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Introduction
In industrial thermal processing there can be no compromise, there must be precision, reliability, and repeatability in results. Tempsens products deliver exactly what today’s industries demand no matter the challenge. For high requirement process situations like annealing, galvanizing, heat treatment, and ultra high temperature process situations, our heaters can produce temperatures of up to 1100°C.
Every Tempsens furnace heating system is the result of exceptional engineering know-how and expertise in metallurgy. Thermal furnace heating systems provide reliable and efficient heat transfer no matter if you are running a continuous production process, or processing specialized thermal cycles, we will maximize service life of the furnace while providing reliability of performance in your specialized process.
Bundle Rod Heater
Bundle rod heater is used with combination of radiant tubes which delivers high power, avoid refractory corrosion and avoid the gas impurity in process materials.
Edge Wound Heater
A nickel-chromium alloy (80/20 or 70/20) forms the basis of these heaters
Bobbin Heaters
Panel Hopper Heater / Hopper Heater
Hopper heater is self-contained heaters whose design provides heat outputs up to 3 watts/squire inch, with a maximum circuit size of 4.5 KW depending on the application, the design of the hopper heater is such that it distributes heat over its entire surface.
Open Coil and Sinusoidal Strip Heaters
Indirect solution to decrease watt density requirements and prevent heat sensitive materials from breaking down.
About Furnace Heaters
Key Features
Advanced Heating Element Technology
We believe the core of a great furnace heater is in its elements. That’s why Tempsens uses only premium materials: NiCr 80:20, ferritic alloys (FeCrAl), and powder metallurgical heating elements for applications up to 1100°C. For extreme needs, our silicon carbide and molybdenum disilicide elements can safely operate up to 1800°C.
Superior Material Construction
When you’re facing high temperatures or corrosive conditions, the right alloy makes all the difference. We use radiant tubes made from HU, Alloy-600, SS310, Inconel 600/800, and specialized cast alloys—each selected to ensure longevity and top performance, even in punishing industrial settings.
Versatile Design Configurations
No two furnaces are exactly alike, so we offer a wide range of heater designs to fit every need:
- Bundle Rod Heaters: For uniform heat distribution in annealing and spheroidizing furnaces.
- Edge Wound Heaters: Tailored for heat treatment and galvanizing.
- Open Coil Heating Elements: Ideal for ammonia crackers and hearth furnaces.
- Ceramic Bobbin Heaters: Perfect for indirect heating up to 600°C.
- Silicon Carbide & MoSi Elements: Engineered for the most demanding, ultra-high temperature applications.
Precision Engineering
Tempsens electric furnace heater is built with strict dimensional tolerances and exact thermal properties. Our radiant tube systems can be customized in both diameter and length, giving you a perfect fit for your unique furnace geometry.
Robust Support Systems
The performance of a heater depends on reliable support. That’s why we manufacture complete hanger systems from NiCr 80:20 materials, ensuring your heating elements are positioned for optimal efficiency and easy maintenance. Our accessory range is designed to make installation and upkeep as smooth as possible.
Applications of Furnace Heaters
Heat Treatment Operations
In processes like annealing or spheroidizing, the smallest fluctuation in temperature can mean the difference between success and scrap. Our heaters deliver uniform heat and precise control for metallurgical operations where quality can’t be left to chance.
Industrial Melting and Holding
Aluminum holding and melting furnaces demand elements that last in tough molten metal environments. Our high-temperature solutions ensure rapid heat transfer and long operating life, shift after shift.
Galvanizing Processes
Continuous galvanizing lines rely on edge wound heaters to maintain coating quality and process efficiency. Tempsens designs every system to guarantee consistent results, batch after batch.
Glass Manufacturing
Ultra-high temperatures are the norm in glass feeder and float glass lines. Our silicon carbide and molybdenum disilicide elements help maintain critical process temperatures and stable production quality.
Laboratory and Research
Research often pushes boundaries—and so do our heaters. For laboratory furnaces, Tempsens supplies elements capable of precise, repeatable temperature profiles for a variety of advanced research needs.
Specialized Industrial Applications
From ammonia crackers to hearth furnaces, open coil heating elements from Tempsens deliver rugged performance for specialized thermal and chemical processing environments.
Why Choose Tempsens?
- Decades of hands-on expertise delivering reliable thermal solutions
- Full manufacturing control, from raw material to finished product, backed by state-of-the-art facilities
- Certified to ISO 9001:2015, ISO 14001:2015, and ASME quality standards
- Custom engineering for your unique process or application
- Coverage from ambient up to 1600°C, ensuring a solution for every need
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Furnace Heaters.
An open coil heater is made of coiled heating element wire that has been arranged into a helical shape, and a sinusoidal strip heater is made of flat resistance wire that has been shaped into a wavy pattern. Although both can be used for heating applications in furnaces and air, they differ in geometric shape and watt density distribution.
Open coil and sinusoidal strip heaters provide faster heat up times than enclosed or sheathed heater designs because they transfer heat by radiance directly into the surrounding material (air or water) without an insulation layer between them.
Whether an open coil heater produces even or concentrated heating is determined by the element’s winding density and coil spacing. With a compactly designed coiled nozzle, an open coil heater enables full 360° heat output, with an optional way for evenly distributing the output wattage.
A hopper is a funnel-shaped container used to collect, store, and channel bulk materials such as coal, ash, or grain into processing or conveying systems in power plants, mining sites, and industrial facilities.
To maintain smooth flow of ashes, eliminates caking, and prevents buildup of fly ash discharge equipment; ensures smooth operation of the Electrostatic Precipitator (ESP).
If you can verify operating temperatures and electrical connections are functioning correctly according to what the manufacturer lists, then your hopper heater is more likely to last longer without requiring unplanned maintenance work.
Bobbin immersion heaters have resistance wire wrapped around ceramic insulators that are partially out of the casing for a better transfer of heat. Tubular heaters encase the entire heating element in a steel sleeve with no direct contact to the outside air; therefore, bobbin heaters are typically better for radiant tube applications and radiators used in furnace applications.
Yes, the Ceramic bobbin heater is specifically manufactured and produces the most efficient heat output in the furnace at maximum temperatures of 600° Celsius and is designed to withstand extremely high temperatures, up to 1200° Celsius, without breaking down. Its ceramic construction coupled with insulative properties provides the Ceramic Bobbin Heater with maximum performance longevity within a furnace system.
The maximum watt density for bobbin heaters is as high as 10 Watts/cm². The sheath material could be nickel-plated mild steel, stainless steel (SS grade), Inconel, or Incoloy based on the operating temperature and corrosive environment requirements of the application.
Our furnace heaters cover the full spectrum, from ambient up to 1600°C. Standard heaters reach up to 1100°C, while our silicon carbide and molybdenum disilicide elements are designed for the most demanding high-temperature applications up to 1600°C.
It comes down to understanding your process: operating temperature, atmosphere, power requirements, and furnace geometry. Tempsens’ technical team works with you to recommend a solution tailored to your exact needs—every step of the way
Routine visual inspections of heating elements and connections are key. Maintenance schedules depend on your specific heater and process conditions. Tempsens provides clear, practical guidelines with every installation to ensure safe, efficient, and long-lasting performance.
