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MODUTHAL
Electric Embedded
Elements

MODUTHAL
Fully interchangeable ceramic modules
for temperatures up to 1350C
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MODUTHAL
Heating Modules
Description
Kanthal embedded elements are prefabricated radiant Kanthal has taken a major step forward with the
heating modules designed to suit a wide range of thermal introduction of MODUTHAL Fully Embedded, Semi
processing applications at element temperatures up to Embedded, Open Coil and High Temperature type
1350C. To optimise performance all element coils are elements produced using the Kanthal exclusive
fabricated primarily from Kanthal A-1 and Kanthal AF manufacturing process.
resistance Alloys depending on the application. The coils The result is an element which possesses the following
of resistance material are held in place in a non electri- features;
cally conductive, castable, high quality ceramic to form
the MODUTHAL panel.
HIGH QUALITY RELIABLE WORKMANSHIP
The coiled element may be fully embedded, semi
embedded or open coil, with the coils being fully or only SUPERIOR ELEMENT SUPPORT
partially supported by the refractory. The construction EXCELLENT TEMPERATURE CAPABILITY
method ensures accurate positioning of the coils and
eliminates the possibility of the sagging, distortion and
GOOD DURABILITY
coil migration associated with conventional open coil FULLY INTERCHANGEABLE MODULES
elements in grooves or on tubes. INDIVIDUAL DESIGN
The high thermal conductivity of the embedding
refractory ensures improved heat distribution when
compared with exposed coils. Multiple zones can be used
to provide sophisticated temperature uniformity within a
furnace and due to the modular construction of the
element system individual units can easily be replaced
without altering the furnace characteristics.
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Types and maximum

temperatures
MODUTHAL cast refractory element modules can be
supplied as one of the following individual types of
heating module.
1 MODUTHAL Fully Embedded
Is capable of operating up to a maximum recommended
element temperature of 1100C. Although being a fully
embedded panel, most of the heating element is covered
with a relatively thin layer of refractory allowing the
element to radiate more efficiently than a standard fully
embedded panel.
2 MODUTHAL Semi Embedded
A conventionally designed panel which offers a cost effec-
tive solution to applications that do not require the higher
temperatures which can be achieved by using
MODUTHAL Open Coil elements. The Semi embedded
panel is capable of operating up to a maximum element
temperature of 1150C.
3 MODUTHAL Open Coil
Due to the unique Kanthal design which allows 75% of
the heating element to freely radiate this element is
capable of operating up to a maximum recommended
element temperature of 1300C.
4 MODUTHAL High Temperature
Kanthals unique design combines MODUTHAL ceramic
casting with freely radiating APM material elements and
is capable of operating at a maximum element tempera-
ture of 1350C.
5 MUFFLES
Please note that all muffles would be of the MODUTHAL
Fully Embedded type of construction and capable of ope-
rating up to a maximum element temperature of 1100 C.
Design
MODUTHAL embedded elements can be designed and
manufactured in a variety of shapes and sizes and can
also include special features such as thermocouple holes,
locating lugs and rebates. MODUTHAL elements are
designed for use in either small furnaces or in multiples
to suit larger industrial furnaces or kilns and would
normally be rated between 1kW and 10kW per element.
Process Atmospheres
MODUTHAL elements are designed to operate in clean
air, but may also be used in process atmospheres within
the normal limitations of the resistance wire.
The effect of furnace atmospheres is tabulated in Figure 4
Control equipment
MODUTHAL elements are normally operated directly from
the mains electricity supply and therefore do not require
any special power supply equipment. All modules are
highly resistant to thermal stress and there is no need to
limit the power input during start up conditions, except
during the initial firing up when a slower heating rate
may be required to expel any residual moisture.

Fig 2. Results of laboratory tests showing the

mechanical strength of MODUTHAL

MODUTHAL PANELS

Fully embedded Semi embedded

Open Coil

Fig 1; Diagram of the three main types of MODUTHAL embedded elements

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Wall loading (kW/m2)

40

30

High Temperature

Fully embedded
20
Semi embedded
Open Coil

10

0
0 700 800 900 1000 1100 1200 1300 1400 1500 1600
Element temperature (C)

Fig 3. Maximum recommended wall loading versus furnace temperature for MODUTHAL. (Diagram for guidance only)

Furnace Metallic MODUTHAL MODUTHAL MODUTHAL MODUTHAL Remarks

Atmosphere Elements Fully Semi Open Coil High
(FeCrAl) Embedded Embedded Temperature
and Muffles

Air 1400 C 1100 C 1150 C 1300 C 1350 C These figures are for dry air.
Moist air temperatures
Air (Moist) 1200 C 1000 C 1050 C 1200 C 1200 C as detailed

H2 1400 C 1100 C 1150 C 1300 C 1350 C H2 has seven times better

heat conductivity than air

N2 1250/1100* C 1100/1050* C 1150/1100* C 1250/1100* C 1250/1100* C *Higher temperature is

for pre-oxidised elements

Endothermic 1050 C 1000 C 1050 C 1050 C 1050 C Carbon deposits are

detrimental. Use a gas
tight muffle if necessary

Exothermic 1150 C 1050 C 1125 C 1150 C 1150 C As for Endothermic above

Sulphate Attacks Use gas tight muffle to

Halogen Alkali Kanthal prevent atmosphere
Alloys contacting the elements

Vacuum 10-5 1100 C 1100 C 1100 C 1100 C 1100 C

Torr

Fig 4. Maximum permissible element temperatures for different atmospheres

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Applications
MODUTHAL elements have been successfully used in
these well-established applications.
Glass toughening furnace
Toughening glass for cooker doors and similar products.
Operating for an eight-hour day five days per week at
650C in an air atmosphere.
Billet heating furnace
for forging or heat treatment of steel, copper, brass and
aluminium billets.
Crucible furnace
Melting or holding aluminium and copper-based alloys.
Both MODUTHAL Fully Embedded and MODUTHAL Crucible furnace
Open Coil panels are suitable. In MODUTHAL Fully
Embedded type some protection is given to the element
against metal splashes and fluxes. MODUTHAL permits
high wall loadings, gives uniform temperature around
the crucible and can be easily replaced.
Wire annealing furnace
For multi-strand annealing. MODUTHAL panels are
mounted in the hearth, roof and walls, operating in the
range 800C-1050C both continuously and intermitt-
ently.
Tundish pre-heating
For casting aluminium. MODUTHAL gives accurate and
even temperature control within a compact design.
Fluidised bed furnace
Interlinked circular muffles (embedded for protection
against bed materials) operating typically at 900C
1000C.
Billet holding furnace
Arch-shaped MODUTHAL Fully Embedded Element for
billet holding at temperature after induction heating.
Intermittent operation at 750C-800C.
Glass melting
Melting of glass for forming into glass billets, and produc-
tion of glass fibre from rod. Both MODUTHAL Fully
Embedded and MODUTHAL Open Coil types are suitable. Glass toughening furnace
Crystal growing
Low-temperature crystal growing using a MODUTHAL
muffle element at 950C-1000C in air.
Brass melting furnace
MODUTHAL High Temperature panels in roof and walls
operating at element temperatures up to 1350C.

The MODUTHAL anchor system, retaining both element

and ceramic fibre backing insulation

Cylinder heater Billet heating furnace

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