In an industrial setting, immersion heaters are installed in containers, tanks, and processing equipment where they are utilized for heating liquid solutions. Using the direct heat transfer process, immersion heaters are able to heat liquids to the desired temperature quickly. Electric immersion heaters are cost-efficient and use cleaner energy. Types of immersion heaters include over the side heaters, circulation heaters, screw plug heaters, and flange heaters. These electric heating elements require minimal maintenance and feature standard 1-inch conduit openings as well as 0.315”, 0.375”, 0.430”, or 0.475” diameter elements. Sheath materials include stainless steel, steel, and Incoloy®. Immersion heaters can be custom designed for the specifications of your application.
Circulation heaters are composed of an electric heater heater housed in a steel, carbon steel, stainless steel, Incoloy®, Inconel®, or titanium vessel. A pump is used to flow oils, water, or process liquids through the closed pipe circuit where heat is applied. When choosing a circulation heater for an application, viscosity must be considered to ensure the liquid will be capable of circulating within the pipes; therefore, a range of watt densities are available to achieve the appropriate viscosity. These electric heating elements feature drain valves, allowing for simplified maintenance. Vertical or horizontal mounting options are available for this water heater element.
Flanged heaters are mounted on the sides of tanks to provide direct heating for liquids. They are a popular heating option for oil sector applications. Flanged heaters are made of a variety of different alloys, including steel, stainless steel, copper, titanium, Incoloy®, and Inconel®, with a heavy wall sheath of 0.028” up to 0.065” thickness available in steel, stainless steel, Incoloy®, and Inconel®. Choosing the appropriate alloy for the water heating element will prevent corrosion and extend the service life of the flanged heater. Flanged heaters are custom built to the wattage appropriate for your application, up to 660 volts.
Screw plug heaters are a form of electric heater used to heat gases and liquid solutions in smaller tanks where fine temperature control is also required. A screw plug heater screws into the tank wall or vessel, or can also be installed within piping. The screw plug heater is immersed in the solution to offer rapid heating. Mechanical thermostats or industrial control panels allow screw plug heaters to achieve target temperatures accurately. Sheath materials include copper, steel, stainless steel, titanium, Incoloy®, and Inconel®. Energy-efficient NPT screw plugs are available in 1”, 1 ¼”, 1 ½”, 2”, 2 ½”, 3”, and 4’’.
Pipe heaters provide indirect heating to the liquid. Use pipe heaters in tank applications as water heating elements or for other substances requiring low watt densities, such as molasses, waxes, tar, and corrosive substances. During the heating process, the pipe heater never comes in contact with the liquid. Pipe heathers are specifically designed to fit within 2” to 3” horizontal schedule 40 NPS piping. Maintenance and replacement of the pipe heater is simplified, as there is no need to drain the tank in these scenarios. Pipe heaters may use coiled, tubular, flanged, or screw plug heaters depending on the needs of the application. Pipe heaters offer easy installation, even heat distribution, and extended service life.
Over the side heaters are designed to be installed in the upper part of a tank. Using this approach, there is adequate space available in the tank for operations. Using over the side heaters creates uniform temperatures while maximizing process heating efficiency. The over the side heater can be conveniently removed upon heating the liquids to the desired temperature. The portability of over the side heaters offers the flexibility to be used in various applications. Over the side heaters utilize heating elements made of steel, copper, titanium, or cast alloy, coated in fluoropolymer or quartz for added protection; diameter sizes include 0.315”, 0.375”, 0.430”, and 0.475”.
Steam and hot water boilers are used in facilities for a variety of purposes. Electric boilers are the most efficient option available for heating steam and water, making them a popular choice for commercial and industrial operations. With pressurized fluids contained inside, boiler heaters are designed for efficient heating as well as building safety. Boiler heaters are easy to install and the flange heaters they use can be replaced easily, lowering maintenance expenses. Various sizes offering a range of wattages are available to meet the specific needs of your application. Square and round flanges are available.
Tubular heating elements composed of steel, stainless steel, Incoloy®, Inconel®, and titanium alloys are the foundation of virtually all industrial heating elements. With a strong exterior sheath, the heater is protected from stress while facilitating efficient heat transfer. Tubular circulation heaters offer great flexibility and are suited for use in a wide variety of applications to heat gases, solids, and liquids, processing temperatures of up to 750 °C. Standard diameter sizes include 0.260”, 0.315”, 0.375”, 0.430”, 0.475”, and 0.625”, allowing you to adjust watt densities to achieve optimal performance and extend equipment life. Tubular heaters feature silicone seals to control humidity, offering superior moisture resistance.
Finned tubular heaters are suited for forced convection heating of air or gas. Fins are attached to the electrically insulated heater sheath, offering fast heat dispersion and superior heat conductivity. Custom bends are available, and finned tubular heaters can be configured to most any shape in order to meet the needs of your application. Finned tubular heaters offer watt densities up to 120 WPSI. They are easy to install and replace, reducing down time. Standard diameters for finned tubular heaters include 0.260”, 0.315”, 0.375”, 0.430”, 0.475”, and 0.625”. Sheath materials available include copper, steel, stainless steel, titanium, Incoloy®, and Inconel®.
