ABOUT
Air Heater
Introduction
Industrial air heaters are essential heating devices designed with the ability to heat air in a controlled manner for many types of manufacturing, processing, and environmental conditioning applications. These electric heating devices convert electrical energy to thermal energy using resistance heating elements such as nichrome, kanthal, and various other types of heating element. Unlike a fluid-based heating system, industrial air heaters will achieve a faster thermal response time, heat without fluid contamination, and produce remarkable temperature uniformity, which is critical for industries in aerospace, pharmaceutical, plastics processing, and semiconductor. At Tempsens, we offer an extensive range of high temperature air heater solutions for continuous duty cycles, harsh environments, and tight process control limitations. Our electric air heater industrial series incorporate advanced materials, high quality constructions, and comply with international safety standards for dependable performance in temperatures spanning from ambient to 450°C.
About Air Heater
Air heaters use resistance components to transfer heat to air flows through convection and conduction. Designed for pressures reaching 40 bar, it is equipped with stainless steel housings, coils insulated with MgO, precise welds, and thermocouples controlled by PID to maintain stability within ±1 °C, avoiding contamination while providing reliability in harsh industrial processes. These design characteristics represent some of the important considerations before choosing an air heater.
Applications of Industrial Air Heater
- Processing of Plastics: Pre-warming air streams for injection molding, extrusion dies, and thermoforming processes that need temperature uniformity of ±5°C.
- Drying Systems: Industrial dryers for bio-drying pharmaceutical powders, food processing, textile finishing and coating curing equivalent processes.
- Manufacturing of Automotive Products: Heating of paint booths, thermal cure ovens, and climate control for assembly line conditioning.
- Mining/Quarry Operations: : Turbine inlet air heating, combustion air preheating, and freeze protection for critical instrumentation.
Specifications of Industrial Air Heater
| Parameter | Specification Range |
| Sheath Material | SS 304 |
| Wattage | Various Wattage available ranging from 2 kW to 30 kW |
| Sheath Outer Diameter | 63.5 mm, 101.6 mm |
| Watt Density | Up to 77 W/inch2 |
| Glass wool Insulation | Up to 1200°C |
| Wattage tolerance | +5%, -10% |
| Resistance tolerance | -5%, +10% |
| Control Method | On-off, SCR phase-angle, contactor-based staging, PID closed-loop |
| Response Time | <30 seconds to 90% setpoint (forced convection) |
| Efficiency | >95% electrical-to-thermal conversion |
| Protection Rating | IP54, IP65 (dust-tight, water-resistant options) |
| Certifications | CE, UL, CSA, ATEX (explosive atmospheres), IECEx |
| Mounting Options | Flange, duct insertion, inline threaded, custom manifold integration |
| Airflow Capacity | 50 CFM to 5000 CFM depending on configuration |
Benefits of Industrial Air Heaters
- Fast Thermal Response: Electric air heater industrial systems achieve operational temperatures in 3-5x the speed of combustion-based systems, decreasing process time to heat, and increasing output capacity in batch process systems.
- Contaminant Free Heating: Sealed resistance elements don’t introduce combustion by-products, particulates and/or moisture, which is critical to cleanroom, food grade and pharmaceutical applications, which require cleanroom to ISO Class 5-8 environments.
- Accurate Temperature Measurement: Built in sensors and PID Controllers with +1°c setpoint accuracy, prevent thermally degrading materials such as plastic, composite and chemical processing.
- Low Maintenance Needs: Solid state heat elements have no mechanical parts, allowing maintenance to be limited to once a year and creating an overall cost of ownership with less risk of unplanned downtime.
- Scalable Heat Output: Modular design allows parallel or series constructions to handle any process thermal load from 1 KW lab new systems to 500 KW tier 1 new industrial systems.
- Corrosion Resistant: Stainless steel and Incoloy construction is able to withstand aggressive chemical vapors, excessive humidity, and corrosive atmosphere to chemical processing, and water treatment facilities.
Why Choose Tempsens?
- Decades of Thermal Engineering Expertise: Tempsens takes pride in its pension of over 30 years of specialized knowledge in industrial heating applications, serving more than 3500 customers in over 75 countries with proven thermal technologies.
- ISO/IEC 17025:2017 Certified Calibration: Our accredited laboratories produce traceable calibration certificates for all high temperature air heaters to international metrology standards and quality assurance.
- Engineering Capabilities: Our R&D engineers and technical staff support customers by designing application-specific heating devices including explosion proof ATEX/IECEx model, ultra-high temperature unit, and exotic alloy devices that are resistant to corrosion.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Air Heater.
Air heaters are used to heat indoor spaces, industrial processes, and dry materials in settings like homes, factories, and laboratories.
An air heater operates by passing air over electrically charged resistance components that use convection to distribute heat.
Warm air heating provides rapid, uniform heat distribution, high efficiency, and precise temperature control.
