Tubular Heating Elements
Tubular Heating Elements that are produced in pipe form and be given different forms. Tubular Heating Elements, which have different qualities depending on the amount of resistance;is the most commonly used type of resistance in industrial areas. This type of resistance, which a wide range of uses, serves by converting electrical resistance to very high temperatures. This type of resistance includes liquid heaters and outdoor heaters.
Elements which have a wide range of uses from kitchen equipment to industrial vehicles, have become frequently used industrial equipment with their robust structure.
Tubular Heating Types
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Tubular Heatings Elements
Special Production Tubular Heater with Buatlı
Teflon Coated Tubular Heater
IP67 Insulated Boiler Heater with Thermostat
Special Production Heater
Head Type Heater
Immersion Type Heating Resistor
Immersion Type Heating Resistor
Sleeve Boiler Heater
Stainless Steel Heater with Special Head
Special Cast Tubular Heater
Chemical Boiler Heater
Spiral Type Heating Element
Headed Type Sleeved Reamer
Spiral Tube Resistance Heater
Special Spiral Tube Heating
Round Flanged Thermosyphon Heating
Technical Information
Tubular Heating Elements wide range of uses in industrial, commercial and scientific fields. Tubular Heating Elements
consist of parts such metal sheaths and connectors. Thanks to the easy forming of resistors, welding can be made and soldered to every metal surface. In this respect,be easily integrated into the systems. Pipe resistors be produced as flat and curved as desired as flat and curved as desired with sleeve, record, flanch, serpentine, aluminum coat,in the size and power determined according to the place. For example, if you want to know what you’re going to Flat bar,U type, type M are the most common uses.
Tubular Heating Elements
which are also developed as industrial types, are preferred in many different areas for heating water, oil, chemical and corrosive liquids. Industrial pipe resistors are also used for heating molds and different metal materials in industrial industrial furnaces.
What is Tubular Heating Elements ?
Tubular heaters are electromagnetic devices of various dimensions and shapes used to control the flow of fluids passing through tubes. High flow rates of fluids within tubes can lead to energy loss and wastage of resources at sources. Tubular heaters are utilized to regulate this energy loss and provide resistance to reduce the speed of fluid flow.
Tubular heaters can be made of metallic materials such as nickel, tungsten, carbon, or their mixtures. They may possess a specific resistance value, which can be utilized to control the speed of fluid flow. Additionally, tubular heaters can operate within a specific temperature range and have a certain power capacity.
Tubular heaters find applications across various sectors including industry, energy, water supply systems, environment, and are selected based on the required features to control the speed of fluid flow.
Types of Tubular Heaters
Tubular heaters can vary in sizes, shapes, materials, and characteristics, and can be classified into different types based on these attributes. Below are some types of tubular heaters:
Electromagnetic Tubular Heaters: These heaters can be made from metal materials such as nickel, tungsten, carbon, or their mixtures.
Thermistor Tubular Heaters: These heaters rely on the change in resistance with temperature variation.
Radial Tubular Heaters: These heaters can be designed with different dimensions and can provide resistance based on the direction of fluid flow.
Axial Tubular Heaters: These heaters can provide resistance based on the horizontal direction of fluid flow.
Thermostatic Tubular Heaters: These heaters can be used with temperature control systems and can change their resistance when a specific temperature value is reached.
This classification can vary depending on the application, operating conditions, and requirements of tubular heaters, and combinations of different types can also be utilized.
Tubular Heaters Areas of Use
Tubular heaters can be utilized in various applications such as:
HVAC Systems: In heating, ventilation, and air conditioning systems, tubular heaters can be used to control fluid flow and heat distribution.
Energy Generation: In systems like thermal, hydroelectric, or solar power, tubular heaters can be used to control fluid flow.
Chemical and Petrochemical Industry: In chemical and petrochemical plants, tubular heaters can be used to control fluid flow and heat.
Water and Wastewater Management: In water facilities, tubular heaters can be used to control fluid flow and pressure.
Industrial Processes: In industrial processes, tubular heaters can be used to control fluid flow and temperature.
This is just a subset of the places where tubular heaters can be employed. The design and characteristics of tubular heaters can vary depending on different applications and requirements.
Tubular Heatings Technical Specifications
The technical specifications of tubular heaters may include:
Operating Pressure: The maximum operating pressure is the highest fluid pressure that the tubular heater can withstand.
Operating Temperature: The operating temperature range refers to the minimum and maximum temperatures at which the tubular heater can be used.
Flow Capacity: The maximum amount of fluid that the tubular heater can pass on a daily basis.
