Electrical process heaters are designed for efficiently heating liquid or gaseous flowing fluids.
Electrical process heaters are designed for efficiently heating liquid or gaseous flowing fluids. The design is based on the general conditions such as the type and properties of the respective fluid, pressure and temperature as well as the desired operating points in the process.
Depending on the application, electric process heaters may be used for both direct and indirect heating, which makes them a particularly versatile heating option.
Heater elements within electric heaters are mainly composed of three elements: an insulating core, a heat conductive coil wrapped around the insulation, and an encasing sheath made from stainless steel, aluminum, nickel or iron.
How does an electric process heater generate and transfer heat to the process fluid?
Electrical process heaters directly heat fluids, converting electrical energy in the heating rods to thermal energy. The thermal energy is then transferred from the heating rods to the fluid. Here, it is important that the design be matched to the general conditions, for each fluid has its specific properties.
The design of the individual heating elements is a function of the application. There are faster or slower heating elements, mechanically robust or more filigree designs. Also, a distinction is made between compacted heating elements and heating elements where the internal heating insert can be replaced without the necessity of draining the fluid.
Tubular heaters, diameter 8.5 or 16 mm
Cartridge-type heaters, diameter 16, 18 or 25 mm
Exchangeable heating elements, including a protective tube, diameter 25, 42 or 65 mm
Heat control is critical to a wide variety of processes, from melting materials into formable resins to superheating gases and initiating chemical reactions. Below is a short summary of common applications in which electric process heaters are used.
Glycol and amine re-boiling
Freeze protection
Tank temperature regulation
Liquid vaporization
Condensate stabilization
Viscosity reduction
High temperature air control
Nitrogen and thermal fluid heating
Heating of process gas, fuel gas, and natural gas
How do you determine the appropriate size and power rating of an electric process heater for a specific application?
Your heating problem must be clearly stated, paying careful attention to defining operating parameters. Take these into consideration:
Minimum start and finish temperatures expected
Maximum flow rate of materials being heated
Required time for start-up heating and process cycle times
Weights and dimensions of both heated materials and containing vessels
Effects of insulation and its thermal properties
Electrical requirements — voltage
Temperature sensing methods and locations
Temperature controller type
Power controller type
Electrical limitations
And since the thermal system you’re creating may not take into account all the possible or unforeseen heating requirements, don’t forget a safety factor. A safety factor increases heater capacity beyond calculated requirements.
What materials are typically used in the construction of electric process heaters to ensure durability and efficiency?
The fluid to be heated and the application temperature mainly define the materials which can be used for the unheated and/or heated surfaces. Otherwise, corrosion may quickly result in a failure of the flow-type heater, for example.
Materials of the wetted and unheated components
Carbon steel
Corrosion-resistant stainless steel
Heat-resistant stainless steel
Titanium, Hastelloy, special materials
Brass
Materials of the heating surface:
Carbon steel
Corrosion-resistant stainless steel
Heat-resistant stainless steel
Titanium, Hastelloy, special materials.
Electric process heaters can reach higher temperatures than fuel heaters. That makes them capable of performing tasks other heaters cannot. Being able to reach and maintain operation at high temperatures gives electric immersion heaters a big advantage over combustion heaters.
Electric process heaters boast higher efficiency rates and offer precise temperature control, leading to optimized energy consumption and enhanced process performance. Unlike fossil fuel heaters, which suffer from combustion losses and heat dissipation, electric heaters convert nearly all input energy into useful heat. This efficiency translates into reduced energy costs and improved productivity, making electric heaters a financially attractive option in the long run.
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