, a leading industrial research institute, in Luleå, Sweden, involved a medium-scale Prothal® TH process gas heater. The tests, conducted with diverse gas compositions such as air, nitrogen, and hydrogen, demonstrated impressive results. The heating solution achieved process gas outlet temperatures up to 1,050°C (1,922°F) without issues, showcasing robust performance in handling input fluctuations while ensuring safety limits.

"Results from the testing of our current electric process gas heater design are highly promising, showcasing remarkable energy efficiency, consistent operational stability, and the potential for achieving elevated gas outlet temperatures. Additionally, our heater relies on critical subcomponents, such as electric heating elements, benefiting from our extensive expertise in their design, fabrication, and operation," explains Thomas Helander from Kanthal's R&D teams.

The evolving Kanthal portfolio has the potential to decarbonize a wide range of applications and industry segments.

While further validation is needed for operational parameters on larger installations, these tests mark a significant step forward. They indicate that the evolving Kanthal portfolio has the potential to decarbonize a wide range of applications and industry segments. The gas inlet and outlet temperature graph, along with electric power and flow rates, demonstrates the effectiveness of the Prothal® TH heater.

The graph shows the gas outlet temperature along with electric power and flow rates.

Collaboration with Nycast

Jesse White, Strategic Area Manager, Business Development Steel, Kanthal.Kanthal and Nycast, with the support of Swerim, have collaborated for over ten years to develop and test the electric gas heater. The heater, tested in different applications and gas compositions, will be available for large-scale commercial installations in the coming years. This development aligns with Kanthal's commitment to providing innovative solutions for large-scale gas heaters in industries such as steel and cement.

"Collaborating with Nycast has been a highly fulfilling experience. The synergy between our expertise in industrial-scale electrical heating solutions and Nycast's innovative gas heating technology will enable us to overcome significant challenges in the development of high-efficiency MW-scale electric heaters. The recent tests at Swerim validate the effectiveness of the gas heating concept and the potential of our combined technologies to revolutionize industrial heating processes," highlights Jesse White, Strategic Area Manager, Business Development Steel at Kanthal.

The Role of Kanthal® APM Alloy:

A crucial element in Kanthal's developing process gas heating solutions is the use of Kanthal® APM as the core heating resistance alloy. Kanthal® APM is an advanced powder metallurgical, dispersion-strengthened, ferritic iron-chromium-aluminum alloy known for its excellent oxidation properties and form stability at elevated temperatures. This unique alloy has provided a robust solution for electric industrial heating applications for more than 30 years.

Kanthal® APM has excellent resistance to high-temperature corrosion for most relevant gas atmospheres. The figure below compares the oxidation properties of Kanthal® APM to other common high-temperature alloys.

Gross mass gain due to oxidation at 1,200°C (2192°F) in the air for Kanthal® APM and common high-temperature alloys.

Electrification for Carbon Footprint Reduction

Thomas Olsson and Ralph Nyström from the Nycast team.Electrification is recognized as an effective way for the steel industry to reduce CO2 emissions. The Prothal® process gas heater allows the industry to use electricity in various heating processes instead of burning gas, contributing to energy efficiency and lower carbon footprints. The use of hydrogen gas for industrial processes further emphasizes the need for reliable and energy-efficient gas heaters.

We believe in the transformative power of electric heating for process gases, driven by its undeniable value propositions.

"Regarding the market outlook for decarbonization of heating processes, we see a promising trajectory ahead. We believe in the transformative power of electric heating for process gases, driven by its undeniable value propositions," say Ralph Nystrom and Thomas Olsson from the Nycast team.

Future Prospects and Collaboration Impact

The successful collaboration between Kanthal and Nycast opens doors for the Prothal® process gas heater to make a substantial impact in various industries. As technology advances, Kanthal envisions rolling out process heaters within the next few years, with expanded capabilities for testing and demonstration planned for 2024. This innovation is not limited to the steel industry; other sectors, including cement manufacturing, stand to benefit from this groundbreaking technology.

In conclusion, the recent successful test of the Prothal® process gas heater represents a significant milestone in the journey towards sustainable and efficient electric process gas heating solutions. Kanthal's commitment to innovation, collaboration with industry partners, and the use of advanced alloys position the company at the forefront of revolutionizing heavy industries, paving the way for a greener and more sustainable future.