Tunnel Furnaces

Tunnel Furnaces

Tunnel furnaces are continuous furnaces with both sides open and heated centrally. Materials in brick-like form pass continuously through these kilns for firing. Large volumes can be fired in tunnel kilns without interruption between batches. Both heating and cooling are carried out in the operation system of these kilns.

Tunnel Furnaces

Tunnel Furnaces are large furnaces used on an industrial scale. As the name suggests, these kilns are typically housed within a tunnel and allow products to move from one end to the other. Such kilns are often utilized for the mass production of large quantities of goods.Tunnel Furnaces find application across various industries including metal, ceramic, glass, plastic, and food. For instance, in the metal industry, tunnel kilns can be used for the hardening or coating of metal parts. In the ceramic industry, tunnel kilns are commonly employed for the firing of porcelain or ceramic products.

Heaters Used in Tunnel Furnaces

• Ceramic Heaters: Ceramic heaters are made of high-temperature resistant ceramic materials. They are particularly suitable for high-temperature processes and resistant to thermal shocks.
• Graphite Heaters: Graphite heaters are made of graphite material with high heat conductivity and resistance to high temperatures. They can be used in some special applications in tunnel furnaces.
• Tungsten Heaters: Tungsten heaters are resistant to high temperatures and oxidation. Due to these properties, they can be used for industrial heating applications in tunnel furnaces.
• Incoloy Heaters: Incoloy alloys are nickel-based alloys resistant to corrosion and high temperatures. Due to these properties, they can be used as heating elements in tunnel furnaces.

Technical Specifications of Tunnel Furnace Heaters

• Electric Power: Ranging from 1 kilowatt to 100 kilowatts
• Voltage Range: Options ranging from 12 volts to 480 volts
• Temperature Capacity: Ranging from 100 degrees Celsius to 1200 degrees Celsius
• Material Variety: Nickel-chromium, stainless steel, iron-chromium-aluminum, and other durable alloys
• Wire Thickness: Ranging from 6 millimeters to 25 millimeters
• Length Range: Ranging from 500 millimeters to 3000 millimeters
• Connection Types: Nut, piston, or other various options
• Thermocouple Types: J, K, T, E, or other standards
• Heating Element Models: Wire-wound, mica band, or ceramic insulated
• Cooling Methods: Can be air-cooled or water-cooled
• Protection Levels: IP65 or higher protection classes
• Mounting Type: Flanged, threaded, or other mounting options available

Advantages of Tunnel Furnace Heaters

• Precise Control: Tunnel furnace heaters are typically integrated with precise control systems. These systems continuously monitor and adjust parameters such as temperature, humidity, and others, ensuring high product quality.
• Lower Energy Consumption: Tunnel furnace heaters generally consume less energy compared to other heating methods. This reduces operating costs and provides significant savings in the long run.
• Fast Heating and Cooling: Heaters can generate heat quickly and be cooled rapidly after the process. This increases production process speed and reduces total production time.
• Less Waste Production: Electric heaters generally produce less waste compared to other heating methods. Fuel does not burn, and gas emissions are kept to a minimum, reducing environmental impact.
• Lower Risk of Combustion: Electric heaters reduce the risk of fire or explosion since combustible materials like gas or fuel are not used. This increases workplace safety and provides a safer working environment for personnel.

Areas of Application for Tunnel Furnace Heaters

• Textile Industry: Tunnel furnace heaters can be used in the processing, dyeing, or drying of textile products. They are commonly preferred for processes such as drying or dyeing fabrics at a constant temperature.
• Rubber Industry: Tunnel furnace heaters can be used in the hardening, shaping, or drying of rubber products. They are widely used in the production of automotive tires, rubber parts, and rubber materials.
• Wood Processing Industry: Tunnel furnace heaters can be used in the drying, pressing, or shaping of wood products. They are used in various applications throughout the furniture manufacturing, carpentry, and wood industries.
• Chemical Industry: Tunnel furnace heaters can be used in chemical processes such as accelerating chemical reactions, crystallization processes, or polymerization.
• Medical Industry: Tunnel furnace heaters can also be preferred in medical applications such as sterilization of medical devices, drying of laboratory materials, or processing of biomedical products.

Technical Details to Consider When Choosing Tunnel Furnace Heaters

• Temperature Range: The operating temperature of the heater should be compatible with the furnace's process requirements. The temperature resistance of the heater should maintain the desired temperature range throughout the furnace process.
• Power Capacity: Depending on the size and process requirements of the furnace, the power output of the heater should be determined. The correct power capacity ensures efficient operation of the furnace.
• Length and Diameter: The length and diameter of the heater should be suitable for the size and geometry of the furnace. The right size heater provides homogeneous heat distribution inside the furnace.
• Material and Durability: The material of the heater should be suitable for the furnace's process requirements and working environment. Nickel-chromium, stainless steel, or other durable materials provide long-lasting and resilient heaters.
• Connection Type: How the heater will be mounted to the furnace is important. Nut, flanged, or other connection types should be suitable for the furnace structure and mounting requirements.
• Cooling Method: The cooling method of the heater should be selected based on the furnace's process requirements. Air-cooled or water-cooled heaters contribute to the furnace's operating environment and temperature control.
• Protection Class and Safety Features: The protection class of the heater should comply with the necessary safety standards in the furnace's operating environment. IP classification ensures protection of the heater against water, dust, and other external factors.
• Controllability: The controllability of the heater allows for the creation of desired temperature profiles throughout the furnace process. Precise control systems ensure homogeneous heat distribution during the process and enhance product quality.