Material: The material used for the construction of the tubular heater should be selected based on the application’s conditions and fluid properties.
Dimensions: The dimensions of the tubular heater should be determined based on the pipe sizes, application requirements, and fluid flow.
Connection Types: Tubular heaters can have different connection types, such as rigid, flexible, etc. The connection type should be chosen based on the application’s conditions and fluid properties.
Tubular Heating Elements
Tubular heaters are metal heaters that can be manufactured in different shapes and are commonly used in industrial settings. These heaters, which have properties that vary according to resistance levels, function by converting electrical energy into high temperatures. Among tubular heaters, there are liquid heaters and open heaters. With various application areas ranging from kitchen equipment to industrial machinery, these types of heaters are often preferred in industrial equipment due to their durable structures.
Tubular Heating Technical Data
Tubular heater types are commonly used for heating chemical and corrosive liquids, as well as for heating molds and various metals in industrial furnaces.
These types of heaters can be manufactured in diameters of 6.5 mm, 8.5 mm, 11.5 mm, 14.5 mm, and 16.00 mm, and can be easily produced in any size from 5 mm to 20 mm.
Tubular heaters have a wide range of applications in industrial, commercial, and scientific fields. They consist of parts such as metal casing and connection ends, and can easily take shape, allowing welding or soldering to any metal surface. Therefore, integrating them into systems is quite easy. Tubular heaters can be produced as desired, with sleeves, sheaths, flanges, coils, and aluminum coatings, in straight or curved shapes. For example, straight rods, U-shaped, and M-shaped are the most commonly used shapes.
Tubular heaters developed for industrial use are preferred in many different fields for heating water, oil, chemicals, and corrosive liquids. Industrial tubular heaters are also used for heating molds and various metal materials in furnaces found in industrial environments.
In addition to round tubular heater types, flat-shaped heaters of varying sizes can also be produced. Common applications of these heaters include railway switch heating, oil heaters in industrial fryers, and dry air heaters in some special ovens.
Tubular heater models are widely used in various fields such as the plastic industry, packaging industry, woodworking industry, construction industry equipment, household appliances, foundry industry, high vacuum applications, and laboratory equipment.
Tubular Heatings Types
Tubular heaters can come in various sizes, shapes, materials, and specifications, leading to classification into different types based on these attributes. Here are some types of tubular heaters:
Electromagnetic Tubular Heaters: These types of heaters, made from metal materials such as nickel, tungsten, carbon, or their mixtures, convert electrical current into heat through resistance.
Thermistor Tubular Heaters: These are tubular heaters that rely on changes in resistance with temperature variations. As temperature increases, resistance decreases, and vice versa.
Radial Tubular Heaters: Tubular heaters that can be designed in different sizes and provide resistance based on the direction of fluid flow.
Axial Tubular Heaters: Tubular heaters that provide resistance when fluid flows horizontally.
Thermostatic Tubular Heaters: Tubular heaters that can be used with temperature control systems and can change their resistance when a specific temperature value is reached.
This classification can vary depending on the application, working conditions, and requirements, and combinations of different types can also be utilized.
Tubular Heatings Technical Specifications
Operating Pressure: Maximum operating pressure refers to the maximum fluid pressure that the tubular heater can withstand. This is an important feature for the safe use of the tubular heater.
Operating Temperature: The operating temperature range indicates the temperature range in which the tubular heater can operate smoothly, covering both minimum and maximum temperatures.
Current Capacity: Current capacity denotes the maximum current that the tubular heater can carry within a specified time period. This feature ensures the safe operation of the heater.
Material: The material from which the tubular heater is made should be chosen based on the application’s requirements and the properties of the fluid. Materials such as stainless steel, nickel, and titanium are commonly used.
Dimensions: The dimensions of the tubular heater are determined based on the diameter, length of the pipe, and the requirements of the application. Proper sizing ensures effective performance.
Connection Types: Tubular heaters can have different types of connections, such as fixed or flexible connections. The type of connection should be selected based on the requirements of the application and the structure of the pipe.
These technical specifications are important for the proper selection and application of tubular heaters and may vary depending on the application field.
Tubular Heating Elements
Technical Details of Tubular Heating Elements
Tubular heating elements are heating components commonly used in industrial heating applications, known for their high efficiency. Designed to convert electrical energy into heat for heating liquids or gases, these devices are chosen for their durability and flexibility across various fields. Below are the technical details of tubular heating elements:
1. Material Selection
Tubular heating elements are made from materials with high electrical resistance that can effectively conduct heat. Commonly used materials include:
• Kanthal (FeCrAl Alloy): Offers high-temperature resistance and long service life. Typically operates between 300°C and 1400°C.
