Process Heaters

In discussing capacity (0.5KW to 2000KW) and temperature ranges (-40C and <= +600C), plus your application (drying, HVAC, etc.) & environmental conditions (coastal, desert, etc.) with our technical experts. Tempsens will help you identify the correct options for you in regards to elements, materials, and control systems best suited for a project in your part of the Gulf.

Tempsens employs a thorough quality assurance program throughout each step of manufacturing. Every electric duct heater manufactured by Tempsens undergoes rigorous testing to guarantee their base product is made with the minimum standards of strength, temperature regulation, and electrical safety. We use high-quality materials (stainless steel or alloy 800 sheath) with built-in protections such as skin temperature controls on electric elements, earth fault protection, and over current protection to give you confidence in the reliability of your electric duct heater.

The immersion heater attaches to the tank or vessel wall through a threaded fitting. Heating occurs through electric resistance coils inside the sheath transferring heat energy to the fluid surrounding the immersion heater. The result is quick and efficient heating of the fluid.

A screw plug immersion heater can be used to heat any type of fluid including water/oil and solvent-based fluids as well as gas heating systems, however you will need to ensure you have the right sheath material and watt density selected for your specific medium to use it correctly.

A screw plug immersion heater installs using a threaded plug and is primarily designed to heat smaller tanks. Flanged heaters install using a bolted flange and are most commonly used with larger tanks while inline heaters are integrated directly into pipelines so they can heat continuously as fluid flows through them.

Industrial radiant heaters from Tempsens are built to run for long periods of time. They have been designed using thermocouples and thermostats, which allow them to maintain a safe and steady temperature when used for long duration or overnight.

Infrared radiant heater is dissimilar to convection (fan) heating systems in that it does not heat the surrounding air, making them much more efficient. High intensity infrared heaters systems will perform very well in large, open and/or ventilated industrial environments, where convection systems will lose a lot of heat.

Finned tubular heater elements have tubular heating elements with metallic fins that are either brazed, crimped or welded onto the heating sheath that provide increased surface area for greater efficiency in transferring heat from the heating element onto the surrounding area for heating air or gas.

Open coil heaters operate by inserting a resistance wire directly into air to create radiation, while finned tubular heaters use a magnesium oxide filled heating sheath, which is then provided with fins to allow more efficient convective heating of the surrounding air and for protection of the wire.

Circulation heaters are electric heat generating devices that operate by using a continuous flow or multiple cycle of the process fluid moving through a heating element-filled pressurized tank. The circulation heater provides an efficient way to raise the temperature of the process fluid rapidly for the purpose of being utilized in many different industrial applications.

In fact, circulation heaters can be used in hot climates such as those in Dubai and Abu Dhabi because they have been properly insulated and have built-in cooling features to enable them to operate continuously in high ambient temperature situations.

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.