Process Heaters

Electric Process Heaters: Different Types, Uses, Considerations

December 22, 2023 Welcome

Electric process heaters are engineered to elevate your operations, providing reliable and controlled heating solutions. They come in different types, each designed for specific uses, and considering the right one for your application is a must.

What is an Electric Process Heater?

An electric process heater is a specialized device designed to heat various substances in industrial applications using electrical energy. These heaters come in different types, each catering to specific processes and industries.

Types of Industrial Electric Process Heaters

Immersion Heaters

Immersion heaters are submersible in the substance they are heating, making them ideal for liquids like water, oil, or chemicals. They are versatile and efficient, directly transferring heat to the liquid.

Circulation Heaters

Circulation heaters feature a heating element immersed in a vessel, promoting fluid circulation through the heater. This design ensures uniform heating.

Band Heaters

Band heaters are cylindrical devices wrapped around a pipe or vessel, providing direct heating to its surface. They are commonly used for applications requiring a consistent and efficient heat transfer.

Flanged Heaters

Flanged heaters are attached to a tank or vessel using a flange, allowing for easy installation and removal. They are suitable for heating gases and liquids in industrial processes.

Process Air Heaters

These heaters are specifically designed for heating air in industrial processes. They find applications in drying, curing, or any process requiring heated air.

Common Uses of Industrial Electric Process Heaters

• Oil and Gas Industry: Immersion and circulation heaters are widely used for heating oil and gas in storage tanks, ensuring optimal viscosity for efficient transportation.
• Chemical Processing: Flanged heaters are vital in chemical processing, providing precise and controlled heating for chemical reactions and processes.
• Water Heating: Immersion heaters are commonly employed for heating water in industrial settings, catering to applications such as cleaning, sterilization, and manufacturing processes.
• Food and Beverage Industry: Process air heaters find applications in the food and beverage industry for drying, baking, and other heat-dependent processes.
• Plastic and Rubber Manufacturing: Band heaters are essential in plastic and rubber processing, ensuring the material reaches the optimal temperature for molding and shaping.
• Nitrogen and Thermal Fluid Heating: Flanged heaters are employed for heating nitrogen and thermal fluids in various industrial applications, ensuring precise temperature control for specialized processes.
• Tank Temperature Regulation: Circulation heaters can regulate tank temperature, maintaining optimal temperatures for liquids stored in industrial tanks.
• Molding & Extrusion: Industrial electric process heaters are used in molding and extrusion processes, providing consistent heating for tasks like plastic molding and extruded material shaping.
• Asphalt Production: Electric process heaters are often used in asphalt production, contributing to the heating and maintenance of optimal viscosity in asphalt mixtures.

5 Key Considerations for Choosing Electric Process Heaters

Choosing the right industrial electric process heater involves understanding the unique requirements of your application. The considerations below are a good starting point.

1. Temperature Range

Consider the temperature requirements of your process. Different heaters are designed for specific temperature ranges, so choosing the right one ensures efficient operation.

2. Heating Element Material

The material of the heating element is crucial. Common materials include stainless steel, titanium, and alloys. The choice depends on the compatibility with the substance being heated.

3. Watt Density

Watt density refers to the amount of power per unit area. Selecting a heater with an appropriate watt density is important to prevent overheating and ensure longevity.

4. Installation and Maintenance

Consider the ease of installation and maintenance. Some heaters, like immersion heaters, are easy to install and maintain, while others may require more intricate procedures.

5. Safety Features

Look for heaters with built-in safety features, such as temperature controls and automatic shut-off mechanisms. These features enhance operational safety and protect equipment.

Learn More About Electric Process Heater Safety

Discover the Industrial Electric Process Heaters at IFS/DXP

Ready to elevate your operations with cutting-edge heating solutions? Whether you’re in the oil and gas sector, chemical processing, or any industrial application, our heaters can be designed to meet the specific needs of your process.

To guarantee exceptional quality, we can produce our electric process heaters to not only meet, but surpass a range of industry standards. All our industrial heaters meet the standards of OSHA, ASME, ANSI, NACE, NFPA, SSPC, and AWS. Discover the difference at IFS/DXP.

Questions? For more information on our electric process heating solutions, contact the experts at IFS/DXP today.