Thermocouple Quick Reference Guide. Aluminium Temperature Sensing Solutions from the Smelter to the Foundry

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1 Thermocouple Quick Reference Guide Aluminium Temperature Sensing Solutions from the Smelter to the Foundry

2 why pyrotek? Pyrotek is a global engineering leader and innovator of technical solutions, integrated systems and consulting services for material processing industries including aluminium, cement, glass and steel. Privately owned since 1956, Pyrotek offers industry-leading technical expertise and global resources with 66 locations in 32 countries. Pyrotek s mission is to provide innovative solutions to customer needs utilizing our global resources. Complete thermocouple / thermocouple protection tube (TC / TCPT) assemblies and accessories Refurbishment and vendor management services Extensive thermocouple and industry experience Over 15 years of thermocouple design and manufacturing combined with 60-plus years of industry experience

3 Thermocouples in Carbon Bake Firing frame Temperature pressure ramp (TPR) and exhaust Isotherm ALUMINIUM SMELTER 1

4 Firing Frame: Flue and Pit Thermocouples LOCATION TC TYPE TCPT AVERAGE LIFE AVERAGE LENGTH QUANTITY USED ALUMINIUM SMELTER Flue Pit FLUE PIT N INCONEL months S Re-SiC 12 months N N 310SS or 253MA INCONEL months 2 3 months 1500 mm (59 in) 1400 mm (55 in) 1450 mm (57 in) 1450 mm (57 in) 1 per flue opening 1 per flue opening 1 4 per section 1 4 per section 2 INCONEL is a registered trademark of the Special Metals Corporation group of companies.

5 Flue and Pit Thermocouples Pyrotek Models I2 Series: Base metal elements protection tube style P4 Series: Thermocouple extensions ALUMINIUM SMELTER 3

6 Temperature Pressure Ramp and Exhaust Cooling frame Firing frame flue and pit thermocouples TPR flue thermocouples Exhaust manifold flue thermocouples ALUMINIUM SMELTER 4 LOCATION TC TYPE TCPT AVERAGE LIFE AVERAGE LENGTH QUANTITY USED PREHEAT AREA TPR DRAFT CONTROLLER K Not specified but can use INCONEL 601 to extend life 2 4 months EXHAUST MANIFOLD K Not required 2 4 months 1100 mm (43 in) 300 mm (12 in) 1 per flue section As low as 1 manifold

7 Temperature Pressure Ramp and Exhaust Custom covers include handle and access points for measuring temperature and pressure ALUMINIUM SMELTER 5

8 Temperature Pressure Ramp and Exhaust Pyrotek Models I2 Series: Base metal elements protection tube style ALUMINIUM SMELTER M2 Series: Mineral insulated elements plug and jack style M3 Series: Mineral insulated elements head and block style 6

9 Measuring Heat Distribution Isotherm Contour temperature mapping Bundle of thermocouples made to varying lengths, used to determine pit head distribution Seven thermocouples of various lengths At the center of the pit section LOCATION TC TYPE TCPT AVERAGE LIFE AVERAGE LENGTH PIT K Cast Iron Single Use Varies ALUMINIUM SMELTER 7

10 Measuring Heat Distribution Pyrotek Models I9 Series: Cast iron and enameled cast iron style ALUMINIUM SMELTER M2 Series: Mineral insulated elements plug and jack style 8

11 Thermocouples in Electrolysis Pots ALUMINIUM SMELTER 9

12 Thermocouples in Electrolysis Pots ALUMINIUM SMELTER Temperature check during start-up Profiling cathode surface temperature Temperature is taken daily or every second day on every pot LOCATION TC TYPE AVERAGE LIFE AVERAGE LENGTH MOLTEN ELECTROLYTE BATH K Heavy wall minimum 5.5 mm (3/16 in) outer diameter Quick Tips Disposable or repeating use with repair Starting length at 1500 mm (59 in) Starting length at 203 mm (8 in) 10

13 Thermocouples in Electrolysis Pots Pyrotek Models M2 Series: Mineral insulated elements plug and jack style M4 Series: Mineral insulated thermocouples with lead wire Quick Tip Series: Quick response sampling thermocouples ALUMINIUM SMELTER 11

14 ALUMINIUM SMELTER Pyrotek Thermocouple Protection Tubes Cast iron O -Sialon Pinnacle Reinforced fibreglass material (RFM ) and more 12

