Furnace Heaters

Tempsens offers Ceramic Bobbin Heaters are fabricated from high-temperature factory insulators in various diameters and lengths for any voltage or wattage within manufacturing limits. Bobbin heaters are made with sheathed and without sheathed material.

The sheath material ranges from nickel-plated mild steel, Inconel alloys and stainless steel. Resistance wire are supported on refractory insulators and connected to a terminal block at one end. Thermowell can be provided for accurate temperature sensing or other controls can be provided as well. They are normally manufactured for horizontal mounting, but may be specially designed and constructed for vertical installation.

Designed for any voltage or wattage within manufacturing limits. These Bobbin Heaters consist of elements, which are exposed partially in air for better transmission of heat. Also, when it is inserted into a radiant/immersion tube, it offers a large heated area to the liquid or semi-solid to be heated.

Advantages

• Suitable for low temperature up to 600°C furnace heating
• Wide range of lengths, voltages and power is available to meet customers’ specific requirement
• Simple and low-cost installation
• Ease of maintenance and repair
• Versatile and non-polluting
• Energy-efficient as 100% of heat generated is within the solution

Application Areas

• Water, chemicals etc
• Offer for semi-solid materials like wax, fats, oil and bitumen
• Suitable for indirect heating of gases and liquids, where it is inserted into a pocket or protection tube in the process tank, wherein, it can be repaired or replaced without draining the process tank

Bundle Rod Heater consists of circular ceramic beads that hold the heating elements. They are designed for long life and maintenance-free operation. Designed & manufactured in low voltages for faster heating in order to achieve temperatures quickly, these heaters can be mounted horizontally or vertically. The element can be provided in ferritic alloys up to 1250° C and Ni Cr alloy up to 1100°C materials.

Construction

• Direct heating element wire
• Ceramic Disc : for hold the heating element & insulation
• Fiber Disc : for holds the terminal rod and prevent heat loss
• Center rod : for alignment & take weight of heater bundle

Advantages

• Carbon Dioxide emissions are reduced to avoid the corrosion of furnace gas to the heating element or avoid the contact of burning outcome.
• Convenient to control temperature, assemble and maintenance and easy to seal.
• Can be Horizontal or vertical mounted
• Better technical properties and longer working life
• Higher resistivity & surface load
• Free from oxide debris
• Cost-effective with High watt density output.

Application Areas

• For melting furnace and aluminum holding
• In steel industries, for galvanizing furnace
• In automotive industries, heat treatment furnace
• Annealing furnace
• Carburizing furnace

Tempsens offers a specially designed and developed edge wound heater which is also known as a bayonet heater. Edge wound elements are used in applications where utmost power is required in a limited space. These elements replace rod elements in furnaces requiring more power and are used to convert gas-fired furnaces to electric heating. Different furnaces such as roller hearth, pit, batch, low-temperature aluminum tempering furnaces and high-temperature exothermic gas generators use these heating elements to meet their heating requirement. A nickel-chromium alloy (80/20 or 70/20) forms the basis of these heaters. It delivers maximum radiation of surface area of the element and delivers high wattage in a limited area.

Advantages

• Higher power density
• Easy to install, replace and install
• Long service life at all temperatures
• Horizontal or vertical mounting
• Repairable to extend the service life

Construction

• Heating element Nichrome 80:20, ferritic alloys Mara FeCrAl
• Diameter Up to 160 mm
• High resistance strip of edge bending in coil form which is wound on high aluminium ceramic bobbins.

The PH Hopper Heating Module is a rugged design, the high-performance heating surface of the hopper. The Marathon hopper heater are self-contained heaters whose designed provide heat outputs up to 3 watt/squire inch, with a maximum circuit size of 4500watts depending on the application, the design of the hopper heater is such that it distributes heat over its entire surface. The  PH module is according to customer requirements of surface heating area and application. The heater is offered in multiple designs, each one includes a heater element made of Inconel/Nichrome/SS. The heater element which provides multiple flow paths for electrical current to pass. This design eliminates the burnout chances common with series wire-based design.

Construction

• Parallel circuit high-temperature alloy heating element.
• Temperature-rated insulation- Mica and glass wool.
• Aluminum/Aluminized steel protective enclosure and its cover with mounting channel attachment.
• High temperature insulated lead wire for connection

Hopper Heating Modules for Power Plants
Conveying coal/oil (other material) from stockpiles to boiler during winter months is a well-documented nightmare for plant operators. Identical conveying problems exist within the mining industry as coal is moved around the mine site.  Coal stored outdoors on the stockpile or delivered by unit train or barges picks up moisture from rain and snow. When this wet or frozen coal is conveyed, it inevitably comes into contact with the plate steel of the various hoppers and chutes within the coal handling system. During winter, this plate steel is below freezing for extended periods. When wet or frozen coal encounters steel at sub-freezing temperatures an instantaneous bond is formed. This bond causes immediate and often catastrophic blockage of the hopper and chutes. The bond and resultant blockage are so severe that often pneumatic drilling equipment and explosives are required to free up the system. This problem, known as  Flash Freezing, is extremely inconvenient and very costly. Several cases are documented where utility and industrial boilers have been shut down due to blocked conveying systems.