What is an electric process heater & primary function?

Electric process heaters can reach higher temperatures than fuel heaters.

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.

What are the main components of an electric process heater and their functions?

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.

What types of heating elements are commonly used in electric process heaters, and how do they differ?

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.

 Heating elements

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

What are the primary applications of electric process heaters in various industries?

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.