Understanding Electric Process Heaters
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# Understanding Electric Process Heaters
Published by Nicole Laney on March 16, 2020, 11:29 PM | No Comments Yet
Electric process heaters leverage electrical energy to elevate the temperature of liquids and gases within various process systems. Depending on the application, these heaters can be utilized for both direct and indirect heating methods, making them incredibly versatile tools in industrial settings. For those looking to invest in the right electric heater for their needs, here's a simplified overview of electric process heater systems and their typical applications.
## Types of Electric Process Heaters
Electric process heaters come in two primary forms: immersion heaters and circulation heaters. Each type excels in specific scenarios.
### Immersion Heaters
Immersion heaters achieve heating by making direct contact with the target substance. As the name suggests, tubular electric components are submerged directly into the process fluid. A significant advantage of this type of heater is its near-perfect efficiency—almost all the electricity produced is converted into heat. These heating elements are generally crafted from materials known for their corrosion resistance and heat tolerance, such as Alloy 800, ensuring prolonged operational lifespan and optimal performance.
### Circulation Heaters
Circulation heaters warm fluids as they move through an enclosed system, passing over the heating elements. Often, the heater is integrated into the tubes or pipes where the gas or liquid material flows. Circulation heaters are highly specialized pieces of equipment, frequently customized to meet the unique demands of each application.
### Electric Thermal Fluid Systems
Thermal fluid heating represents a form of indirect heating where a liquid phase heat transfer medium is heated and circulated through a closed-loop system to one or more heat users. Common heat transfer mediums include thermal oil, glycol, and water. An electric circulation heater can serve as a heat source for these closed-loop thermal fluid systems.
## Common Applications
Temperature control is essential across a broad spectrum of processes, from melting materials into formable resins to superheating gases and initiating chemical reactions. Here's a brief rundown of some common applications where electric process heaters are employed.
### Jacketed Reactor Heating & Cooling
Jacketed reactors are typically kept at processing temperatures up to 800°F and must maintain a stable temperature to function correctly. These reactors feature a secondary protective layer, or jacket, around the reactor vessel. Steam or thermal fluid circulates through the jacket to regulate the reactor’s temperature.
### Molding & Extrusion
Molding and extrusion processes demand precise temperature control. Not only does the resin need to be kept at the correct temperature for ideal part formation, but the temperature of the extruder or mold forming the parts must also be controlled. Closed-loop thermal fluid systems are used to monitor and adjust the system temperature accordingly. While steam heating systems are also utilized in molding and extrusion applications, they are less safe than thermal fluid systems due to the high pressures involved in effective steam heating.
### Molten Salts
Molten salts, or salt melts, encompass materials made of fluoride, chloride, or nitrate compounds used for thermal energy storage and high-temperature industrial processes. Molten salts are prized for their ability to remain in liquid form at temperatures exceeding 1000°F without increasing vapor pressure. They are commonly used in high-energy batteries for solar arrays and in high-temperature metal treatments.
### Other Applications
In addition to the aforementioned uses, electric process heaters are also widely applied in:
- 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
When selecting the most suitable electric process heater for your application, it's crucial to take into account the requirements and constraints of your equipment. Be sure to evaluate the following critical factors:
- **Flow Rate**: Assess the volume or flow rate of the fluid to be heated to determine the necessary heater capacity.
- **Temperature Requirements**: The higher the temperature increase, the greater the power output required.
- **Thermal Properties**: The fluid's thermal and physical properties help determine the appropriate watt density.
- **Physical Constraints**: Space and other physical limitations must be considered when deciding the heater's size and placement.
## Video Overview
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## Sigma Thermal Solutions
Sigma Thermal Solutions provides the highest-quality thermal immersion and circulation electric heaters on the market. Our watt-density range spans from 2 to 60 watts per square inch, and each system is meticulously designed for versatility to accommodate a wide array of system requirements. To guarantee top-notch quality, our electric process heaters can be manufactured to comply with and exceed numerous industry standards, including ASME Section VIII Div I, CRN, and PED.
For more details about our exceptional thermal solutions, contact the experts at Sigma Thermal today or request a quote.
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