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Process Heaters in UAE & Other Gulf Countries
Introduction
Tempsens Instruments is an internationally recognized manufacturer of cutting-edge process heating solutions for use in various critical industries, across UAE & Gulf regions including Oil & Gas, Petrochemicals, Refineries, Power Generation and Chemical Processing. We offer a full portfolio of electric process heaters, including immersion heaters, circulating heaters, duct type heaters, tubular heaters, finned tubular heaters and industrial radiate heaters. These products are developed for Maximum Efficiency/ Reliability.
Tempsens offers custom process heater solutions that meet the most demanding international standards through both national and international agencies' certifications. Our industrial process heating solutions utilize advanced thyristor controls for the most precise Temperature Control and almost complete 100% energy efficiency and long product life in critical Process Heating Conditions to 1600°C, which makes them ideal for the extreme operating environments found in Gulf region industries.
Over the Side Immersion Heater
The application for over the side heaters varies greatly from simply water heating or freeze protection to some more complex setup such as viscosity control for oil or wax products that require a steady flow.
Duct Heater in UAE
Duct heaters are heat transferring devices which are an assembly of heating elements mounted in a frame or duct.
Circulation Heater
Some of the typical applications of circulation heaters include heating of process water, soap and detergent solutions, Boiler and water heaters etc.
Screw Plug Heater
Screw plug heaters are widely used for various purposes in many industries including the food and beverage industry.
Finned Tubular Heater
Finned Tubular Heaters find applications in Convective Air & Gas Heating Dehumidification Curing Ovens and Plastic Dryers Organic Resins & Paint Curing etc.
Infrared Radiant Heater
Infrared radiant heaters are electric heaters specifically designed to emit infrared heat radiation, where heating by other means is not ideal.
About Process Heaters
Key Features of Process Heaters
- Custom-designed heater coils made from SS304, SS316, SS321, Alloy 600, 625, 800, 825, Titanium, and Hastelloy grades.
- Pressure vessels that meet international pressure equipment standards are certified to ASME Section VIII Division 1 & 2 with "U" stamp approval.
- ATEX Ex'd flame-proof certified for hazardous Zone 1 installations (IIC, T6, IP66) meeting UAE and Gulf region safety requirements.
- Heaters can operate in the temperature range of -40°C to 1600°C for diverse industrial heating applications.
- Heater power ratings are available from 1 kW to 10000 kW and voltage options are available up to 690V.
- Multiple connection methods including direct seal welded, bite coupling, and standpipe connection methods can be used for assembling elements into flanges.
- Mineral-insulated tubular heating elements are filled with high-purity MgO for excellent heat transfer capabilities.
- Integrated thyristor (SCR) control panels with multi-bank configuration provide precise power control.
- Rod type and segmental baffle cage assemblies provide even heat distribution.
- All models are compact in size with maximum element length up to 10,500 mm.
- Multiple heating configurations: direct immersion, indirect immersion, L-shaped, and duct-mounted designs.
- Infrared radiant heaters and ceramic heating solutions for specialized applications.
- Over the side immersion heaters and screw plug heaters are customized for specialized tank heating applications.
- ATEX Ex'd (Flame proof) / PED/ASME U stamp / any other based on regional requirements.
Benefits of using process heaters in the UAE and surrounding Gulf Countries
- No emissions and safe for the environment operation; therefore ideal to replace fossil fuel heating systems and meet sustainability goals of the UAE and Gulf Countries.
- Tempsens electric process heaters respond nearly instantaneously to required temperature changes with precision +/-1°C, allowing for excellent precision and management of the manufacturing or production process.
- The use of electric process heaters eliminates combustion hazards; consequently, Tempsens electric process heater products are an excellent choice for installations in hazardous locations.
- Reduced maintenance needs avoid problems with fouling/scaling normally seen with established forms of heating systems.
- A modular design allows for easy replacement or upgradation of parts of the unit without requiring complete system shutdown.
- Compared to a conventional shell and tube heat exchanger, a space-efficient configuration requires significantly less space.
- Against overheat and earth leak safe operation is an extra safety feature that protects both equipment and personnel.
