This Article takes an In-depth look at Electric Heaters
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The idea of an electric heater seems to be out of place in modern society since most buildings have a sophisticated central heating system. That may be true, but electric heaters can be a helpful way of saving energy while providing efficient heating. Electric heaters are a creative method to support a central heating system, because they can be personal and maintain a set temperature much like a central heating system while using less energy. The true asset of an electric heater is how it can save on heating costs.
Sometimes, the temperature isn't cold enough to trigger the heating system but still leaves you feeling uncomfortable. While layering up can help, it's not always practical for every activity. In these situations, an electric heater can create a warm and cozy environment, making work or play more enjoyable.
At times when only one person is at home, using an electric heater can be more cost-effective than running the central heating system. This is especially true for activities like working in a home office, being alone in the bedroom, or cooking. Modern electric heaters are lightweight and portable, making them easy to move and adapt to any space.
According to the United States Department of Energy, more than half of an electric bill goes to heating and cooling. A practical solution to lowering those costs could be the use of an electric heater. The energy department estimates that approximately $1800 is spent on the use of an electric furnace each year. If the cost of electricity is $0.12 per kilowatt hour, an electric heater could be run, in a single room, for 12 hours per day from November to the end of March at a cost of $315, a significant savings.
The climate significantly impacts the effectiveness of electric heaters. In regions of California with mild temperatures, homes may not need heat for extended periods, making electric heaters less essential. Conversely, in colder states like Minnesota, Wisconsin, Idaho, and North Dakota, where temperatures can drop well below freezing for weeks, electric heaters can provide substantial savings. However, it's important to remember that electric heaters are designed to warm a single room and should be used to complement a central heating system.
When using an electric heater as a supplementary source for a central heating system, several practical steps can enhance its effectiveness. The key benefits include lowering heating costs while boosting convenience and comfort. To maximize energy savings and efficiency, it's important to follow specific practices and strategies when incorporating an electric heater.
Installing a programmable thermostat is a smart initial move to cut heating costs. These efficient devices, also known as setback or clock thermostats, allow you to adjust temperatures at different times of the day, reducing heat when it's not needed or when rooms are unoccupied. By setting the thermostat to lower the temperature by 10 to 15 degrees during these periods, you can reduce heating expenses. According to the U.S. Department of Energy, this simple adjustment can lead to a 5 to 15 percent decrease in heating costs.
Reducing the temperature in a building when only a few rooms are in use is another effective strategy. Electric heaters can be employed in the occupied rooms to maintain comfort and warmth. To implement this system, it’s essential to identify the rooms being used and equip them with suitable electric heaters for each space.
Electric heaters are ideal in this era of environmental consciousness. They heat a specific area and use less energy. None of the energy used to operate a portable heater is wasted. Since they do not use natural gas or oil, they do not produce any form of air pollutants. Infrared type heaters are especially popular as an environmentally safe device.
An electric heater operates on a similar principle as a central heating system but on a smaller scale. With a wide range of options available, it's crucial to select a heater that suits your specific needs and situation. Making a hasty, random purchase is not advisable. Choose carefully to ensure the best fit for your requirements.
The core component of all heaters is an electrical resistor, which transforms electrical energy into heat energy. While resistance is often viewed negatively as it implies opposition, in electric heaters, it is crucial for generating heat. A material with high electrical resistance resists the flow of current, causing the energy to convert into heat. Thus, greater resistance results in more heat and a higher temperature.
The resistor is the central piece of an electric heater and serves several functions. It controls the flow of electric current in a circuit and is normally made of carbon. They ensure that the components of a heater receive the proper amount of voltage and protect against spikes. The quality of the resistor determines the effectiveness of the heater and how long it will last.
There are different kinds of resistors such as ceramic cylinders, mica-embedded wires, coiled in ceramic, tubular core, or coiled insulated with magnesium oxide powder. Ceramic is used as an insulator and is an excellent heat conductor. When a resistor is made with ceramic, the resistor can use low to moderate power without the need to reheat. A mica embedded wire resistor is an economical solution that provides high resistance for low power applications. Tubular core resistors can come in several diameters depending on how it is to be used and can handle high power loads. One version of a tubular resistor is magnesium oxide powder insulated, which insulates the electric wiring and conducts thermal energy.
