The document provides a comprehensive overview of industrial heaters, detailing their principles, types, materials, and applications across various industries. It explains electric resistance heating, circuit configurations, and specific heater types such as component heaters, cartridge heaters, and immersion heaters, alongside their unique benefits and suitability for different processes. The document also highlights specific applications in industries like steel, aluminum, chemicals, oil and gas, and automobiles, underscoring the need for innovative heating technologies.

1. Industrial Heaters

2. 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.

3. • Mode of heat transfer is conduction, convection or radiation.
• 100% efficient
Contd.

4. Ohm’s Law

5. 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

6. 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.

7. Heating Element Material
Different materials depending upon the
temperature, medium and application.
• Nichrome alloy
• Ferritic alloys
• MoSi2 alloys
• SiC alloys

8. Nichrome Alloy

9. Ferritic Alloy

10. 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)

11. 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.

12. 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.

13. 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.

14. 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.

15. 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.

16. Strip Heater
• Outstanding industrial heating element that
can meet any budget.
• Durable, versatile and easy to control
• Uniform heat distribution
• Corrosion and vibration resistant

17. 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.

18. 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

19. 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

20. 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

21. 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

22. Tubular Heater
• Versatile, rugged and dependable
• Factory-configured to suit a variety of
industrial heating applications
• Regarded as the foundation of all
heating elements

23. 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

24. 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.

25. 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.

26. 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.

27. Circulation Heater

28. 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

29. 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.

30. 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.

31. 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

32. 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.

33. Edge wound Heater
• Used where utmost power is
required in limited space.
• Easy to install and replace.
• Horizontal or vertical mounting.

34. 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.

35. 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 .

36. Steel Industry Focus
• Galvanizing & Galvalume Plant:
Bundle Rod Heater & Edge Wound
Heater
• Oxygen Plant: Tubular Immersion
Heater & Air Duct Heater

37. Power Generation
• Flanged Immersion heaters
are used for process water
applications
• Duct heaters are used for
heating air for combustion

38. 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

39. 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

40. 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.

41. Chemical Industry

42. 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.

43. Oil & Gas Industry

44. • Big Tank Heaters
• Ammonia crackers
• Air Duct Heating
Heaters used: Tubular Heater, Immersion Heater
Oil & Gas Industry Focus

45. 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.

46. Automobile Industry

47. • Carburizing Process
• Heat treatment Process
• Hardening
• Nitriding
• Annealing
Heaters used: Bundle Rod Heater, Bobbin Heater
Automobile Industry Focus

48. THANK YOU!
Tempsens Instruments (I) Pvt. Ltd.
B-188 A, Road No. 5, MIA, Madri
Udaipur - 313 003 (Rajasthan) INDIA
Phone : +91-294-3057700
Fax : +91-294-3057750
E-mail : info@tempsens.com
Website : www.tempsens.com
ENGINEERED SOLUTIONS FOR HEATING & SENSING