• Nickel-Chromium (NiCr): Suitable for medium-temperature applications and is durable.
• Stainless Steel: Some tubular heating elements are made of stainless steel, especially used for low to medium temperatures.
2. Tube Type and Dimensions
The size of tubular heating elements varies according to the system’s capacity and heating requirements. General measurement details include:
• Diameter (Ø): Typically ranges between 6 mm and 50 mm. Larger diameters are used to meet high energy and power requirements.
• Length (L): Tube length varies with the heater’s power and usually ranges between 50 cm and 300 cm. Length is directly proportional to the heating area and capacity.
3. Electrical Power
The electrical power of tubular heating elements is expressed in watts (W) and varies by application. Power is related to the tube’s length, diameter, and the material used. Common power ranges:
• Low Power: Between 500 W and 2000 W.
• Medium Power: Between 2000 W and 5000 W.
• High Power: Above 5000 W.
High-power tubular heaters are preferred for large industrial applications.
4. Resistance Wire Structure
Tubular heating elements typically contain a resistance wire coated with ceramic or aluminum oxide. This wire conducts electric current, and due to energy loss (Joule heating), heat is generated. The resistance wire generally has the following properties:
• Resistance Wire Diameter: Chosen in proportion to the tube diameter, usually between 1 mm and 5 mm.
• Thinner wires are used for low energy requirements, while thicker wires are suitable for high power needs.
5. Insulation Material
Appropriate insulation materials are used to ensure efficient operation of tubular heating elements. Insulation minimizes heat loss by preventing heat from escaping to the environment. Main insulation materials used:
• Magnesite (MgO): Known for high-temperature resistance and good insulation properties.
• Ceramic: Resistant to high temperatures and provides electrical insulation.
• Mica: Cost-effective, highly durable, generally preferred for low-temperature applications.
6. Operating Temperature
The working temperature of tubular heating elements varies depending on the material and design:
• Kanthal and NiCr Alloys: Suitable for high temperatures, capable of operating between 300°C and 1400°C.
• Stainless Steel: Suitable for medium temperature ranges, generally operates between 200°C and 600°C.
Tubular heating elements can be designed according to the temperature level required by the application.
7. Mounting Type
Tubular heating elements are typically mounted using flanged or screw connections. These connection types ensure secure installation of the heater:
• Flanged Mounting: Frequently used in industrial systems. Flange diameters are commonly 50 mm, 100 mm, or 150 mm.
• Screw Connection: Preferred for smaller systems, usually available in screw sizes like M10, M12, M16.
8. Protective Coating
To protect against external factors and extend their lifespan, tubular heating elements are often equipped with protective coatings. These coatings primarily provide oxidation protection:
• Stainless Steel Coating: Resistant to corrosion and extends the life of tubular heating elements.
• Ceramic Coating: Efficiently conducts heat while protecting against external influences.
9. Application Areas
Tubular heating elements have a wide range of applications, including:
• Heating Systems: Used in liquid heating, air heating, and industrial heating systems.
• Sandblasting and Baking Furnaces: Preferred for metal heating and baking processes.
• Water Heaters: Utilized in household water heaters and industrial water heating systems.
• Air Heaters: Employed in systems that operate with air.
Tubular heating elements play a crucial role in industrial and commercial applications, offering a wide range of material and structural options to meet heating requirements. The right material selection, sizing, and insulation materials directly impact the efficiency of tubular heating elements. Therefore, choosing tubular heating elements with appropriate specifications for the intended application ensures efficient operation of heating systems.
Measurement Details of Tubular Heating Elements
Tubular heating elements are important heating components commonly used in various industrial and commercial heating applications. These devices convert electrical energy into heat to warm liquids, gases, or solids. The measurements of tubular heating elements vary depending on the system’s energy requirements, the material used, and the application’s needs. Below is information on common measurement details and dimensions for tubular heating elements:
1. Tube Diameter (Ø)
The diameter of tubular heating elements is generally proportional to the material used and the application. The diameter directly affects energy capacity and the heating surface. Common diameter measurements:
• Small Diameter: 6 mm – 15 mm, suitable for small systems.
• Medium Diameter: 16 mm – 30 mm, used for medium-scale systems and heated liquids.
• Large Diameter: 31 mm – 50 mm or larger, preferred in industrial systems with high power requirements.
2. Tube Length (L)
The length of tubular heating elements affects heating power and the size of the heating surface. Tube length may vary according to the system’s operating conditions:
• Short Lengths: Between 50 cm and 1 m, suitable for applications with low power requirements.
• Medium Lengths: 1 m – 2 m, commonly used in medium-sized industrial heating systems.