When a heater is turned on, the electrical current heats up the nichrome wire component, the heating coil. As the electrical energy goes through the resistor, heat is produced, which gives electric heaters the name resistance heating units. The fan on a heater will pull air into the heater, which is forced over the heating elements and into the room like a hair dryer. The process of drawing in air and passing it over heating coils is known as convection heating.
When a fan is not present, air goes over the coils and makes its way out of the heater, which is radiant heating. This type of heater is designed for small areas since it heats the air around it and would take time to heat a large room. The main type of radiant heaters are electric baseboard, which are inexpensive and use natural convection.
When buying an electric heater, you can choose between models with or without a thermostat. Heaters without a thermostat simply heat up and blow warm air into the room, operating with just an on/off switch. In contrast, heaters with a thermostat feature either a digital display or a dial, allowing you to set a specific temperature and automatically turning off once that temperature is reached. Most modern electric heaters come equipped with a thermostat, a feature that manufacturers often highlight in their marketing materials.
The term electric heaters or space heaters has gained a negative reputation due to the types that were produced years ago. The poor quality of the early version of electric heaters has been enhanced and improved. Modern technology has taken electric heaters and radically advanced them into the present. There is a diverse assortment of them available on the market today making choosing one more difficult than it was fifty years ago.
Prior to shopping for a new electric heater, it is important to determine how much heat will be required. The size and type of heater depends on the dimensions of the room where it will be used. The traditional type of heater can heat a room of approximately 400 square feet while more powerful ones can heat areas up to 1000 square feet. A careful measurement of the space can save time and money helping to avoid having a heater too powerful for the space or not powerful enough. For practical purposes, unless you plan on heating a milking barn, a small compact heater is usually sufficient.
Once the size of the room is determined, the next step is to decide on the characteristics of the heater. Most electric heaters advertise having some form of energy saving feature that carefully monitors the flow of electricity through the unit. A programmable timer can be a huge convenience since it allows the user to set it to activate automatically. This can also be included as a function of the thermostat.
The price of an electric heater generally rises with the number of features it includes. While heaters without a thermostat are cheaper and provide only radiant heat, it's highly recommended to choose one with a thermostat. A thermostat offers better control and enhances safety by automatically turning off the heater once it reaches the set temperature.
When buying an electric heater, it's challenging to gauge the noise level in a store. While some manufacturers may include noise information on the box or in their literature, online listings for high-quality heaters often provide this detail, whereas physical stores might not. Baseboard and radiant heaters are typically the quietest options, as they lack fans.
Choosing an electric heater wisely requires being well-informed. Although it might feel like a spur-of-the-moment decision, careful planning and preparation can lead to selecting a device that saves energy and reduces your electric bills. Utilize all available resources to gather essential information for making a smart purchase.
The design of an electric heater should complement the space it will warm. A significant factor in this choice is the aesthetic appeal. For instance, a tower heater, which rotates to distribute heat, might not enhance the room's look if placed centrally. In contrast, a wall-mounted stove heater blends in discreetly. Selecting the right design can be a creative and enjoyable process.
Air heaters are defined as electric heaters that provide heat for industrial and residential purposes by way of air circulation or a blower mechanism. Air heaters can be rectangular or barrel shaped, large in size, and portable, but other models of air heaters that vary in size and shape are also available.
Air heaters are designed by placing a stationary heating element within an enclosure. Air ducts periodically expose different sections of the heating element to circulating air by rotating alternately. While heating elements can vary, they are typically made of wires or coils. Wire heating elements are frequently used in industrial and commercial drying applications, often found in machines like kilns and surface treatment heaters.
Air heaters serve various purposes and come in diverse configurations with different heating elements. In homes, they are used daily to heat spaces, food, and water, while industries depend on electric air heaters to regulate temperatures for various processes. To ensure optimal efficiency and safety, it is crucial to evaluate the heating system and its intended application thoroughly.
