Understanding Electric Process Heaters
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# Understanding Electric Process Heaters
Published by Nicole Laney on March 16, 2020, at 11:29 PM | Leave a Comment
Electric process heaters are essential tools in many industries, using electricity to raise the temperature of liquids and gases within various systems. Whether you're dealing with direct or indirect heating, electric heaters provide a flexible solution that adapts to your specific needs. For those looking to invest in the right electric heater, here's a concise overview of the different types and common applications.
## Types of Electric Process Heaters
Electric process heaters come in two main categories: immersion heaters and circulation heaters. Both types serve unique purposes and offer distinct benefits depending on the application.
### Immersion Heaters
Immersion heaters work by directly contacting the substance being heated. These heaters are named for their design, where tubular electric elements are submerged into the process fluid. This method ensures nearly 100% efficiency, as most of the electricity consumed is converted directly into heat. To ensure durability, heating elements are usually made from corrosion-resistant materials like Alloy 800, which guarantees long-lasting performance even under harsh conditions.
*An example of an immersion heater designed for maximum efficiency and longevity.*
### Circulation Heaters
Circulation heaters, on the other hand, heat fluids as they pass through a closed system. The heater is often integrated into the pipes or tubes through which the gas or liquid flows. Unlike immersion heaters, circulation heaters are highly specialized and often require customization to fit specific applications.
*This image shows how circulation heaters are seamlessly integrated into existing systems to maintain precise temperatures.*
### Electric Thermal Fluid Systems
Thermal fluid systems represent another indirect heating method. These systems circulate a heat transfer medium—such as thermal oil, glycol, or water—through a closed-loop system to transfer heat to various components within the process. Electric circulation heaters are commonly used to generate the necessary heat for these systems.
## Common Applications
Effective temperature control is crucial across a broad spectrum of industries, from managing chemical reactions to ensuring the correct viscosity of materials. Here’s a brief overview of some of the most common applications for electric process heaters.
### Jacketed Reactor Heating & Cooling
Jacketed reactors are frequently maintained at temperatures up to 800°F, requiring precise temperature management. These reactors feature an additional layer called a "jacket," which circulates steam or thermal fluid to regulate internal temperatures. Proper temperature control ensures the reactor operates efficiently and safely.
*A jacketed reactor setup demonstrating how thermal fluid maintains consistent temperature levels.*
### Molding & Extrusion
Both molding and extrusion processes demand tight temperature control. Not only does the resin need to be at the right temperature for forming parts, but the molds and extruders themselves must also remain at optimal temperatures. Closed-loop thermal fluid systems play a key role in monitoring and adjusting temperatures dynamically.
Although steam heating systems are also used, they are less favored than thermal fluid systems because they require higher pressures to function effectively, posing additional safety risks.
### Molten Salts
Molten salts, or salt melts, are compounds made from fluoride, chloride, or nitrate that are used for thermal energy storage and high-temperature industrial processes. These materials remain liquid at temperatures exceeding 1000°F without increasing vapor pressure, making them ideal for use in solar arrays and high-temperature metal treatments.
*Molten salts are widely used in advanced industrial applications due to their unique thermal properties.*
### Other Applications
Electric process heaters also play a vital role in a variety of other industries, including:
- Asphalt production
- 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
## Key Considerations When Choosing an Electric Process Heater
Selecting the right electric process heater requires careful consideration of your system's unique needs. Here are some important factors to keep in mind:
- **Fluid Flow Rate:** Determine the volume or flow rate of the fluid to be heated to establish the heater’s required capacity.
- **Process Temperature:** The greater the temperature increase, the more power output the heater will need.
- **Thermal Properties:** The fluid’s thermal and physical properties help dictate the appropriate watt density.
- **Footprint:** Physical space and other limitations should be factored into the heater’s size and placement.
## Sigma Thermal Solutions
Sigma Thermal Solutions provides top-tier thermal immersion and circulation electric heaters. With a watt-density range of 2–60 watts per square inch, our systems are custom-engineered for versatility to meet diverse requirements. Each heater is built to exceed industry standards such as ASME Section VIII Div I, CRN, and PED.
For more information about our cutting-edge thermal solutions, contact the experts at Sigma Thermal today or request a quote.
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