• Long Lengths: 2 m – 3 m or longer, used for high power requirements.
3. Resistance Wire Diameter
Inside tubular heating elements, the resistance wire carries electric current to generate heat. The diameter of the resistance wire is chosen based on the tube diameter and heating capacity:
• Small Diameter: 0.5 mm – 1 mm, suitable for low-power systems.
• Medium Diameter: 1 mm – 2 mm, used in medium-scale systems.
• Large Diameter: 2 mm – 5 mm, preferred for high-power and industrial heating systems.
4. Power (Watt)
The power of tubular heating elements is expressed in watts (W) and varies based on the material, length, diameter, and application:
• Low Power: 500 W – 2000 W, suitable for small systems or residential applications.
• Medium Power: 2000 W – 5000 W, used in medium-scale industrial heating systems.
• High Power: 5000 W and above, used in large-scale industrial applications.
5. Flange Sizes (If Used)
Tubular heating elements are sometimes connected to the system with flanged mounts. Flange sizes are generally determined by the system’s needs:
• Small Flanges: 50 mm – 100 mm, suitable for small systems.
• Medium Flanges: 100 mm – 150 mm, preferred for medium-sized applications.
• Large Flanges: 150 mm – 200 mm and larger, used in large industrial systems.
6. Insulation Thickness
Tubular heating elements are often coated with insulation materials to provide efficient heating by preventing heat loss. The thickness of the insulation varies depending on the application’s operating temperature and the surrounding of the tube:
• Low Thickness: 5 mm – 10 mm, suitable for low-temperature applications.
• Medium Thickness: 10 mm – 20 mm, preferred for medium-temperature applications.
• High Thickness: 20 mm and above, used for high-temperature applications and to ensure energy efficiency.
7. Connection Types
The connection points for tubular heating elements are usually made with screw or flanged mounting systems. Common connection types:
• Screw Connection: Generally preferred for small tubular heating elements with standard screw sizes like M8, M10, M12.
• Flanged Connection: More common in large and industrial systems, with flange diameters typically ranging between 50 mm and 150 mm.
8. Operating Temperature
The operating temperatures of tubular heating elements vary depending on the material and application:
• Kanthal and NiCr Alloys: Generally operate between 300°C and 1400°C.
• Stainless Steel: Suitable for medium-temperature applications, generally operating between 200°C and 600°C.
9. Protective Coating (Optional)
Tubular heating elements can be equipped with protective coatings to shield them from external influences and extend their lifespan. The thickness of these coatings is also part of the measurements:
• Stainless Steel Coating: Typically 0.5 mm – 1 mm thick.
• Ceramic Coating: Generally 1 mm – 3 mm thick, especially suitable for high-temperature applications.
10. Mounting Type and Application
The mounting types of tubular heating elements vary depending on the heating application. These mounting options include:
• Immersion Type: Used in systems where liquids need to be heated. Diameter and length are adjusted according to the viscosity of the liquid.
• Air Heater Type: In air heating systems, tubular heating elements are typically available in diameters between 20 mm and 50 mm and can be longer.
The measurement details of tubular heating elements are determined specifically for each application and play a critical role in efficiency, safety, and durability. Factors such as diameter, length, power, and insulation thickness directly affect the performance of tubular heating elements. Selecting measurements appropriate for the application area and requirements ensures that the system operates efficiently and safely.
Working Principle of Tubular Heating Elements
Tubular heating elements are components that convert electrical energy into heat and are commonly used in industrial heating systems and various heating applications. These elements have a tubular structure, and by passing electrical current through resistance wires inside the tube, they heat up and warm the surrounding environment to achieve a desired temperature. The working principle of tubular heating elements can be described in the following steps:
1. Passage of Electric Current Through the Resistance Wire
The fundamental working principle of tubular heating elements is converting electrical energy into heat by passing it through a resistive material. The key component performing this task is the resistance wire inside the tube. When electric current passes through the resistance wire, energy is lost due to the resistance encountered by the current. This lost energy is transformed into heat.
• The resistance wire is typically made from alloys such as Kanthal, Nickel-Chromium, or Stainless Steel. These materials withstand high temperatures and provide efficient conversion of energy into heat.
2. Heating According to Ohm’s Law
As electric current flows through the resistance wire, heating occurs proportional to the resistance, according to Ohm’s Law. As the current passes through the wire, a portion of the electrical energy is released as heat due to the resistance. The size and type of the resistance wire affect the efficiency of this heating process. The generated heat is then transferred to the surface of the tube, where it heats the surrounding air or fluid, providing energy.