Strip heaters utilize their surface area to conduct direct heat transfer. These heaters can reach temperatures of up to 500°F, and provide adequate and inexpensive heating for smaller areas and surfaces indoors. Components of a strip heater include the heating element, a protective sheath made of steel, stainless steel, iron, aluminum, or zinc-coated steel, and mounting hardware. Strip heaters are insulated with magnesium oxide, mica, or fiberglass to minimize heat loss. Temperatures can be easily controlled by installing a mechanical thermostat or bimetal thermostat on the surface of the heater. Strip heaters can also be used in applications requiring radiant heat.
Finned strip heaters allow you to transfer heat in a targeted area effectively by increasing heating intensity as well as surface are. Finned strip heaters utilize mechanical or bimetal thermostats installed on the heater surface for temperature control. Finned strip heaters are versatile and commonly used in applications such as process air heating, space heating, and food warming. They can be used as duct heaters or radiant heaters; their fins expand surface area, allowing for optimal heat transfer. Finned strip heaters are easy to install by clamping or bolting to the surface being heated. Finned strip heaters can heat to temperatures up to 500°F.
Cartridge heaters are fit tightly within a cartridge, and can house a thermocouple inside for accurate temperature control. The sheath of a cartridge heater can reach temperatures of up to 1400°F and are suited for high temperature applications, such as molds, sealing, and metal dies. Sheath materials include stainless steel, Incoloy®, and titanium. Cartridge heaters are made of high-grade nickel chromium resistance wire that is wrapped around a magnesium oxide core housed in a stainless steel casing. Cartridge heaters are designed for safety using high-quality materials. They are designed to maximize heat transfer as well as maintain even temperatures.
Band heaters provide indirect heating for tanks. Fitting around the exterior of a drum or pipe, they heat the surface of the container to create progressive, uniform heat transfer. This method of heating is safe for use to heat volatile substances which are too dangerous to heat via direct methods. Band heaters are energy efficient and offer flexibility for use in various applications. Band heaters feature a built-in insulating mat composed of ceramic fiber. The outer stainless steel shell can reach temperatures of approximately 350°F to 450°F. Medium to high range band heaters can reach internal temperatures of up to 1200°F.
Silicone rubber heaters are used in low to medium temperature applications of up to 450°F that are irregular dimensions and shapes. Silicone rubber heaters are used to provide direct heat where traditional heaters are unable to be installed. Made of fiberglass reinforced silicone rubber, these heaters are highly flexible and durable. Silicone rubber heaters can be affixed to surfaces using pressure sensitive adhesives or field-applied adhesives, or they can be mounted mechanically using various methods. The standard thickness of silicone rubber heaters is 0.056”, with lengths ranging from 1” to 120” and widths ranging from 1” to 36”.
Open coil heaters offer a highly efficient option as an electric heating element which is economical for use in most applications. Using open circuits, air is directly heated by suspended resistive coils ranging in diameter from 0.250” to 0.875” with wire gauges of 6 gauge up to 38 gauge. Open coil heaters are designed to fit within 2” or 3” schedule 40 NPS pipe. Open coil heaters provide fast heating times, lowering energy consumption and improving efficiency. Use open coil heaters for applications requiring even heating distribution across broad surface areas, including duct heating, pipe heating, forced air heating, and ovens. They are easy to maintain and replacement parts are inexpensive.
Duct heaters are used in ventilation and comfort heating applications, as well as industrial heating situations involving non-pressurized air heating. Types of duct heaters include tubular, finned tubular, and open coil. The electric heating elements are inserted directly into the duct or flanged. Duct heaters can be custom designed and built to fit the specific needs of your industrial heating product, with capacities of as much as 1000kW. Duct heaters are easy to install and maintain or service. Repairs or replacement can be performed quickly to minimize downtime. Duct heaters are versatile and offer optimal heat transfer with minimal heat loss.
Infrared heaters produce clean, radiant heating for heating in exposed indoor or outdoor areas. Infrared heaters can be used in process applications, to provide comfort process heating, and can be used in food service to maintain target temperatures. Infrared heaters utilize tubular circulation heating elements to produce direct heat transfer. The terminals are protected from moisture penetration and excessive humidity by waterproof housing. They are resistant to harmful corrosion and oxidation. Mechanical or digital controls are used to adjust and regulate temperatures. Infrared heater tubing options include: singular tubing elements, double tubing elements, hairpin tubing elements, quartz tubing, double quartz tubing, and quartz lamp elements.
Digital control panels regulate temperatures, protect the heater element, and prevent overheating and other issues such as chemical disintegration. The control panel can be customized for your application to ensure safety while maintaining accurate and efficient heat transfer. Digital control panels offer ambient and target temperature readings for the solution being heated. There are multiple terminal box options available, including NEMA 1, NEMA 4, NEMA 7 explosion proof, dust-proof, and waterproof. The terminal box houses the various components of a digital control panel, including contactors, fuses, relays, and on-off switches. Digital control panels arrive ready to connect for quick installation, and are compatible with various materials including dangerous and corrosive materials.
The Solid State Switching devices are semi conductor devices that control the power, either voltage or current that is supplied to the production system. While their job is primarily to switch the power on and off at rapid pace according to the instructions of the controller, they are capable of doing multiple standalone functions that primary include diagnostic functions and supervisory functions.
Also known as Phase Angle Controllers or solid state switching device – work using the modulation of the load voltage until the targeted temperature is reached. Its smoother temperature control (virtually no noise) makes it a preferred choice over mechanical contractors which involves full load on/off during a cycle and improves your temperature response time.
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