Process Heaters for Industrial and Commercial Applications

Most people consider Thomas Edison as the inventor of the electric heater but there is an ambiguity to it. Some people also believe that Alexander Graham Bell was the man behind the idea of electric heating. The basic electric heater has been altered very modestly as it is still used the same way. The electric heater converts electric energy into heat. Electric currents flow through the metal component which radiates heat in the surrounding area. In 1905, Albert Marsh discovered chrome. It was the first metallic amalgamation to serve as a heating element and was made of four parts nickel and one part chromium. This new alloy, called Nichrome was 300 times stronger than other heat elements founded so far. It created and dispersed heat more efficiently than the light bulbs in Bell’s heater. After Marsh’s invention, electric heating began to overtake the sales of fuel-based heating sources. For this reason, Marsh is called the “father of the electrical heating industry”. A patent on the development was acquired in 1906. Selecting the right process heater for your application is critical to ensure you get the consistent heating your application requires.

Electric process heaters, popularly known as tubular heaters or electric heat exchangers are very similar to shell n tube heat exchangers, except the fact that heating energy is provided by the electric power flowing inside the tubes or heating elements. Multiple numbers of mineral-filled sheathed heating elements (tubular heating elements) will be installed into Baffle plate assembly and inserted inside the pressure vessel. Once energized, the electric energy converted into heat and transferred to the fluid which will flow through the vessel from the inlet nozzle to outlet. Pyrosales work with our supplier to design a complete thermal process and strength of the vessel using proven Software. For accurate control and safety, each heater will be controlled by a dedicated Thyrister control Panel. Our supplier also has expertise in designing and supplying such panels as a part of the complete Process heating system.

Band heaters are an economical method for heating where heating contents via immersion is not an option. The band heaters are constructed with the highest grade mica insulation which not only provides excellent electrical insulation but is also resistant to moisture. Nickel/chromium resistance wire is wound evenly in the heater to ensure consistent heat distribution and accuracy. Commonly used in the plastic industry.

Ceramic band heaters provide the ability to heat cylindrical items. Band heaters are durable and are medium-high temperature heaters. The maximum working temperature is 648°C. Ceramic band heaters are energy efficient and offer an optional in-built ceramic fiber jacket to further the energy savings. Fully flexible, the ceramic band heaters can accommodate holes and cut-outs and are available with different termination styles.

Coil heaters are also referred to as high-performance tubular heaters, or cable heaters. The construction method consists of compacted MgO, high-temperature resistance wire and chrome-nickel steel tube. Coil heaters can be constructed with or without built-in thermocouples. The applications for coil heaters include Hot runner distribution plates, Tube extrusion, Sealing and cutting bars and jaws for packing machines, Pipe forming, Small manifold heating, Hot metal forming dies and punches, Semiconductor manufacturing, Hot-runner nozzles and brushings, Water processing.

Cartridge heaters are available in a variety of diameters and configurations and have high-temperature lead wires that can handle temperature up to 450°C. These high-performance heaters often outperform other heaters due to their robust design. They have specifically designed cores and are manufactured under carefully controlled production processes.

The cartridge heaters have a ceramic cap that can withstand high vibration which makes it suitable for a large range of applications where vibration is an issue. Nickel-chromium resistance wire provides a longer heater life which is evenly wound for even distribution of heat. Available in either 304, 316 SS sheath, or Incoloy.

An air heater is a great solution for plastic welding, laminating, drying, heat staking, heat sealing, and other applications where air must be heated up to 500°C. They are constructed from an open coil of high-temperature resistance wire which is electronically isolated in a stainless steel sheath. Air passes over the resistance wire which allows maximum heat transfer.

The silicone rubber heaters is the flexibility. They can be mounted either flat or on curved surfaces and their versatile design allows special heat profiles where higher or lower heat concentration can be provided. Silicone rubber heaters provide outstanding performance in applications up to 250°C and are unaffected by flexing, vibration, or ongoing mechanical shock.

Pyrosales supply a range of process heating elements suitable for many industrial and commercial applications. Our supplier’s range includes cartridge elements, band heaters, coil heaters, strip heaters, flexible tubular heaters, and box heaters. We can also help with selecting the right heating elements and calculating the wattage for your application. We also have solid-state relays and controllers to help complete your project.