Industrial Heaters

Basics of Heater

• Based on the principle of electric resistance

heating

• Electric current is passed through highly

resistive material (heating element)

• Heat produced due to I2R losses in the element

is transmitted to the medium to be heated.

• Called as Joule heating, Resistive heating or

Ohmic heating.

• Mode of heat transfer is conduction, convection or radiation.

• 100% efficient

Contd.

Ohm’s Law

Circuit

• A series circuit has two or more heaters connected end-to-end.

Total Rt = R1+R2+R3+R4

• A parallel circuit has two or more heaters strung together end-to-end.

Total Rt = 1/R1+1/R2+1/R3+1/R4

Power Supply

The circuit can be created by:• Single phase supply : 2 wires are used; one for

power and the other one for neutral

• Three phase supply : 2 types of connection

• Delta connection : 3 wires are used; R, Y and B.

• Star connection : 4 wires are used; R, Y, B and neutral.

Heating Element Material

Different materials depending upon the temperature, medium and application.

• Nichrome alloy

• Ferritic alloys

• MoSi2 alloys

• SiC alloys

Nichrome Alloy

Ferritic Alloy

MoSi2 Alloy

• Consist of MoSi2 and a SiO2 phase. At high temperatures, a protecting layer of SiO2 is formed on the surface.

Furnace atmosphere Max temperature °C (F)Air

1700 (3090)Nitrogen 1600 (2910)

Argon, Helium 1600 (2910)Dry hydrogen, dewpoint -80°C (-86 F) 1150 (2100)Moist hydrogen, dewpoint 20°C (68 F) 1450 (2640)Endgas (e.g. 40% N2, 40% H2, 20% CO) 1400 (2550)Cracked and partially burnt ammonia 1400 (2550)

SiC Alloy

• Silicon carbide (SiC) electric heating

elements for element temperatures

up to 1625°C (2927°F).

• Capable of high power output, and

may be mounted either vertically or

horizontally.

Heater Types

Component Heaters

• Used for Component Heating such as

Plastic Packaging, Plastic Extrusion,

Plastic Forming, Surface heating

through conduction/convection

Process Heaters

• Used for Process Heating such as

Immersion Heating of Liquids/

Gases/Solids, Furnace Heating,

Reduction, Oxidation and carburization

of Sulphur, Nitrogen, Air and other

gases.

Component Heaters• Component Heaters are used in various industries for thermal heating of

components in the machine or the plant.

• Highly reliable and Energy efficient with uniform heating.

• Fast heating with long, trouble free service life.

• Unique shapes and design for customized heating.

Cartridge Heaters

• High watt Density

• Cylindrical shaped, heavy-duty heating

element.

• Provides compact, insert type heating.

• Distinguished for long, trouble free

service and fast heating.

Silicon Rubber Heaters

• Also known as flexible heaters.

• Rugged, moisture and chemical resistant

• Flame retardant, high dielectric strength

and non toxic

• Improve heat transfer, speed warm ups

and reduce wattage requirement.

Strip Heater

• Outstanding industrial heating element that

can meet any budget.

• Durable, versatile and easy to control

• Uniform heat distribution

• Corrosion and vibration resistant

Finned Strip Heater

• Fins improve heat transfer in free or

forced air heating applications.

• Fins can be in rectangular or round shape.

• Lower sheath temperature and

maximized element life through fins.

Ceramic Band Heater

• Medium to high temperature heaters

• Thermal insulation layer reduces heat

loss and power consumption

• Flexible with versatile configurations

• No risk of failure due to Hot Spotting

Mica Band Heater

• Mica provides exceptional insulation,

dielectric strength and heat transfer

capability

• Efficient heating solution for external

indirect heating

• Terminal boxes protect termination as

well as provide the option of

temperature control

Duct Heater

• Mainly Three types: Open coil,

tubular or finned tubular heating

elements

• Quick response time, energy efficient

and easily adaptable

• Replaceable elements permits easy

service and reduced downtime

Process Heater

• Process Heaters are used in various industrial applications to heat medium

(solid, liquid or gas)

• Tailored to meet customer’s unique needs.

• Engineered to provide precise process temperature control with control

equipment.

• Easily adaptable for every industrial process.

• Smart industrial heating solutions for process control

Tubular Heater

• Versatile, rugged and dependable

• Factory-configured to suit a variety of

industrial heating applications

• Regarded as the foundation of all

heating elements

Finned Tubular Heater

• Fins increase surface area, permits

faster heat transfer and puts more

power in tighter spaces.

• Mechanically bonded fins prevent

vibration at high velocities

• Extremely rugged, negligible

maintenance

• Adaptable to every industrial

environment

Flanged Immersion Heater

• Wide customization, easier installation

and operations in stringent environment.

• Heating chemical, petroleum and water

based applications specially heat transfer

fluids, medium and lightweight oils.

• Mounting flange to provide support

• Heating elements to heat medium

• Thermowell and thermostats for

temperature sensing and controlling.

Screw Plug Heater

• Used as a direct heating element, they are ideal for heating gases and liquids in tanks or vessels, process water heating, oils and heat transfer process, heating up flammable liquids or gases which require explosion proof housing.

• Extremely useful for the purpose of steam generation.

• Energy efficient and easy to regulate. The installation is a snap and the maintenance is easy as well.

• Mounting bushing to provide support• Heating elements to heat medium• Terminal Housing for holding terminals of power

supply• Thermowell and thermostats for temperature

sensing and controlling.

Circulation Heater• Also known as inline heaters

• It is an immersion heater covered by an

anti-corrosion metallic vessel chamber.

• Accompanied by National Pipe Thread

(NPT) screw plug or ANSI flange heater

assemblies mated with a pressure

vessel.