- The reduction in energy costs and decrease in downtime results in lower overall costs of owning the equipment.
- The consistent pattern of heat evenly distributes heat across all of the process fluids being heated.
- The unit has been engineered to meet ASME standards for high pressure and aggressive (corrosive) environments.
- Remote monitoring and control are available using integrated PLC systems.
- Installation/Commissioning takes place quickly with little civil work required.
- Scalable Power Capacity via Multi-Stage heating configurations.
- Thermal Shock Protection will extend heating element Life.
- Manufactured in accordance with international safety and quality standards, ensuring consistent long-term performance.
Process Heater Applications in the UAE and Other Gulf Countries
- Continuous Catalytic Regeneration (CCR) heaters are used in the production of aromatic compounds and need to operate in the temperature range of 495°C to 535°C.
- Isomerization process heaters can increase the octane number of gasoline at refineries.
- In addition, Fuel Gas Preheaters and Fuel Gas Superheaters are used in conjunction with Gas Turbines.
- In addition, TEG (Triethylene Glycol) Reboilers and TEG Regeneration Circulation Heaters are utilized in the dehydration of natural gas.
- Air Separation Unit (ASU) Molecular Sieve Regenerator Heaters are also available.
- In Petro-Chemical Complexes, the following are examples of SRU Heater Applications.
- Catalyst Reduction and Calcination- Radiant Process Heating.
- Flaring KO drums- Flaring KO drum heaters can be configured using both immersion heaters and circulation heaters.
- Steam Generation/ SuperHeating Systems in Power Plants.
- Crude Oil/Heavy Oil heating in storage tanks and pipelines.
- Amine Reboilers for Gas Treating Applications.
- Hot Oil Circulation Systems wrapped around Process Technology Heaters.
- Freeze protection and viscosity control by utilizing a heat tracing system.
- Air Handling Unit Heat Tracing with ESP Hopper Heaters and Duct Heaters.
- Heating of Reactors, Start-Up Reactors, and Catalyst Circulation Heaters.
- Cryogenic Thawing and Heating
- Heating Consoles for Lube Oil for Turbines, Compressors, and Pumps.
- LNG & Industrial Gas Vaporizer Heaters.
- Heat Trace Applications for Marine, Nuclear Power Industry, Bio-Tech/Pharma, R&D.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Process Heaters.
A Tempsens process heater consists of tubular heating elements, heater flange, terminal enclosure, baffle cage assembly, temperature sensors, ASME-certified pressure vessel, and thyristor control panel for power regulation and safety monitoring.
Routine maintenance activities assure you of optimal operation and maximum longevity of your process heater(s). Maintenance should include regularly inspecting the resistance and insulation in the heating element(s), as well as the terminal connection(s); calibrating temperature sensor equipment; cleaning up control panels; and doing scheduled annual preventive maintenance (PM) as per ASME and Hazardous Area Certification Standards.
Selection depends on process fluid properties, heat duty (kW), operating temperature/pressure, material compatibility, electrical supply, hazardous area classification, and regional codes. Tempsens provides customized electric process heater solutions including immersion heaters, duct heaters, circulation heaters, and industrial radiant heaters designed specifically for UAE and Gulf applications.
Common sheath materials include 304 and 316 stainless steel for corrosion resistance, INCOLOY for severe corrosive environments, copper for clean water applications, and titanium for highly corrosive chemical solutions. The heating element of the heat exchangers has nichrome (80/20) coils that utilize magnesium oxide insulation.
Over-the-side immersion heaters attach on top of tanks without requiring threaded openings, while screw plug heaters need threaded (NPT) fittings on tank walls. Over-the-side designs provide more heated length and coverage area, making them suitable for larger tanks.
Establish a schedule to routinely check for scale buildup on heating elements; ensure that the heating element is submerged sufficiently in the liquid; visually verify electrical connections; test the electrical insulation; and clean the outer surface of the heater sheath regularly to optimize heat transfer capability.
This unit is well suited for applications involving open-top tanks, vessels that have no access from the side walls, retrofitting existing systems, large container size, and processing systems operating at atmospheric pressure, storing petroleum products, handling chemicals and heating viscous fluids where draining the tank is not practical.