Band heaters, also known as knuckle heaters or barrel heaters, are a variety of heating element that provides direct or radiant heating by clamping around nozzles, pipes, or cylinders. Band heaters are used primarily in metal and plastic forming processes such as extrusion, and are similar to strip heaters in terms of application and configuration. The range of temperature that band heaters provide can vary from 300 to 1400 degrees Fahrenheit. (approx. 149 to 760 degrees Celsius). Strip heaters can also be clamped or bolted in order to achieve the direct transfer of heat to either the air or a solid object.
Band heaters, along with other heating equipment, are essential for various industrial processes, particularly extrusion. This process requires melting materials and maintaining their plasticity for successful extrusion. Friction during extrusion generates heat, but band heaters supplement this by providing efficient, direct heat. They are especially effective in heating irregularly shaped areas where other heaters may struggle.
Cartridge heaters are small, cylindrical electric heaters used to provide localized or precision heat to materials and equipment parts in a variety of settings. Similar to immersion heaters, cartridge heaters are usually inserted into a material to heat the surrounding area; unlike immersion heaters, which are usually submerged in water or other liquids, cartridge heaters are inserted into small holes drilled in metal materials and parts that require internal heat. While capable of providing localized high temperature heating, cartridge heaters can also radiate heat throughout the interior of a material or product.
Cartridge heaters provide localized, interior heating for specific components in various machinery across industries such as packaging, die cutting, mold forming, hot stamping, labeling, sealing, printing, fluid heating, and food service. Internal cartridge heaters are commonly used in hot plates, platens, semiconductors, shrink wrap machines, and labeling equipment. They are particularly vital in plastic and rubber forming processes, where they aid in material plasticization alongside other localized heating systems like strip heaters.
Ceramic heaters are among the most widely used electric heater varieties. Ceramic heaters are used as heating elements in a variety of configurations to provide conductive and radiant heat. Conductive ceramic heaters can be combined with aluminum nitride or other compounds to form warming plates or bonding instruments for medical devices and semiconductor applications. Stand-alone ceramic heating elements may be packed with magnesium oxide and terminated with lead or copper wires for use in a number of industrial applications.
Ceramic space heaters feature ceramic-insulated heating elements along with aluminum baffles and fans to deliver safe and energy-efficient radiant heat. These heaters are commonly used in rooms as ceramic room heaters. Additionally, other electric heaters, such as ceramic strip heaters and ceramic band heaters, also utilize ceramic insulation to transfer heat effectively.
Ceramic-insulated heating coils offer enhanced safety compared to uninsulated coils, particularly in industrial and consumer ovens. The insulation shields the coils from exposure to dripping grease or other materials, maintaining their effectiveness and significantly lowering the risk of fire.
Coil heaters are electric heaters that generate heat through the use of heating coils. A heating coil is a device that converts electricity to heat. Heating coils are among the most widely used heat generation materials in existence. Across industry, commerce and in the context of consumer products, heating coils are used to generate heat in buildings, equipment, small appliances and in other applications.
These heaters can be customized to various sizes and shapes, including round, coiled, and spiral forms, ideal for high-temperature needs in confined spaces. Star wound coils are inserted into pipes and ducts to induce turbulent flow in air or liquids. They find applications across industries such as heating, plastic manufacturing, food processing, textiles, and paper production.
There are a few different styles of drum heaters out there in order to accommodate a wide range of applications and industries. While the designs may be different, drum heaters are all manufactured in a way that allows them to increase the overall temperature of a liquid that is being stored within a container, or 55 gallon drum. The reason why the word container is thrown around is that some drum heaters have the ability to heat multiple containers instead of being restricted to one drum at a time. The type of drum heater that you require is all based on the individual needs and requirements that are present in your specific application. Whether you require a large drum heater, such as a drum oven, or a mobile single drum heater, finding the right drum heater manufacturer can save you time and money.