• Vessel is mainly used to provide

insulation to prevent heat loss in the

circulation system.

• Thermal simulation at any stage of

design to check compatibility.

Circulation Heater

Over The Side Heater

• Installed in the upper portion of tanks where side heating is not available.

• The substance to be heated is either below the industrial tank heater or onto one side.

• Ample space is left in the tank for other operations to take place

• The heater can easily be removed when the required temperature is achieved within the substance.

• Terminal Enclosure• Heating elements• Legs for spacing between floor and heater• Thermowell and thermostats• For acidic application; quartz, titanium or other

special outer tubes

Bundle Rod Heater

• Consists of circular ceramic beads that hold the heating elements

• Also known as Tubothal Heating elements or Bayonet Heaters

• Designed for long life and maintenance free operation.

• In combination with the radiant tubes, a system is created which delivers high power, is rugged and versatile

• Ceramic Disc which consists of through-penetrating holes encompassing the heating elements.

• Fiber Disc which holds the terminal rod and the center rod.

Open Coil Heater

• Have open circuits consisting of coiled

resistance wire fixed onto a supporting

element that heat the medium directly.

• Most efficient and versatile while also the

most economically feasible solution for

heating.

• Fast heat up times that improve efficiency

and have been designed for low

maintenance and inexpensive replacement

parts.

Bobbin Heater

• Made with sheathed or without sheathed

material.

• Offers a large surface area to heat liquids

or semi-solid materials such as water, oil,

wax, fats, and bitumen.

• Used for direct heating of air and indirect

heating of liquids and gases.

• Easy replacement

Infrared Heater

• Specially designed to emit infrared heat,

where heating by other means is not ideal.

• High intensity heaters used where high

temperatures are necessary.

• Simple, easy to clean, cost effective and

efficient.

• Categorized as the most useful heaters.

• Designed to work in large and exposed

areas and heavy duty projects.

Edge wound Heater

• Used where utmost power is

required in limited space.

• Easy to install and replace.

• Horizontal or vertical mounting.

Applications

• From chemicals, water, oil, liquids, petrochemicals to aluminum, steel,

power, pharmaceuticals, automobile, rubber and plastic industry,

industrial heaters are used everywhere.

• Every industry requires a specific industrial heater depending on the

process

• Modern industrial infrastructure are in an inevitable need of innovative

heating technology for sustainable development.

Steel Industry• Immersion heaters are used in hot dip galvanizing

process

• Radiant tubes and bundle rod heaters are used in

galvanizing furnaces

• Duct heaters are used for Air separation plant

(Oxygen plant) in steel melting

• Radiant tubes are used in ammonia cracking

generators to be used for annealing of steel .

Steel Industry Focus

• Galvanizing & Galvalume Plant: Bundle Rod Heater & Edge Wound Heater

• Oxygen Plant: Tubular Immersion Heater & Air Duct Heater

Power Generation

• Flanged Immersion heaters

are used for process water

applications

• Duct heaters are used for

heating air for combustion

Aluminum Industry

• Radiant tubes for primary aluminum

production

• Open coil duct heaters for heating air

• Radiant tubes and bundle rod heaters for

secondary aluminum processing

Aluminum Industry Focus

• Cast House: Holding, Melting Furnace & homogenizing Furnace :Bundle Rod

Heater (Accessories Radiant Tube, U Hanger & Swing Hanger), Edge Wound

Heater, Silicon Carbide Heater

• Sow Caster: Preheating of sow caster application : Molybdenum Disilicide

(MoSi2) Heating Elements

• Green Anode Plant: HTM oil heating Application : Tubular Immersion Heater

Chemical Industry

• Processing chemical mixtures requires heating elements to allow for even flow

heat transfers along an entire area.

• Immersion heaters are used to apply a gradual heat within the container.

• Flanged heaters are used for lower watt densities.

• Screw plug heaters are used for ease of use and maintenance.

• Over the side heaters are used where access opening is not provided at bottom

of tank.

Chemical Industry

Oil & Gas Industry

• High temperatures are desired in petrochemicals in order to maintain its viscosity

in external environments as well process applications.

• Heaters support original equipment manufacturers (OEMs), after-treatment

system integrators, retrofitters of over-the-road, medium and heavy-duty

vehicles, and off-road construction.

• Integrated with application-specific sensors, controllers, control panels and heater

components, it is an ideal solution for processing oil and gas.

Oil & Gas Industry

• Big Tank Heaters

• Ammonia crackers

• Air Duct Heating

Heaters used: Tubular Heater, Immersion Heater

Oil & Gas Industry Focus

Automobile Industry

• Metal melting furnace and Tempering furnace are widely used in the

manufacturing of automobiles. Hardening and tempering are normally used to

improve the wear resistance, strength and toughness of the component. Industrial

heaters have wide application in these furnaces.

• Cartridge, tubular, and silicone laminate heaters for engine manifold and crankcase

preheating, emissions controls component exhaust air heating, and urea tank

heating (selective catalyst reduction); thick film heaters for a variety of preheat

applications and supply lines.

Automobile Industry

• Carburizing Process

• Heat treatment Process

• Hardening

• Nitriding

• Annealing

Heaters used: Bundle Rod Heater, Bobbin Heater

Automobile Industry Focus

THANK YOU!

Tempsens Instruments (I) Pvt. Ltd.B-188 A, Road No. 5, MIA, Madri Udaipur - 313 003 (Rajasthan) INDIAPhone : +91-294-3057700Fax : +91-294-3057750E-mail : info@tempsens.comWebsite : www.tempsens.com

ENGINEERED SOLUTIONS FOR HEATING & SENSING