ABOUT
Introduction
Bobbin heaters are highly effective heating devices designed for use in industrial applications across the UAE and Gulf region, utilizing resistance wire wrapped around ceramic insulator materials. A ceramic bobbin heater consists of ceramic blocks with accompanying nichrome or ferritic alloy heating elements that produce excellent thermal distribution and long-term durability suitable for the region's harsh operating conditions. Tempsens bobbin heaters can accommodate specific voltage and power requirements up to 12kW and are produced in a variety of diameters and lengths. Bobbin heater element have the capability to provide direct or indirect heat to liquids, semi-solids, gases, etc., which makes them essential for process heating applications across petrochemical, chemical manufacturing, oil refining, and industrial processing operations throughout the Gulf. Bobbin heaters operate at temperatures from ambient up to a maximum of 600° Celsius, and watt densities between 1 W/cm² and 10 W/cm²; thus providing the most energy-efficient performance while generating 100% of the heating efficiency of the heater within the heated medium. For industrial use, Tempsens Instruments produces bobbin warmers that are both encased and unsheathed, and they satisfy ISO 9001-2015 certification requirements.
About Bobbin Heaters
Advantages of Bobbin Heaters
- Energy efficiency: Energy savings are incredible because 100% of the heat generated goes into heating the solution with zero heat loss and significantly reduced operational cost, which is a critical advantage in the Gulf region's industrial operations.
- Wide Temperature Range: The bobbin heater can function efficiently upto 600°C, making them suitable for use in various applications in heating the furnace throughout the UAE and Gulf industries.
- Simple Installation: The simplicity of mounting provides for easy, cost-effective installation and allows for minimal downtime of the existing system, making them essential for continuous operations in critical industrial facilities.
- Easy Maintenance: The bobbin heater's modularity allows for ease of repair/replacement without major disruption to the overall system or requiring emptying the process tank.
- Versatile Applications: Water/chemical/oil/wax/fat/bitumen heating services that do not produce emissions; various applications within all industries aligning with regional environmental standards.
- Customisable Options: Long lengths, high voltages, and high wattage are available for max operator flexibility with customer process specifications to match local industrial specifications.
- Optimised Heat Transfer: Elements partially exposed to the air or immersed in radiant tubes produce large heating surfaces for the best thermal transfer.
- Durable Construction: Superior-quality refractory insulation and quality resistance wire create a longer life in the harsh conditions of the Gulf.
Bobbin Heater Applications
- Indirect heating of liquids and gases in tanks to protect them from contamination and maintaining process integrity.
- Precised controlled heating of chemical solutions requiring exact temperature control while remaining free from contamination during processing.
- Heating viscous materials like bitumen, fat, oil, and wax effectively to facilitate processing.
- Bobbin heater technology was used in low-to-medium-temperature furnaces to treat industrial heat at temperatures as high as 600 degrees Celsius.
- Reliable and reasonably priced electric water heating systems for industrial application.
- Oil and petroleum industries use bobbin heater technology to heat oils/petroleum products for viscosity reduction/processing needs, which is a core application in the UAE and Gulf region's oil and gas sector.
Refer to our guide for additional information about Bobbin Heaters - Understanding Bobbin Immersion Heater: A Comprehensive Guide..
Specification for Bobbin Heaters
| Temperature Range | Up to 600°C |
| Heating element | Ferritic alloys wire mar FeCrAl and non-ferritic wire NiCr 80-20, NiCr 70-30 |
| Bobbin size | Standard: 25,30,36,42,45,57,93 other customize size available |
| Watt density | 1 to 10 W/cm² |
| Power Generation | Up to 12kW |
| Heater Parameters | Customized – power rating, voltage, resistance, length, diameter, and other dimensions |
| Radiant Tube/Immersion Tube | Stainless Steel SS Grade, Incolay, Cast Alloys |
| Thickness of Tube | 1.5 to 3mm |
| Length of Tube | 300 to 2800mm customize |
| Terminal Box | MS, IP54 standard, IP66 waterproof terminal box |
| Control | Thermocouple, RTD, Thermostat for temperature control |
Construction of Bobbin Heaters
- Ceramic Insulator Assembly: The ceramic blocks are refractory ceramic blocks assembled to the length specified, providing excellent electrical insulation and thermal resistance suitable for extreme industrial conditions.
- Resistance Wire Element: The nichrome heating element is inserted into the ceramic blocks and wound evenly to provide uniform heat distribution and maximum service life across continuous operations.
- Nickel-plated mild steel, Inconel alloys, and corrosion-resistant stainless steel grades are the available sheath material alternatives.
- Mounting Configuration: Bobbin heaters are typically made to be mounted horizontally; for applications that call for vertical mounting, other mounting arrangements are offered.
- Terminal Block Design: The refractory insulator supports the resistance wire and connects to robust terminal blocks at one end, providing a dependable electrical connection.
- Thermowell Provision: Thermowell provision will be available as the optional method for temperature sensing and process control.
- Sheathed Version and Unsheathed Version: Both sheathed and unsheathed versions will be available based on specific applications and heat transfer requirements and heat transfer performance needs.
Why Tempsens Is the Leading Manufacturer Of Bobbin Heaters
- Cutting-edge facilities at our manufacturing facility, we use advanced methods to manufacture bobbin heaters. Our precision engineering guarantees consistently high-quality bobbin heater products.
- Custom designs for each application and products that are tailored to the rated capacity (power), voltage, resistance, length, and diameter of the necessary application.
- For over 30 years, we have designed and manufactured heating elements used in many thermal applications.
- We provide technical assistance for the selection, installation, and ongoing operation of your heaters.
- Globally known as a leader in bobbin heater manufacturer, Tempsens is at the forefront of providing energy-efficient heating solutions delivering energy-efficient heating solutions specifically engineered for Gulf region industrial operations.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Bobbin Heaters.
Bobbin heaters are an excellent fit for use within petrochemical plants, oil refineries, chemical processing facilities, bitumen heating systems and furnace operations where high temperature applications exist (up to 600 °C), and can be configured based upon specific kerf requirements.
Yes, ceramic bobbin heaters are rated for continuous use up to 600 °C when using a combination of hightemperature ceramic insulation and ferritic/non-ferritic heating elements provide an inherently stable and safe means during longextented operation.
Bobbin heaters use ceramic insulators made from high-temperature refractory materials, which have excellent thermal resistance and electrical insulation properties to withstand the extreme industrial conditions typically found in the UAE.
