Electric Heating Elements
The heaters for the industrial environment are usually power by an electrical source. The heaters manufactured by WATTCO™ all electric heaters with heater elements made out of specially designed electric heating rods. The typical heating elements are made of steel or stainless steel. They are used in heating water or similar liquid medium for a general purpose and usually corrosion free.
Other corrosion resistant materials used are a composition of alloy such as copper or titanium. They are most resistant to high temperature and withstand the highly corrosive medium. Recently, specially manufactured alloy such as Inconel® and Incoloy® were introduced for more advanced application.
Electric Heating Elements
The heating elements are a vital part of the industrial heater with various added benefits contingent on a particular application. The selection of heating elements depends largely on the type and nature of the medium used.
In addition to the medium, the type of heaters it will be installed also has a bearing on what kind of alloy it must be constructed of. The heater elements are factory configured into any shape and size.
They operate in an extremely high temperature as some heater elements are required to operate well above the process temperatures of 1,600⁰F.
Industrial heater elements convert electrical energy into heat. They are used in the heat treatment process to attain specific temperatures. They provide supplemental heat in air handling units and space heaters.
Their mechanism is controlled and allows safe heating with high energy. Electric heating elements are necessary for consistent and reliable heating in industrial, commercial, and residential applications. It is used in furnaces, ovens, water heaters, toasters, dryers, medical equipment, and automotive systems.
Also read: Do Electric Heating Coil Materials Matter?
Types and Materials of Heating Elements
Electrical heating elements are produced with different materials based on the industry/application, service temperature, and environment. Immersion heaters often require materials that are highly resistant to breakdown at extreme temperatures and to stay immersed without giving in to an erosion factor. Material selection will have a lasting bearing on efficiency, durability, and use safety, which means these three elements are directly part of the material selection process.
Common materials used in heater elements
Stainless Steel: One of the most common materials due to its corrosion resistant, durability. Stainless steel is made of a minimum of 10.5% chromium, which provides protection in the form of an oxide layer, thus allowing stainless steel to be safe and resist oxidization under even normal industrial conditions. This material can be observed largely in water heating applications, or even general purpose heating as long as there is a need for corrosion resistance.
Copper and Copper Alloys: Because of copper having high electrical conductivity, combined with no reaction with water. It is for this reason that copper heating elements are recommended in water and fluid heating devices. Copper can oxidize after being in contact with atmospheric oxygen for an extended period of time.
Titanium: Extremely resistant to corrosion, especially in extreme environments. It is lightweight with durable properties, so it is often recommended in extreme corrosive or specialized applications.
Nickel-Based Superalloys (Inconel® and Incoloy®): Superalloys are used here because of the extreme environments include high temperatures and high pressure. Nickel-based superalliows have substantial corrosion resistance and can withstand attack from chemical compounds combined with kinetic energy, required in all industrial applications above 1600°F.
Tailored Designs: Heating elements can be arranged into rods, coils, or other shapes and sizes at the factory to suit your application. This is done to maximize heat transfer and fit.
By specifying the right material for a given temperature range, corrosion resistance, and mechanical stress, Wattco™ tries to provide each electric heating element with a long life span and safety for the desired industrial environment.
Also read: Guide to Water Heating Elements
Wattco™ heater elements
For extreme environments, WATTCO™ manufactures heater elements made with super alloys such as Inconel® or Incoloy®. The superalloys are mostly nickel-based and excellent corrosion-free materials typically suitable for environments under particularly high pressure and kinetic energy.
They are also fully resistant to an extreme temperatures, specifically to certain chemicals otherwise not sustainable with the general alloys of heating elements. The heating elements are vital to the manufacturing of industrial heaters, and the proper choice of alloy under a specific condition is of the utmost importance to the designing of a suitable application for the particular industrial heater. More information can be found at Wattco.
Get a quote for a heating element today. Wattco also manufactures other industrial heating products such as infrared heaters, control panels, circulation heaters and more. Click here to view all of our products.Frequently Asked Questions (FAQs)
What is the most suitable heating element material for corrosive conditions?
For environments with a high level of corrosion, Wattco™ suggests that the best heating element materials are titanium and nickel-based superalloys such as Inconel® and Incoloy®. These materials have an outstanding resistance to chemical attack, erosion, and oxidation, which makes them exceptionally well suited for harsh industrial tabular heating applications.
What maintenance do electric heating elements require?
Electric heating elements should be inspected regularly for signs of corrosion, wear, or damage. It is also important to clean away any buildups or deposits from the element surface in order to maintain its efficiency. It is critical to ensure that the electrical connections are tight and corrosion-free. To extend the life of the electric heating element, always follow the manufacturer’s recommendations regarding service intervals.
How long do electric heaters usually last?
The longevity of electric heaters depends on operating temperature, environment, material, and maintenance. With the right care, Wattco heaters can last for many years, normally more than 5 to 10 years of industrial use.
What is the maximum temperature Wattco™ heating elements can achieve safely?
Wattco™ heating elements can be used with safe operating temperatures above 1,600°F (870°C) with some elements able to withstand maximum temperatures above this depending on the alloy and installation process. Additionally, some form of superalloy combined with design allows for safe, high-temperature wear and use in some applications.
Are Wattco™ heating elements available in custom shapes and sizes?
Wattco™ can provide fully custom heating elements in different shapes, sizes, and designs. This provides the potential for the best fit and heat transfer for your application.
Will Wattco™ heating elements work in air and water heating applications?
For sure, Wattco™ heating elements are reliable in some air heating applications and can be used in a variety of liquid (water or oil) heating processes. Wattco™ heating elements can be incorporated based on material choice and element design accordingly.