ABOUT
Introduction
Circulation heaters are sophisticated industrial heating systems designed for continuous effective heating of process fluids. These heater bundles utilize an electric heater bundle to heat flowing process fluids quickly and efficiently within a pressure vessel. The system operates by an inlet where cold process fluid enters and passes through the active heating zone before exiting through an outlet at the desired elevated temperature.
The circulation heating system is engineered to provide accurate temperature control while keeping element temperature and pressure drop within defined acceptable ranges. Flexible configurations are available; circulation heaters can be designed as either horizontal or vertical one stage or multi stage types according to the specific requirements of the process and installation space. Tempsens produces circulation heaters with wattages from 1kW to 10,000kW, and can operate at design temperatures ranging from -40°C to 650°C and design pressures up to 350 bars.
About Circulation Heater
Features of Circulation Heater
| Parameter | Specification |
|---|---|
| Rating | From 1 kW to 5000 kW maximum, in single bundle or combination |
| Design Temperature | -40°C to 650°C |
| Design Pressure | Up to 350 bar(g) |
| Pressure Vessel | LTCS / CS / SS / Alloy Steel |
| Heating Element | Mineral-filled insulated heating elements or tubular heating elements with Ni-Cr (80-20) heating coil and suitable outer sheaths |
| Control System | Thyristor control panel + local control stations for effective temperature control and safe operation, suitable for safe area or hazardous area |
| Terminal Enclosure | As required: weatherproof or flameproof |
| Installation | Horizontal / Vertical |
| Certifications | Provided based on requirement: IECEx, ATEX, CCOE, U |
| Protection and Control | Element skin temperature control, process temperature control, earth leakage protection, overload current protection |
Applications of Circulation Heater
- Fuel gas and natural gas heating in oil and gas processing skids
- Crude oil heating, and hydrocarbon fluids in refineries and petrochemical facilities
- Process fluid heating for chemical manufacturing and fertilizer production
- Gas heating applications including air, nitrogen, hydrogen, argon, and flue gas systems
- Water heating applications and steam generation in vaporizer systems
- Steam boiler feed water preheating in power generation facilities
- Edible oil heating for food and beverage processing industries
- Compressed air heating in air separation units and industrial processes
- Heat transfer fluid heating in thermal oil systems
- Process gas conditioning in gas processing plants
- Any process fluid heating in steel plants and aluminum manufacturing facilities
- OEM applications including compressor packages, heating skid system, lube oil heating and boiler systems
For more information, visit : https://tempsens.com/blog/7-points-to-consider-when-choosing-a-circulation-heater/
Construction of Circulation Heater
- Insulated enclosure designed to contain electrical connection from dust, moisture, and impact from outside, while allowing power connection
- Heater bundle consists of multiple U pin heater elements supported by baffles and tie rods in a manner that optimizes the transfer of heat
- Fixed to the heater flanges with standoff sleeve pipes and attached by means of brazing, direct welding or threaded couplings
- Heat transfer divided into multiple subgroups (banks) which enable and facilitate control flexibility throughout each phase of heating
- Pressure vessel constructed in accordance with ASME or similar international standards, including inlet & outlet piping connections
- Pressure vessels that provide for drain and venting for both maintenance & safe operation
- Vessels to be insulated on the outside to minimize heat loss and to provide protection from thermal shock
- RTD or thermocouple temperature sensors for monitoring of element skin temperatures and process temperatures
- Control panels provide visual indication for heater power, operational status, trip conditions, and high-temperature alert.
- Safety Interlocks for high element temperature, earth fault, process over-temperature, and emergency stop functions incorporated.
Why Choose Tempsens Electric Circulation Heaters?
- 35+ years working in manufacturing within thermal and heating industries.
- Environmental sustainability by not having emissions or smoke from conventional burning of fossil fuels.
- Compact design allows for fast heating of continuous fluids while taking very little space.
- Engineering efficiency in order to maximize dielectric strength and reliability.
- Experienced and has had reputation for dependability in many industrial markets globally.
- Certified for safe area and hazardous area installations with proper area classification compliance
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Circulation Heater.
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.