15 Thermocouples in Casthouse Furnaces ALUMINIUM SMELTER 13

16 Casthouse Furnace Metal Immersion PRODUCT COMPARISON *THERMOCOUPLE PROTECTION TUBE APPLICATION MECHANICAL STRENGTH LIFE EXPECTANCY (Proper maintenance and care) WORKING TEMPERATURE PYROTEK MODELS ALUMINIUM SMELTER CAST IRON PLAIN / CAST IRON ENAMEL Both withstand the rigors of furnace environment. Their physical strength is ideal for casthouse handling. Ceramic-coated tubes provide 25 50% longer life than plain cast iron tubes. PINNACLE The unique properties of Pinnacle thermocouple tubes provide long life, are non-wetting and ideal for temperature-sensitive applications. RFM Non-wetting to aluminium and its alloys. Reinforced material coupled with an internal steel tube has the ability to withstand mechanical abuse. Reverb melting furnaces Degassing Holding furnaces Reverb melting furnaces Degassing Holding furnaces Degassing Holding furnaces Troughs Cast iron strong Refractory with steel pipe reinforced Composite refractory with steel pipe reinforced 1 2 weeks 3 6 months 3 6 months 800 C (1472 F) 1100 C (2012 F) 800 C (1472 F) I9 Series T2 Series I5 Series I6 Series T1 Series I5 Series I6 Series T1 Series 14 *Always consult with a Pyrotek sales engineer to properly define the TCPT solution for your application.

17 Casthouse Furnace Atmospheric PRODUCT COMPARISON *THERMOCOUPLE PROTECTION TUBE APPLICATION MECHANICAL STRENGTH LIFE EXPECTANCY (Proper maintenance and care) WORKING TEMPERATURE PYROTEK MODELS INCONEL 601 Well known and standard material with great resistance to heat and corrosion. It is not intended for direct immersion in molten metal. ALUMINA Roof furnace free air application in the heat treatment, glass and ferrous metal industries. MULLITE Another option for roof furnace free air applications with a lower temperature rating than alumina tubes. Preheat section and pit / flue firing chambers in carbon bake Roof furnaces Heat treatment Roof furnaces Heat treatment Roof furnaces Heat treatment Stainless steel strong Alumina ceramic Mullite ceramic 7 9 months 3 5 months 3 5 months 1260 C (2300 F) 1600 C (2912 F) 1400 C (2552 F) I2 Series I3 Series IP Series I4 Series I4 Series ALUMINIUM SMELTER *Always consult with a Pyrotek sales engineer to properly define the TCPT solution for your application. 15

18 Thermocouples in High Pressure Die Casting Dosing Furnace Atmospheric Thermocouple FOUNDRY CASTING PROCESS Die / Mould Thermocouple Pressurized Immersion Thermocouple 16 Additional Thermocouples: Sampling, extensions, wires and accessories

19 Thermocouples in Gravity Permanent and Semi-permanent Mould Sand Casting Immersion Thermocouple Atmospheric Thermocouple FOUNDRY CASTING PROCESS Additional Thermocouples: Die / mould, sampling, extensions, wires and accessories 17

20 Thermocouples in Low Pressure Die Casting Atmospheric Thermocouple Pressurized Immersion Thermocouple FOUNDRY CASTING PROCESS 18 Additional Thermocouples: Die / mould, sampling, extensions, wires and accessories

21 Thermocouples in High Pressure Die Casting and Robotic AutoPour Die / Mould Thermocouple Immersion Thermocouple Atmospheric Thermocouple FOUNDRY CASTING PROCESS Additional Thermocouples: Sampling, extensions, wires and accessories 19

22 Immersion Thermocouples Various TCPT Assemblies IMMERSION THERMOCOUPLE 20

23 Molten Metal Immersion Series *TCPT TYPE RFM Sialon/SiN RATED OPERATING TEMPERATURE 800 C (1472 F) 1100 C (2012 F) IMAGE RELATIVE RESPONSE LIFE (#1 Fastest) #3 #1 RELATIVE SERVICE LIFE 3 6 Months Months PYROTEK MODELS I5 Series I6 Series I7 Series I8 Series IMMERSION THERMOCOUPLE O -Sialon 1100 C (2012 F) #1 2 4 Months *Always consult with a Pyrotek sales engineer to properly define the TCPT solution for your application. 21

24 Molten Metal Immersion Pressurized Vessel Series IMMERSION THERMOCOUPLE *TCPT TYPE Pinnacle Sialon/SiN RATED OPERATING TEMPERATURE 1100 C (2012 F) 1100 C (2012 F) IMAGE RELATIVE RESPONSE LIFE (#1 Fastest) #2 #1 RELATIVE SERVICE LIFE 3 6 Months Months PYROTEK MODELS I5 Series I6 Series I7 Series I8 Series O -Sialon 1100 C (2012 F) #1 2 4 Months 22 *Always consult with a Pyrotek sales engineer to properly define the TCPT solution for your application.

25 Atmospheric Thermocouples ATMOSPHERIC THERMOCOUPLE Protection Tube Selection Thermocouples 23

26 Atmospheric Thermocouples Series *TCPT Type Rated Operating Temperature Type of Atmospheric Applications Relative Service Life (months) Pyrotek Models ATMOSPHERIC THERMOCOUPLE INCONEL 601 Alumina Mullite 1260 C (2300 F) 1600 C (2912 F) 1400 C (2552 F) Roof furnace Heat treat Open carbon bake furnace: preheat section and pit/flue firing chambers Roof furnace Heat treat Roof furnace Heat treat 7 9 I2 Series >12 I4 Series 24 *Always consult with a Pyrotek sales engineer to properly define the TCPT solution for your application.

