Industrial heating elements are among the most crucial components in any industrial heating system. Selecting the right industrial heating element can save money, time, and create a more efficient process, regardless of the application.
Some plant engineers overlook the importance of the role an industrial heating element plays in a manufacturing process, so we put together this guide to demonstrate how to select the right heating element. Please don’t hesitate to contact our expert staff to address any questions you may have.
Selecting the right heating element starts with collecting the right information, and that begins with asking the right questions. These questions should concentrate on how to heat up the solid, liquid, or gas in question in your industrial process, and what the specifications of the heating element must be to achieve the best heating performance. These key questions include:
– What alloy should be used?
– What temperature does the heating element need to reach?
– What sort of control is required?
– What is the required voltage?
– How long will the intervals be during which the heating element needs to be active?
Having precise answers to the questions above is critical to selecting the appropriate heating element. It’s helpful to have the answers organized before reaching out to a company to procure a heating element or industrial heater because it expedites the process.
The most common question clients ask is how much power is required to heat up a tank of fluid to reach the desired temperature. The answer must be calculated based on factors including location (indoors or outdoors), the flow rate, the type of liquid being heated, and the ambient temperature
Selecting an ideal heating element for an industrial heater has tremendous impact on the quality of the product of the process the heater is used in, the cost of creating the product, and, most importantly, the safety of the operation.
Not having the right heating element can lead to serious safety risks. Installing the right heating element in an industrial process heater yields the following benefits:
1. Reduced Operational Costs
Even if the heating element which is ideal for your industrial heater is more expensive than an alternative element, costs over time will be lower, saving money over the operational life of the heater.
2. Improved Operational Efficiency
Selecting the right heating element will improve the productivity of industrial processes. When the element is constructed of the correct material and set up to conduct heat optimally for the medium being heated, energy consumption goes down.
3. Heightened Safety
Choosing the appropriate heating element alleviates the potential for malfunction which can lead to serious safety consequences. Industrial-process downtime is the of the lowest concern when the consequences of having incorrect equipment can be as serious as an explosion.
4. Higher Return on Investment
Optimal operational efficiency mean the return on investment of each dollar allocated to an industrial process sees a higher return. With the right equipment, you see higher profit margins, lower waste, and more efficient business.
5. Improved Longevity of Operational Life
When all components of an industrial heating system are ideally compatible, the system works at optimal efficiency and doesn’t degrade as quickly as a system without ideal components. Similarly, when an industrial heating system is running at peak efficiency the entire industrial process runs smoothly, extending the lifecycle of the entire system as each cycle degrades the equipment less.
One of the most significant ways to improve operational efficiency in industrial heating is often overlooked: The simple difference between construction material. The difference between a steel element and stainless steel element, for example. A steel heating element is more efficient than a stainless steel element at transferring heat between mediums, and this small difference translates into significant cost savings and longer operational life for the equipment.
More information about improving operational energy efficiency is available from the Department of Energy.
Even when the appropriate heating element is selected, a suitable temperature control panel is required to use the equipment effectively. Aside from having the right industrial heating element, using an appropriate temperature control panel has the greatest impact on operational efficiency.
The cost associated with using the wrong industrial heating element for heating applications can be represented in terms of labour costs, material replacement cost, and most importantly, the potential health and safety cost.
In one example mentioned to Wattco, a maintenance worker was tasked with replacing a heating element in an oil-heating system. The maintenance worker was unaware that an oil-heating element of specific parameters was the only suitable replacement part, thinking that he could instead use a water-heating element for the oil-heating application.
Thankfully there were no disastrous consequence in this particular example, however, the maintenance worker learned the hard way that a heating element for water cannot be used in oil-heating equipment because each liquid has a different viscosity and therefore requires specific equipment.
The incident described here had serious costs and impact, as the entire process was compromised because one part was incompatible. The heating element failed under the stress of working in an application it was not suited for, causing all of the liquid to be contaminated. The mishap incurred heavy costs because of process downtime, the cost of parts for replacing the original oil element and the water element which was also destroyed, and the cost of the additional labour which needed to be employed.
The whole situation would have been avoided if the appropriate heating element had been used.
Begin the procurement process for acquiring a Wattco industrial heating element by filling out our quote request form or phoning our office toll-free at 1-800-492-8826. You’ll receive a quote back within 24 hours.
We build trusted relationships with our clients, and below are just a few reasons companies choose Wattco as their preferred supplier of industrial heating equipment.
– Our heating elements can be made to be compatible with practically any existing industrial heating infrastructure. Simply tell us your specifications and we can supply the product or build it custom if it isn’t standard.
– We are a “one-stop-shop” for all industrial heating needs for any industry. We offer and service not only industrial heating elements, but also offer fully-customized heaters and replacement parts. Working with one centralized supplier makes the procurement process, fast, easy, and straightforward.
– Wattco has been supplying heating products to companies all over the world since 1969. We’ve built strong, lasting relationships with clients in industries ranging from nuclear to chemical manufacturing over decades in the business.
– We recognize that when something goes wrong and interrupts your industrial process every second counts, so we keep a “Priority One,” team standing by to handle emergencies and critical situations.
Order custom heating elements or custom industrial heating equipment for your niche or non-standard application through Wattco. Whether you are procuring equipment for a new project or looking for a new supplier, contact us to discuss your project.
Fill out our quote form and we’ll get back to you with the requested information in 24-hours or less.
Why is Mineral Oil Used in Thermal Heaters?
Thermal heaters, also known as thermal fluid heaters, employ the use of a thermal liquid such as wat...
What to Use When Heating Wax
SituationA popular chemical compound that often requires heating is wax, which is an organic compoun...
What is Passivation? Why do We Need to Passivate Flanged Heaters?
Most of the parts of flanged heaters are made of stainless steel—an alloy that is mainly compri...
What is a Digital Controller?
Control panels are essential elements of any electrical device. Control panels are especially i...
Vegetable Oil Heating
Food Industries and Vegetable Oil Viscosity In Cleveland Ohio, a large food manufacturer called WATT...
Application of Immersion heaters in the Cheesemaking Industry
A centuries-old art, cheesemaking requires skill and precision. Cheesemaking is a complex process in...
Tank Heating and Flanged Heaters
Whether your company is in the food industry, the oil industry or has another industrial application...
Industrial Heating Significance of Over-The-Side Heaters
Industrial Over-The-Side Heaters are used in numerous industries to enable users work freely in a sa...
Application of Tesla’s Battery Technology in Heating Applications
Tesla’s Battery technology has revolutionized the electric vehicle (EV) and brought EVs from being...
Industrial Heating System Insulation Materials
Industrial heating systems offer more profitable processes when they operate at high efficiency and ...
Electric Heating Coils: Selection & Design
Electric heating coils transfer energy into heat in a variety of heating applications. They’re an ...
What is a Pressure Vessel?
Pressure vessels are carefully fabricated, enclosed containers designed for the purpose of holding e...
Duct Heating in HVAC and Building Construction
Heating, ventilation, and air-conditioning (HVAC) systems are used for heating and cooling residenti...
Temperature and Power Controls for Industrial Electric Heating
A control system is an essential part of every industrial heating system. Whereas some applications ...
.Crude oil, unprocessed fossil fuel, is one of the most important natural resources. In its unproces...