The 7 Best Ways to Use Tubular Heaters in 2023

It is crucial for a business owner to keep energy costs manageable, especially with colder months approaching. Finding an energy-efficient solution to ensure your facility stays warm without incurring high costs is essential. Tubular heaters present a viable option for those aiming to reduce energy expenses while effectively maintaining a comfortable environment in their commercial or industrial spaces.

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In this article, we will delve into the numerous advantages of tubular heaters, including their innovative design, construction, and energy efficiency ratings. Additionally, we will cover various types of tubular heaters, such as Hi-Density Miniature Cartridge Heaters, Convector Heaters, and Masonry Heaters, highlighting their distinct features like integrated temperature sensors and flexible leads.

Introduction to Tubular Heaters

What is a tubular heater? Tubular heaters comprise tubular elements encased in a metal tube, crafted to maximize energy efficiency, making them an excellent choice for commercial and industrial applications. They provide fast response times, exceptional energy efficiency, and low operational costs. Tubular heaters are designed to resist corrosion, possess outstanding thermal inertia, and can be customized to meet any specific heating requirements.

A variety of tubular heater types exist, including Hi-Density Miniature Cartridge Heaters, Convector Heaters, and Masonry Heaters, each suited for unique applications. For instance, Hi-Density Miniature Cartridge Heaters are ideal for scenarios where space is constrained, while Masonry Heaters are designed for efficient and long-lasting heat in large commercial or industrial environments.

Considering the need for an energy-efficient solution to keep your commercial or industrial area warm during cold weather, tubular heaters offer exceptional energy efficiency and low energy costs, making them an excellent investment in maintaining a comfortable temperature.

Seven Ways to Use Tubular Heaters in

Tubular heaters serve a crucial role in various industrial applications, providing reliable and efficient heating for air, liquids, and surfaces. Consisting of tubular elements enclosed in a sturdy metal tube, these heaters are both durable and versatile. This section will review industrial applications of tubular heaters and their key benefits.

Hot Water Systems

One notable application of tubular heaters is within hot water systems. They heat water pipes effectively, especially during cold conditions, and can be utilized in hot water heaters, baseboard heaters, and other associated systems. Tubular heaters can be tailored for specific uses, including built-in temperature sensors for precise temperature management.

Operating across various temperature ranges, tubular heaters are suitable for high-temperature assignments, including furnaces, ovens, and other heat-intensive applications requiring exact temperature control.

Industrial Processes

Tubular heaters find usefulness in numerous industrial scenarios, such as chemical and food processing. They efficiently heat oil or other liquids in reactors, distillation units, and heat exchangers. Furthermore, tubular heaters can be engineered for hazardous environments, making them apt for explosive conditions.

Thanks to their durability and corrosion-resistant properties, tubular heaters excel in demanding environments. Commonly employed in oil and gas refining, chemical manufacturing, and wastewater treatment, they ensure robust performance.

Wastewater Treatment

Tubular heaters are vital in wastewater treatment systems, as they maintain the temperature necessary for effective treatment processes. Their deployment enhances efficiency through rapid heating and supporting the retention of the correct treatment temperature.

Heating Air and Gas

These heaters are also indispensable for heating air and gas within commercial and industrial settings. They play a crucial role in HVAC systems, keeping the air circulating throughout buildings warm. Tubular heaters aid various industrial tasks like drying, curing, and annealing, ensuring uniform heat distribution even at elevated temperatures.

Freeze Protection

Another significant application for tubular heaters is preventing freezing in pipes, tanks, and various equipment during cold spells. They serve outdoor functions such as in water supply lines and sewage treatment facilities, where they can be constructed with diverse sheath materials to withstand rough conditions.

Comfort Heating

In both commercial and residential buildings, tubular heaters can also provide essential heating. Commonly used in areas requiring supplemental warmth, they can be wall or ceiling-mounted to generate radiant heat, delivering energy efficiency advantages compared to forced-air systems.

Process Heating

These heaters excel in applications that call for precise temperature control. They can be configured for desired watt densities, voltages, and temperatures, accommodating various process demands, including liquid, gas, and solid heating across lab and industrial contexts.

Other Applications

Tubular heaters are employed across various additional industries, such as aerospace, automotive, and manufacturing, reliably heating air or liquids across demanding applications.

In aerospace, these heaters maintain critical component temperatures like fuel lines and hydraulic systems. In automotive sectors, they are advantageous for heating engine blocks and oil pans, while in manufacturing, they serve molds and extruders.

Benefits of Using Tubular Heaters in

As prevalent electric heaters, tubular heaters offer exceptional performance and efficiency for numerous industrial applications. Their tubular element construction is enclosed in metal tubes, providing durability and adaptability. Below, we elaborate on how these heaters can enhance the efficiency and effectiveness of various industrial processes.

Energy Efficiency

The primary advantage of tubular heaters is their supreme energy efficiency. They are built to transfer heat effectively, resulting in quick response times and excellent thermal inertia. Consequently, they can reach desired temperatures rapidly and maintain them with minimal energy expenditure.

These heaters are also adaptable to operate across various temperature ranges, making them fit for high-temperature applications. They can be customized with built-in sensors or leads to boost their performance and accuracy.

Furthermore, tubular heaters are largely customizable, allowing for effective adaptation to specific operational contexts, including hazardous areas, reinforcing their utility in various industrial applications.

Durability and Corrosion Resistance

Built from high-quality materials like stainless steel or Incoloy, tubular heaters are designed to withstand corrosion, making them suitable for harsh working conditions. Their ability to resist exposure to corrosive substances and moisture makes them ideal for use in chemical processing and oil and gas sectors.