A duct heater is a heavy duty modular unit installed in the ventilating ductwork of commercial, residential and institutional HVAC systems, although smaller "duct" heating elements are used in the forced air heating systems of vehicles. Duct heaters can be complementary to a central heating system that utilizes forced air heating, also known as forced circulation heating or convection heating, where air is the medium that transfers heat. Fans and blowers are integral to the transfer of heat; their motion conveys the air through the duct heater.
Duct heaters integrate with existing central forced-air heating systems to preheat either fresh or returned air. The central air handler filters the air, reheats it, and circulates it through the ductwork. This conditioned air is distributed throughout the building and eventually returned to the central air handling unit (AHU). While most electric heater manufacturers design duct heaters in rectangular or square boxes, they can also create rounded models to fit specific sheet metal ductwork configurations.
Flexible heaters are great for a wide range of applications as they are able to fit into tight spaces and provide heat to areas or products that other traditional methods may not be able to reach. Flexible heaters are commonly found in applications such as air heating in baking ovens, surface heating, cabinet warming and a number of different other industrial applications. A majority of flexible heaters tend to be made from plastics or metals; obviously this all depends on the requirements of the application and the temperature range that they will be exposed to during the process. Other materials that are commonly used to manufacture flexible heaters include rubber molding, rope, certain adhesives, and polyimide films. These flexible heaters are manufactured in a way that will allow them to conform to a surface which requires heating in a number of different applications.
Foil heaters are used in many industries and they can be found in products like car battery warmers, cabinets, defrost applications, heat exchangers, laboratory equipment, incubators, ceiling panels, and wall panels. Most foil heaters are etched using an automated machine. The etching in the foil helps to distribute the heat evenly when the power source is turned on by putting more of the surface in contact with the device being heated. The computer-designed etched foil is sometimes manufactured with a laminated coating on either side to insulate it.
One major advantage of foil heaters is their rapid heating capability, thanks to the highly conductive and thin foil material. These thin foil sheets can be seamlessly incorporated into products with limited space. Foil heaters utilize wider elements, which can be placed closer together. This allows for multiple elements to be arranged side by side, generating more heat in a compact area.
Infrared heating works by using electromagnetic waves to transfer heat directly to objects or materials. An infrared heater heats its panels until they emit infrared radiation, similar to the sun's rays. This radiant heat travels directly to solid objects, effectively warming them without altering the surrounding air temperature.
An infrared heater transfers heat through the emission, reflection, and absorption of electromagnetic waves. Its key components include a heating system and a reflector. The heating system converts electrical or chemical energy into thermal energy, while the reflector directs this thermal energy toward surrounding objects. The efficiency of the heater largely depends on the reflector. Common reflector materials are aluminum, stainless steel, ceramics, and quartz, with some high-performance models using gold or rubies to enhance reflectivity and focus heat more effectively.
Infrared heaters are highly efficient and energy-saving, making them perfect for industrial applications like drying coatings, welding, and embossing or laminating. There are three main types of infrared heaters: quartz, ceramic, and metal sheathing. These heaters can rapidly achieve temperatures between 1300°F and 1600°F (704°C to 871°C). Among them, quartz heaters reach the highest temperatures, while ceramic heaters offer the most cost-effective solution.
Forced air heaters generate heat by using a fuel source or electricity to warm a heat exchanger. Air passes over the heated exchanger, absorbs the warmth, and is then circulated through ductwork by a fan or blower. Their versatility makes them a popular choice for many applications and processes.
The core element of a forced air heater is the heat exchanger, which can be one of three types: shell and tube, plate, or air-cooled. Shell and tube heat exchangers feature multiple small tubes within a cylindrical shell, expanding and contracting with temperature changes. Plate heat exchangers consist of a series of stacked plates, either brazed or gasketed, depending on the application and fuel type. Air-cooled heat exchangers are compact and portable, providing both heating and cooling.
The next crucial component of a forced air heater is the blower or fan, which draws in air to be heated and then circulates it throughout the space. In an electric forced air heater, electricity heats a heating element that transfers warmth to the heat exchanger. Once the air is heated, the blower expels it into the room. The direction and distribution of the heated air depend on the specific type and design of the forced air heater.
