Walking beam furnaces for billet preheating

Steel manufacturers can significantly reduce energy consumption and eliminate emissions by switching to electric heating in walking beam furnaces. By replacing gas-fired systems with high-performance electric heating solutions, including Kanthal’s Globar® silicon carbide (SiC) heating elements, producers can achieve higher thermal efficiency and precise temperature control while virtually eliminating emissions when powered by renewable energy. Despite its advantages, misconceptions about electric heating’s capabilities remain a key barrier to wider adoption, says Sachin Pimpalnerkar, Global Product Manager at Kanthal.

In steel production, preheating blooms or billets is essential before downstream operations such as hot rolling and forging. The walking beam furnaces used for this heating operation need to achieve a uniform target temperature across the entire billet to avoid affecting the quality and yield of the final product. These furnaces represent a substantial portion of energy consumption in steel plants. However, like most furnaces, the walking beam furnaces operate with low thermal efficiency.

“Typically, only 30 to 60 percent of the heat generated is used to heat billets, while most of the remaining heat is lost through the flue gases released into the atmosphere,” Pimpalnerkar explains. “The process also results in high carbon emissions, at around 60 kilograms of CO2 for every ton of steel heated.”

Possible to scale up heating processes 

By replacing industrial burners with electric heating systems, the thermal efficiency of walking beam furnaces could be increased to more than 90 percent, resulting in substantial cost savings. This is achieved through the absence of flue gases. 

Electrification would also remove all direct carbon emissions from the heating process itself, if the electricity comes from a renewable source, there would be no emissions associated with heating. 

“The biggest obstacle to electrical furnaces is the perception in the industry that they are only suitable for small-scale heating,” says Pimpalnerkar. “But within Kanthal we have our own electrically heated walking beam furnace currently used in regular production, which can be scaled up. This is proof that it can be done.” 

Investment pays off

For steel producers, electric heating would mean lower production costs, higher yields, and a better-quality final product.

CaptionSachin Pimpalnerkar, Global Product Manager, Kanthal.In addition to significantly reducing energy consumption and CO2 emissions, electrical heating can achieve precise target temperatures. This improves the quality of the final product and reduces the number of rejections in downstream operations. In contrast to fossil-fuel-fired heating, electrical heating also allows for controlled atmospheres with low oxygen levels. As a result, the oxide scale levels on the surface of the billets can be substantially less. 

“For steel producers, electric heating would mean lower production costs, higher yields, and a better-quality final product,” Pimpalnerkar says. “Combined with the energy savings and CO2 reductions, electrical heating equipment doesn’t take long to repay its investment.” 

Key benefits of electric preheating of billets in walking beam furnaces

Billet preheating is essential in steel production for a high-quality end product. However, the fossil-fuel-based heating typically used in walking beam furnaces is inefficient, consuming large amounts of energy and emitting high volumes of CO2. 

By electrifying the heating process through Kanthal’s Globar® and Kanthal® Super heating elements, steel producers can achieve much higher thermal efficiency and potentially reduce CO2 emissions to zero. Globar® can achieve temperatures as high as 1,625ºC (2,960ºF), and Kanthal® Super can reach as high as 1,850ºC (3,360ºF). 

Here are four good reasons to choose Kanthal’s heating elements. 

  • Thermal efficiency of more than 90 percent: When using conventional gas-heated industrial burners in walking beam furnaces, only 30 to 60 percent of the heat generated is used to heat the billets. Most of the remaining heat is lost through the flue gases released into the atmosphere. In contrast, electric heaters do not generate flue gases, the thermal efficiency can be higher than 90 percent. This means a significant reduction in energy consumption and a substantial reduction in costs. 
  • Zero emissions: Industrial burners that use fossil fuels also produce high CO2 emissions. However, using electric heating can substantially eliminate this problem. Electricity derived from a renewable source can make the heating emission-free. 
  • Precise temperature control: Both Globar® and Kanthal® Super enable precise temperature control in the furnace and turn in the billets. This improves the overall quality of the final steel and reduces costs by minimizing the number of rejections in downstream operations. 
  • Less oxide scale: Since electric heating has greater flexibility to operate in controlled atmospheres that do not contain high levels of oxygen, there is significantly less oxide scale forming on the surface of billets compared with fuel-fired heating. This reduces time and costs in downstream operations and increases the overall yield. 

Connected products

Here you can find the Kanthal product offering

Kanthal® Super

Kanthal® Super

Robust electric molybdenum disilicide (MoSi₂) industrial heating elements - designed for high temperatures, superior performance, extended lifespan, and unmatched flexibility. 

See product details
Globar® SiC heating elements

Globar® SiC heating elements

Globar® silicon carbide heating elements deliver high-power, even heating at temperatures up to 1,625°C (2,927°F), with customizable designs to fit various industrial processes. Trusted for their durability and performance, these elements are available in multiple sizes, grades, and element types.  

See product details

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