Maintaining the proper temperature is important in chemical processing to facilitate consistent reaction, product quality, and operations. Industrial heaters are indispensable in this regard, as they provide controlled space heating and controlled uniform heating for a variety of chemical processes. Industrial heating is used to heat reactors, distillation columns, storage tanks and pipelines; ultimately, industrial heaters allow for performance, reliability and safety for chemical manufacturers.[/caption]
In this blog post, we will discuss how industrial heaters support chemical processing performance and support the functionality of modern chemical processes.
- Temperature Control – Provides consistent and reproducible reactions
Chemical processes are mostly temperature-dependent processes; there are many chemical processes that are impacted by the slightest deviation in temperature [impacts kinetics of reaction, yield, safety, etc.]. For example, the type of temperature-controlled chemical processes that industrial heaters can support include:
- Catalytic reactions
- Distillation and evaporation
- Crystallization
- Polymerization
- Thermal cracking
Electric process heaters such as circulation process heaters, immersion process heaters, and inline process heaters are unsurpassed for providing temperature control in a process because, as well as being able to provide uniform heat, they use programmable temperature controllers and sensing devices such as thermocouples or RTDs to allow for improved process control, consistency, and repeatability.
- Energy Efficiency and Cost Reduction
Industrial heaters are often designed with a strong consideration of energy efficiency. Electric heaters now have the unique ability to convert electric energy to heat energy directly, ensuring minimal losses in the process and a maximized output. This is an exceptional advantage to chemical plants, where energy is a large part of their operational cost.
In addition:
- Zoned space heating systems allow for sending energy only where it is required.
- Smart control panels provide the ability to control heater output to match the process needs.
- Insulation on heaters minimizes the potential for heat loss and provides the practicality of lowering your energy bill.
Using heaters efficiently as an energy source lowers your carbon footprint and operational costs when compared to other energy sources while achieving other sustainability targets and goals.
- Reliability and Uptime of the Process
Chemical plants/systems have time windows and methodologies for safety. Production reliability is of utmost importance, as downtime often comes with great expense to the owner and/or a compromised product (product quality shipped).
Heaters designed for industrial duty and optimized for high performance are designed for long-term operation, even in harsh environments with continuous duty including:
- Corrosive atmospheres
- High-pressure vessels
- Hazardous area locations (heaters that are ATEX/IECEx/ISO certified)
Additionally, many heater models are designed with operational features like:
- Over-temperature protection features
- Fail-safe shapes and functions
- Thermally insulated and vibration tolerant construction
These features markedly improve durability, reliability, and scheduled maintenance down-time, therefore reducing the potential for unplanned downtime, and ensure processes remain safe and reliable, even in the harshest of conditions.
- Versatile Heating Solutions for the Diverse Demands of the Chemical Industry
The chemical industry processes a range of products that have varying heating requirements, from acids and alkalis to plastics such as resins and solvents. This industry can take advantage of a selection of industrial heaters that can be made to order with different designs and materials to suit their needs.
Typical applications in the chemical industry are:
- Tank Heating: Flange or screw plug immersion heaters supply heat for bulk chemical storage
- Pipeline Heating: heat trace cables or inline heaters for heating viscous fluids
- Reactor Heating: circulation heaters provide the heat necessary to achieve the required reaction
- Drying and Curing: tubular or heating for drying activity
Heaters can be constructed with designer finishes, made with corrosion resistant materials, for example Incoloy, Hastelloy or PTFE coatings, to withstand aggressive chemicals and provide service over prolonged periods.
- Improved Safety and Compliance
Safety is not a privilege in chemical processing, it is essential. Industrial heaters give you improved safety around your plant in several ways:
- Explosion-proof: Certified heaters are designed to work properly in hazardous zones, where flammable vapors may exist.
- No “Happy Hour” heating: Electric heaters cannot leak or fail under pressure like steam can.
- Smart monitoring: Smart sensors and PLC-based control systems include real time feedback and fault detection.
- Over-temperature protection: Heaters generally include high-limit cut-outs to limit thermal runaway.
These not only ensure operator safety, but also assist in meeting the rigors of industry, and compliance bodies, such as ISO, IEC or ATEX etc.
- Reduced Downtime from Ease of Maintenance
Downtime in chemical processing environments can cost you; A lot! Industrial heaters are configured for easy access, modularity, and simple maintenance that gives you:
- Replaceable heating elements
- Plug and play control systems
- Diagnostic capability for preventative maintenance
Some configurations such as circulation heaters with skidded installations offer and easy way to install services without dis-assembling complex installations and mechanical systems which can reduce down-time, lower Mean Time to Repair (MTTR), and ensure productivity.
- Digital Integration and Smart Monitoring
Digital integration has become standard practice in process heating as the industrial revolution continues to advance. Modern industrial heaters come with various smart monitoring features, diagnostics, and connectivity, allowing end-users to receive:
- Real time performance data
- Predictive maintenance alerts
- Complex data logging for quality control
When heaters, and their controls, are connected to the host facilities total control system, operators have easy opportunities to optimize the heat input, minimize manual control, and have the ability to use data analytics for operational optimization, and overall plant performance improvements.
- Adopting Greener Chemistry and Decarbonization
Sustainability is changing the chemical industry. Industrial electric heaters will help decarbonize thermal processes, particularly when these thermal processes are powered by renewable energy.
Electric heaters:
- Have zero direct greenhouse gas emissions,
- Do not use fossil fuels (i.e. natural gas, oil),
- Offer precise temperature control, leading to reduced operational waste and inefficiency.
Electric heaters are quickly displacing traditional steam or combustion-based heating systems as the industry moves towards greener ways of conducting operations.
Wnioski:
Industrial Heaters Are the Unsung Heroes of Chemical Processing Industrial heaters do much more than simply maintain temperatures for reactions; they improve safety, increase energy efficiency, and enable smart process control, which has been an increasingly significant contributor to performance improvements in chemical processing. Their versatility, reliability, and accuracy make them indispensable components in any chemical manufacturing operation. Naturally, prioritizing a brand-new industrial heater or refurbishment of an old heater will require considering specific needs to deal with various chemicals and processes. Subsequently, tailoring systems for increased productivity and decreased energy consumption can produce the best performance, sustainability, and product quality related to environmental compliance and long-term operational needs. Whether in the context of modernizing its plant or designing a new chemical processing facility, the application of modern industrial heaters will provide benefits associated with safety, performance, and sustainability.