Industrial forced air heaters come in various sizes, ranging from models that can heat large buildings to compact units designed for smaller sections. Their flexibility and mobility contribute to their widespread popularity. Furthermore, among the different heating methods, forced air heaters are often the most economical and cost-effective option.
Electric fan heaters operate using resistive or ohmic heating, also known as the Joule-Thomson effect. In this process, electric current flows through a resistant material, converting electrical energy into heat. This heat is produced on a microscale as conduction electrons transfer energy to conductor atoms through collisions. A fan then disperses the generated heat into the surrounding environment.
A fan heater works similarly to a forced air heater but utilizes electricity-generated heat differently. Like a forced air heater, it draws air from the surroundings, blows it over a heating element to warm it, and then releases the heated air into a room, enclosure, or portable office.
Electric fan heaters feature a straightforward design that simplifies their use and installation. They generate heat quickly and efficiently, converting a minimal amount of electricity into warmth with minimal waste. However, due to their high operating costs, electric fan heaters are typically used only for short periods.
Modern fan heaters now feature advanced power settings and thermostats that automatically turn off the fan once the desired temperature is achieved. Their portability makes electric fan heaters perfect for factories and manufacturing environments where precise, targeted heat is essential for various processes.
Strip heaters are direct contact heaters designed to be bolted, clamped, or secured onto the surface of an object for efficient heating. Their compact size allows them to be used individually or in arrays based on application requirements. They feature a flat, straight design akin to a ruler, with added fins for heating the surrounding air.
A strip heater operates by converting electrical energy into thermal energy through the Joule-Thomson effect. Its design facilitates increased collisions between electrons and atomic ions on the surface, resulting in vibrations that generate heat.
Strip heaters consist of a heating element, sheath or sleeve, and mounting hardware. When used for radiant heating, they include additional fins. Their flexibility allows for bolting or attaching them to walls, pipes, and other surfaces to distribute heat over extensive areas. Typically used indoors, strip heaters are commonly found in baking ovens and vacuum dehydration systems. In colder climates, they are also employed to heat equipment and provide moisture protection.
Strip heaters are popular for their straightforward design, affordability, and portability. They feature insulation made of mica or ceramic and outer shells constructed from steel, stainless steel, or nickel alloys. These heaters can achieve temperatures ranging from 700°F to 1400°F (371°C to 760°C).
Cable heaters consist of narrow-diameter cables that can be bent, shaped, and configured to suit any heating requirement or application. These heating cables, also known as trace cables, heat cables, or heater cables, generate heat by passing an electric current through them. They come in various types, each designed to achieve specific temperature ranges for diverse applications and processes.
The heating cable looks similar to standard wiring but is stiffer due to its protective housing. This design allows the heating cable to be cut and trimmed to various lengths, enabling it to be shaped to fit the specific requirements of different applications.
There are two main types of heating cables: self-regulating (or self-limiting) and constant wattage. Self-regulating heating cables are designed to prevent overheating by maintaining a set temperature limit, which avoids burning out. These cables typically operate at lower temperatures, reaching up to 250°F (121°C).
Constant wattage heating cables do not have a fixed temperature and require a control mechanism for operation. They can achieve temperatures up to 500°F (260°C) and operate across voltages from 120 V to 480 V. Additionally, these cables are available in various types, each tailored to specific applications.
Convection heaters, or convector heaters, are fan-free units that use natural convection to distribute heat. By heating the air inside, these heaters create a difference in density, causing the warm air to rise and push cooler air into the unit. This method of heat transfer is quieter and avoids circulating dust and pollutants, as it lacks fans or blowers.
A convection heater consists of two main components: the heating element and the fins. Convection heating works by converting electrical energy into heat through resistance wires in the heating element. This element features metal sheaths that enclose spiral-wound resistance wires within an insulating powder, like magnesium oxide, all encased in a metal sheath.
The fins of a convection heater function like a chimney, enhancing heat transfer by directing airflow over the heating element and its surface to warm the incoming air. The design of these fins varies based on the heater's intended use. Standard convection heaters typically feature aluminum fins, while heavy-duty models, designed for high-demand applications, use steel fins that are brazed for added durability and explosion resistance.