Tubular heaters maintain efficiency even at extreme temperatures, providing dependable heating solutions for challenging applications.

Quick Response Times

The quick response ability of tubular heaters makes them ideal for various industrial processes. They swiftly achieve targeted temperatures while maintaining energy efficiency, contributing to reduced energy expenses and improving overall facility ratings.

The characteristic thermal inertia ensures they can sustain target temperatures despite surrounding temperature fluctuations, greatly enhancing the reliability of industrial processes.

Customizability

With a high degree of adaptability, tubular heaters can be tailored to specific applications. They come in various shapes, sizes, and watt densities tailored for distinct heating needs, allowing their application in diversified industries from food processing to aerospace.

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Tubular heaters may also accommodate different mounting options for seamless integration into existing systems, making them ideal for retrofitting.

Safety Features

Various safety features can be integrated into tubular heaters to guard against potential risks like overheating or electrical malfunctions. They can have built-in temperature fuses or thermostats to control operational temperatures, as well as thermal cutoffs to avoid equipment failures.

Designed for hazardous applications, these heaters can receive various safety certifications (such as ATEX, IECEx, or UL) to met the highest safety requirements.

Cost-Effectiveness

Tubular heaters present a financially viable option for diverse industrial heating tasks. Due to their efficiency, they can lower energy bills and enhance facility energy ratings. Additionally, they offer durability and longevity, minimizing maintenance requirements or replacement expenses.

Types of Tubular Heaters

Tubular heaters are electric heaters that consist of a metal tube encasing an electrical heating element. The choice of materials for the metal sheath—like copper, stainless steel, or Incoloy—coupled with various heating element compositions—such as nickel-chromium or iron-chromium-aluminum alloys—gives tubular heaters their versatility across applications. This section will review the different types available on the market.

Straight Tubular Heaters

Straight tubular heaters, distinguished as the most prevalent type, feature a uniform metal tube. The central heating element is surrounded by insulating magnesium oxide powder, which enhances efficient heat transfer to the environment. Available in a range of lengths and diameters, their adaptability allows for a host of applications.

Formed Tubular Heaters

Formed tubular heaters are tailor-made to fit specific configurations. The metal tubes are bent into desired shapes, allowing them to excel in compact areas needing custom heating solutions. They find application particularly in medical and semiconductor sectors where precise temperature regulation is integral.

Finned Tubular Heaters

Finned tubular heaters feature external fins to increase the heat transfer area. This additional surface contact makes these heaters suitable for air heating applications including duct heating and space heating. The fin materials may vary, and they can be affixed to the tube using methods like welding or brazing.

Flange Tubular Heaters

Specifically built for flat surface mounts like tanks or vessels, flange tubular heaters come with a flange on one end and a terminal box on the other for electrical connections. They are common in industrial settings, particularly for oil and gas processing and chemical processing.

Circulation Heaters

Designed to heat liquids or gases during their flow through pipes or tanks, circulation heaters include temperature sensors to monitor fluid or gas temperatures. Widely applicable in the food and beverage, oil and gas, and chemical industries, these heaters ensure precise temperature control.

Process Heaters

These heaters target industrial processes in environments like furnaces, ovens, and dryers. Each heater can be customized based on specific requirements, including elevated temperature, efficient heating, and precise control, applicable across various industries including automotive, aerospace, and electronics.

Choosing the Right Tubular Heater for Your Application

Selecting the appropriate tubular heater is essential for achieving optimal performance and energy efficiency in any industrial heating task. With a multitude of options available, determining the best fit can be daunting.

However, making informed choices by considering several key aspects can simplify the process.

For top-tier and dependable tubular heaters, HASTECO Heating Technologies is a prime option. With numerous customizable variants tailored for distinct needs in industrial, commercial, and residential settings, they stand out for reliable heating solutions.

When selecting the right tubular heater, reflect on the following considerations:

Temperature Requirements

First, ascertain the temperature needs of your application. Varying heaters operate at different temperature ranges, with some capable of reaching up to significant thresholds, while others cater to lower limits. HASTECO provides an array of tubular heaters that accommodate different temperature needs.

Watt Density

Watt density, reflecting the heat produced per square inch of surface area, is another critical factor. Those with high watt densities yield more heat in compact spaces, though they require more frequent maintenance and possess shorter life spans. Conversely, low-watt density heaters last longer with less maintenance but produce less heat overall. HASTECO presents a wide selection to suit various watt density requirements.

Material Selection

The construction materials used for heaters play a crucial role, as they impact corrosion resistance, thermal conductivity, and structural strength. Tubular heaters use materials like copper, stainless steel, or Incoloy, with HASTECO offering options tailored to individual application prerequisites.

Heater Size and Shape

The size and shape are key elements to consider; size affects heat output capacity, while shape influences heat distribution. HASTECO provides diverse shapes and sizes to ensure all heating needs are properly addressed.

Voltage and Power

Assess the power and voltage specifications required by the heater, ensuring they align with the available power supply in your facility. HASTECO supports a range of voltage options to comply with existing electrical systems.

Customization Options

Lastly, evaluate any required customization options, which HASTECO offers, including built-in sensors, thermocouples, and specialized lead wires to enhance heater performance.

Conclusion

Making an informed decision on the right tubular heater necessitates careful evaluation of multiple factors to guarantee optimal function and energy efficiency. HASTECO Heating Technologies provides a diverse selection of customizable tubular heaters tailored to meet varying heating needs, making them a great option across industrial, commercial, or residential sectors.

In addition to delivering superior tubular heaters, we also supply high-quality coil heaters and cartridge heaters. Contact us to obtain premier heating elements at competitive prices.

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