3. Heat Distribution
In tubular heating elements, electrical heating is not confined only to the region of the resistance wire. The produced heat spreads over the tube’s surface, causing the fluid or gas surrounding the tube to warm up. Since the tube is usually made of metal, it effectively conducts heat, facilitating its distribution to the environment.
• Liquid Heating: When a tubular heater is used in liquid-containing systems, the liquid comes into contact with the tube and absorbs heat. This is typically used for water, oil, or chemical liquids. Heating the liquid enables industrial processes such as warming substances or heating production lines.
• Air Heating: Tubular heating elements are also used in air heating systems. As air passes around the tube, it absorbs heat radiating from it and becomes warmer. In such applications, the tube is often longer and wider to maximize heat transfer.
4. Insulation and Thermal Efficiency
Tubular heating elements are generally coated with insulation materials to increase energy efficiency and minimize heat loss to the surroundings. This insulation ensures that heat remains within the target area—be it fluid or gas—and does not dissipate into the environment, thereby conserving energy.
• Insulation Materials: Various insulating materials cover the outer surface of tubular heating elements to prevent temperature loss and ensure efficient operation. The thickness and type of insulation directly affect the heating capacity.
5. Operating Temperatures and Control
Tubular heating elements can operate at different temperature levels and are designed to work efficiently within a specific temperature range. Most tubular heaters are integrated with thermostats, thermocouples, or other temperature control devices for safety and precise temperature regulation.
• Operating temperatures vary based on the material and type of application. For example, alloys like Kanthal that withstand high temperatures allow tubular heating elements to operate at very high temperatures. Therefore, selecting the appropriate material is crucial.
6. Insulated Systems and Safety
Tubular heating elements are typically equipped with waterproof and overheat-resistant systems. Especially in applications involving liquids, various insulation systems and safety valves are used to ensure safety. These systems prevent uncontrolled temperature rises and ensure the heater operates safely.
Tubular heating elements efficiently convert electrical energy into heat for temperature management in various industrial and commercial applications. Their working principle is based on passing electric current through a resistance wire inside a tube, which transforms the energy into heat, spreads it over the tube’s surface, and warms the surrounding environment. This process is optimized with proper insulation, material selection, and temperature control systems, ensuring high efficiency and safe operation.
Tubular Heating Elements
Pipe heater elements are heating components typically consisting of a heating wire placed inside a metal pipe. When electric current passes through the wire, it generates heat. The metal pipe efficiently distributes this heat, warming a specific area. These heaters are ideal for applications requiring high temperatures and pressures.
The material of pipe heater elements is chosen based on their intended use and operating conditions. Common materials include stainless steel, titanium, and ceramics. Stainless steel is widely favored for its corrosion resistance and high-temperature durability, while titanium is used in more aggressive chemical environments. Ceramic pipes are preferred when electrical insulation is required.
Pipe heater elements are highly energy-efficient, effectively converting electrical energy directly into heat. Their design promotes even heat distribution, which minimizes energy losses. This efficiency allows them to deliver the same level of heating with lower energy consumption.
Pipe heater elements are commonly used in hot water production, chemical heating, air heating, machinery heating, and industrial heating systems. They are also prevalent in applications such as steam generation, dry heating, and immersion heating systems.
Pipe heater elements typically operate between 300°C and 800°C. Depending on the material and design, some models can reach even higher temperatures. For high-temperature applications, durable materials such as stainless steel or ceramics are preferred.
Maintenance of pipe heater elements involves regular cleaning and inspection. Electrical connections should be checked for wear, corrosion, and thermal expansion. Dirt, scale, and deposits on the pipe’s surface can reduce efficiency, so periodic cleaning is necessary. Additionally, ensure the pipe is properly installed.
Pipe heater elements are widely used across many industrial sectors, including petrochemicals, chemical processing, automotive, power generation, food processing, medical devices, and metalworking. They are especially preferred in processes requiring high temperatures and pressures.
The lifespan of pipe heater elements depends on the materials used, operating conditions, and maintenance level. Generally, high-quality pipe heaters can last between 5 to 10 years with regular maintenance. However, factors like extreme temperatures and chemical exposure can shorten their lifespan.
Pipe heater elements can generally operate with either AC (alternating current) or DC (direct current) power supplies. The voltage requirements depend on the specific type of element used. Models that are compatible with common industrial voltages, such as 220V and 380V, are widely available.
The main advantages of pipe heater elements are their ability to operate at high temperatures, durability, and versatility across a wide range of applications. Their design allows for effective heat distribution, which increases energy efficiency. They are also known for easy installation and long service life, making them popular for industrial applications.