Convection heaters are equipped with an over-temperature sensing device positioned near the heating element. This device halts the flow of electricity if temperatures exceed safe levels, typically due to a blocked air inlet causing excessive heat buildup.
Electrical cabinets need to maintain a stable temperature to ensure the proper functioning of electrical components. Enclosure heaters help regulate this temperature by warming the air inside the enclosure, reducing humidity, and preventing electronic components from freezing.
Enclosure heaters come in different types based on the size of the enclosure. Small enclosures typically use small ceramic heaters, while larger ones may require convection or forced air heaters. These heaters are designed to prevent condensation and ensure even heat distribution. Moisture buildup inside enclosures can lead to corrosion and rust, potentially causing failure in critical electronic components like circuit breakers, relays, busbars, circuit boards, and transformers.
Enclosures can utilize a variety of heaters, including fan heaters, convection heaters, surface or strip heaters, cartridge heaters, flexible heaters, and tubular heaters. When selecting an enclosure heater, the primary consideration is the cabinet's dimensions—height, width, and depth—as these define the cabinet's volume. The second factor is the density of the enclosed instruments, which impacts the overall volume of the cabinet.
The next crucial step in selecting a heater for an enclosure involves considering the cabinet's location. This includes factors like exposure to harsh weather, risk of freezing, and the availability of energy sources. Additionally, enclosures on ships, planes, rockets, and satellites must be specially engineered to meet their unique environmental conditions.
Kickspace heaters are installed at floor level, typically near the bottom of cabinets or cupboards. These compact, space-saving units are often hidden along baseboards and are commonly known as toe kick heaters due to their placement. They work by drawing cool air over electrical coils, which heat the air and then release it back into the room.
Kickspace heaters are compact enough to fit into almost any space, overcoming layout or structural challenges. Their discreet design makes them a popular choice for heating, as they blend seamlessly into the surroundings without disrupting a room's ambiance. This allows for greater design flexibility in interior spaces.
Kickspace heaters are designed for heating compact or hard-to-reach spaces like small rooms, powder rooms, dressing rooms, and kitchens. Due to their size, they are not suitable for large areas. Each unit operates independently with its own controls, allowing it to function without connection to the main heating system. This setup enables precise temperature control for individual rooms or areas without affecting the main system.
Mica heaters, also known as micathermic heaters, are highly efficient due to their dual-function heating method, combining convection and radiant heat. They feature heating elements similar to convection heaters but are covered with mica panels. Mica is renowned for its ability to emit electromagnetic rays, enhancing the heater's effectiveness.
Mica is a preferred material for heating applications because it can quickly achieve temperatures up to 1112°F (600°C). Its thin sheets contribute to low thermal mass and very fast heating times. Mica heaters are constructed with etched foil heating elements sandwiched between high-temperature mica layers, ensuring superior heat transfer. To maximize efficiency, mica heaters are secured between rigid plates to prevent layer separation.
Mica possesses key qualities such as heat resistance, electrical conductivity, and chemical stability, which collectively ensure a safe and efficient heat source. Its thermal stability prevents fires and malfunctions, allowing mica heaters to be installed without the risk of burning or scorching surfaces.
Mica heaters' exceptional heating efficiency stems from their unique blend of convection and radiation. Unlike traditional infrared and convection heaters, which have limitations on the areas they can warm, mica heaters operate silently without the need for blowers or fans, effectively heating any size space.
Unlike traditional heating methods that generate heat through plates or tubes, heat pumps absorb heat energy from the outside air. Similar to an air conditioner, a heat pump manages unwanted temperatures by transferring heat. However, while an air conditioner only removes warm or hot air, a heat pump can both extract cold air and add heat, adjusting its function based on the season and settings.
A heat pump draws heat from the ambient air, which circulates over a heat exchanger's surface. This heat causes the refrigerant to evaporate into a gas. The gas is then compressed, increasing its pressure and temperature. The heated gas flows over an internal heat exchanger, warming the air that is distributed throughout the building.