27 Die / Mould Thermocouples DIE / MOULD THERMOCOUPLE Thermocouple with Compression Bayonet Adapter Thermocouple with Bayonet Adapter and Armor 25

28 Die / Mould Thermocouple Series *TYPE IMAGE PYROTEK MODELS DIE / MOULD THERMOCOUPLE 90 angle with compression fitting or bayonet adapter Spring adjustable with bayonet adapter Armour adjustable with bayonet adapter P1 series P2 series P3 series MgO with extension wire M4 series 26 *Always consult with a Pyrotek sales engineer to properly define the correct mould thermocouple.

29 Sampling Thermocouples for Quick Temperature Measurements SAMPLING THERMOCOUPLE Coated MgO sampling thermocouple Quick tip sampling thermocouple 27

30 Sampling Thermocouple Series *TYPE IMAGE PYROTEK MODELS SAMPLING THERMOCOUPLE Quick tip MgO Coated MgO Quick Tip series M2 series M4 series Sleeve and coated MgO 28 *Always consult with a Pyrotek sales engineer to properly define the correct sampling thermocouple.

31 Thermocouple Intelligence Mining Present situation What type of thermocouple and thermocouple protection tube are currently being used? Type of thermocouple junction used? Extension leads, fixed to or separate from the thermocouple assembly? Are there refurbish or recycle programs in place? What are current pains, problems, shortcomings? Application and position or installation situation What is the application? Do the thermocouple and thermocouple protection tube require special fixtures? Are solids charged close to the thermocouple location? Is there vibration present during normal operation? Is there electrical interference? REFERENCES 29

32 Thermocouple Wire Types THERMOCOUPLE TYPE WIRE METAL + SUITABLE CONCERNS REFERENCES TYPE J BASE METALS TYPE K BASE METALS Iron, magnetic response Chromel, 10% chromium Constantan nickel 45% copper Alumel magnetic response Suitable in vacuum, air, reducing or oxidizing atmospheres to 760 C (1400 F) Mainly used in plastic applications Used for annealing and homogenizing furnaces Traditional base metal choice in the aluminium industry Performs best in clean oxidizing or inert atmospheres, up to 1260 C (2300 F) Should not be used in sulfurous atmospheres above 540 C (1000 F) Must not be exposed to sulfur-containing atmospheres TYPE N BASE METALS Nicrosil Nisil Performs best in clean oxidizing or inert atmospheres, up to 1260 C (2300 F) Less calibration drift than type K when used in temperatures above 1000 C (1800 F) Must not be used in vacuum or reducing atmospheres Non-magnetic wires 30 TYPE S NOBLE METALS Platinum, 10% rhodium Platinum Best for continuous inert atmospheres, up to 1480 C (2700 F) At continuous use in 1100 C (2000 F), wires must be protected from exposure to metallic and nonmetallic vapors

33 Thermocouple Wire Base Metal (Industrial) Element No sheath protection Ceramic bead insulation Unprotected hot junction Susceptible to green rot REFERENCES Butt Weld Twisted Weld 31

34 Thermocouple Wire Mineral Insulate (MI) Element REFERENCES Ability to withstand corrosive environment Magnesium oxide (MgO) insulated Hot junction is protected Long service life compared to industrial wire Formable JUNCTION TYPES Exposed Grounded 32 Ungrounded

35 Mineral Insulated Wire Sheath MATERIAL MAXIMUM OPERATING TEMPERATURE BENEFIT / WIDELY USED IN 304 SS 900 C (1650 F) Most common low temperatures Holding and melting furnaces with protection tube 316 SS 310 SS 900 C (1650 F) 1150 C (2100 F) Better corrosion resistance than 304 stainless steel Holding and melting furnaces with protection tube Better mechanical and corrosion resistance at higher temperatures Carbon bake pit, melting furnace with protection tube REFERENCES 446 SS 1150 C (2100 F) Resistance to sulfurous atmospheres Commonly used in steel and cement industry Alloy C (2150 F) Oxidation resistance Carbon bake flue Pyrocable 1260 C (2300 F) High temperature corrosion resistance Applications requiring 1200 C (2192 F) without protection tube 33

36 Thermocouple Wire Tolerance TC TYPE Wire size mm diameter (Numbers 30 to 8 AWG) TEMPERATURE RANGE STANDARD TOLERANCES SPECIAL TOLERANCES C F C F* C F* REFERENCES TYPE K or N TYPE S ±2.2 or ±0.75% ±1.5 or ±0.25% Note Note ±1.1 or ±0.4% ±0.6 or ±0.1% Note Note *Whichever is greater 34 NOTES: Tolerance expressed in F is 1.8 times larger than expressed in C. Percentage-based tolerance must be computed from temperatures that are expressed in C.

37 Pyrotek Thermocouple Protection Tubes Cast iron O -Sialon Pinnacle RFM and more REFERENCES 35

38 C F C F C F C F C F REFERENCES

39 Millimeter Inch Decimal Inch Fraction Millimeter Inch Decimal Inch Fraction 1/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / REFERENCES 37

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