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Introduction
Tempsens Instruments is an internationally recognized manufacturer of cutting-edge process heating solutions for use in various critical industries, 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.
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
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 Immersion 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 Gas Heaters
- Custom-designed heater coils made from SS304, SS316, SS321, Alloy 600, 625, 800, 825, Titanium, and Hastelloy grades.
- Pressure vessels 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).
- Heaters can operate in the temperature range of -40°C to 1600°C.
- Heater power ratings are available from 1 kW to 10000 kW and voltage options are available up to 690V.
- 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 options.
- 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.
Advantages of Process Heaters
- Zero emissions and environment safe operation, compared to the emissions associated with a fossil fuel heating system.
- Immediate temperature response with precise control accuracy within ±1°C.
- No risk of combustion hazards makes these units perfect for installations in hazardous locations.
- The need for minimal maintenance means that fouling and scaling issues are avoided.
- The modular design of these units allows for simple and easy replacement and upgrading of modules without requiring the complete shutdown of the unit.
- These units are also highly space-efficient as they take up significantly less area compared to a shell-and-tube heat exchanger.
- The added built-in protection against overheating and earth leakage adds to the operational safety of the equipment.
- Energy savings and reduced downtime lead to a total cost of ownership that is less than other units in this class.
- A consistent heat distribution pattern results in uniform heating of process fluids.
- The devices are designed for use in high-pressure & corrosive applications meeting the requirements of ASME standards.
- The PLC that has been integrated into the system lets the user monitor & control the unit from a distance.
- Fast installation and commissioning are achieved with minimal civil work needed.
- These units offer scalability in terms of power capacity through the use of multi-stage heating configurations.
- There is no risk of thermal shock occurring to the heating elements.
- These units have been manufactured in compliance with both international safety and quality standards, providing reliable performance for years to come.
Uses of Process Heaters
- Continuous Catalytic Regeneration Heater Applications (CCR Heaters) for Aromatics Production (operating temperature range 495 – 535°C)
- Isomerization Process Heaters for Octane Number Improvements at Refineries
- Preheater and Superheater Applications for Fuel Gases To Be Used With Turbines
- TEG (Triethylene Glycol) reboiler and regeneration heaters for gas dehydration.
- Molecular sieve regenerator heaters for air separation units (ASU).
- Sulphur Recovery Unit (SRU) heaters in petrochemical complexes.
- Radiant process heaters for catalyst reduction and calcination processes.
- Flare KO drum heating with immersion and circulation heater configurations.
- Steam generation and superheating systems for power plants.
- Crude oil and heavy oil heating in storage tanks and pipelines.
- Amine reboilers for gas treating applications.
- Hot oil circulation systems for process technology heaters.
- Heat tracing solutions for freeze protection and viscosity control.
- ESP hopper heaters and duct heaters for air handling systems.
- Reactor startup and catalyst circulation heating.
- Cryogenic Defrosting and Thawing Heaters.
- Turbine and Compressor Lube Oil Console Heaters.
- LNG and Industrial Gas Vaporizer Heaters
- Marine, nuclear, pharmaceutical, and R&D heating applications.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Process Heaters.
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.
A circulation heater is a packaged system that includes the heating elements in a pressure vessel for continuous flow or multiple cycle, whereas an immersion heater consists of only the heating element in the tank or vessel with no dedicated flow control.
Industrial Circulation Heaters are utilised around oil and gas, refineries, petrochemical plants, gas processing facilities, air separation plants, power generation stations, chemical & fertilizer manufacturers, steel & aluminum producers, food & beverage processing, and OEMs.
Tempsens Process Heaters are designed with: Tube-type Heating Elements, Heater Flange, Terminal Enclosure & Baffle Cage Assembly, Temperature Sensors, ASME Certified Pressure Vessel and thyristor control panel for power management and safety functionality.
To maintain optimal performance and longevity, process heaters need to be regularly maintained through the following procedures: inspecting resistance and insulation of the heating elements; checking the terminal connections; calibrating the temperature sensors; cleaning the control panel; and performing annual preventive maintenance according to both ASME and the hazardous area certifications.
Selecting a suitable heater for your process is dependent on a variety of factors such as the process fluid’s characteristics, how much heat (kW) is needed, what temperature/pressure you want to operate at, if your heater needs to be compatible with the materials being heated, what electrical supply you will have available, the type of installation environment, and what codes may be applicable. Tempsens can provide a custom designed heating solution to meet your exact requirements.
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.