Heat pumps are highly efficient, extracting more heat energy from the environment than the energy they consume. They produce two to three times more heat than the electricity they use. Hybrid heat pumps work with traditional heating systems, adjusting their operation based on the outside temperature to optimize heating. Unlike other heating methods, heat pumps generate minimal emissions due to their exceptional efficiency.
When identifying which immersion heating company to purchase from, consumers should be sure to choose carefully. There are many different types of water heaters on the market today each with different useful applications and abilities. Some of these include pipe (or dry-well) heaters, flange heaters, over-the-side heaters, tubular heaters, and screw plug heaters. Consumers would be wise to choose a vendor who can accurately advise them on exactly which type of product will be most applicable in each of their individual situations. Companies who specialize in manufacturing immersion heating products must take multiple factors into consideration and should use ethical construction practices, high-quality materials, and well-researched engineering techniques.
Electric heaters of all kinds must be crafted with precision and care to ensure safety and effectiveness. Manufacturers should prioritize rigorous quality control to guarantee client satisfaction and safety. The best manufacturers possess a deep understanding of the electric heating industry and can effectively guide consumers in selecting the most suitable heating device for their needs.
Immersion heating systems come in various forms, and consumers might discover they need a different type of immersion heating element than initially expected. For those uncertain about the best heating device for their needs, experienced industry professionals can assist both companies and individuals in selecting the most suitable product for their specific heating requirements.
Industrial heaters are just that, heaters for industrial purposes. This includes a wide range of products from furnaces and ovens to immersion heaters and temperature sensors. Whatever your application may be, we strongly encourage consulting a knowledgeable, trusted industrial heater manufacturer in order to ensure that you receive the right type of industrial heater for your application. There are many different styles of industrial heaters, and each style can be further broken down into even more subcategories.
Certain industrial heater manufacturers focus on specific industries and heater types, so knowing the exact type of heater you need can help you narrow down the options and find the best match. Ovens and furnaces are industrial heaters that function similarly to kitchen ovens but on a larger scale. Subcategories include furnaces, keyhole ceramic insulated elements, and rectangular ceramic insulated elements.
A Kapton heater is a type of electronic heater that uses polyimide film to encapsulate heating circuits. This thin, ultra-flexible and lightweight material makes Kapton heaters a great solution for compact applications. The name" Kapton" comes from the polyimide film that was first developed by the company Du Pont for applications where a thin, flexible housing for heating circuits is necessary. A Kapton heater has the capacity to operate at extremely low and extremely high temperatures. Even though they are flexible, they have incredible tensile strength and durability. During manufacturing, a pattern is etched into the thin foil to help spread heat across a surface. This very thin film or foil can be created using materials like copper, kanthal and constantan.
Pipe heaters range in style and type depending on the application, as pipe heaters can be found in a vast range of industries and applications. There are a number of different forms of pipe heater solutions available in order to prevent your pipes from freezing.
Pipe heaters are available in various styles, including fiberglass cloth tape and wrap-on heating cables. Each style is designed for specific applications, with some being more effective under certain conditions. Wrap-on heating elements vary widely; some are engineered for sub-zero temperatures, while others are intended to prevent freezing in temperatures just below freezing and may fail in more extreme cold. Additionally, in-pipe heaters, which are installed inside the pipe, are ideal for heating drinking water and tap water quickly, often outperforming wrap-on solutions.
A silicone heater is a flexible heater with an internal wire element and a body made of silicone rubber. These durable heaters can operate at temperatures of up to 450 degrees Fahrenheit. Silicone performs well in environments where there are rapid changes in temperature and it is highly resistant to moisture and chemicals. These durable qualities make silicone the material of choice for heaters that will be exposed to harsh conditions in industrial or commercial settings. The circuit‘s surface can also be chemically etched to create a more even heat distribution pattern. Adhesive backing can be added to the heater if it is being fitted to a flat surface after manufacturing, and fasteners of various sizes are available for many applications.
In most silicone heaters, a fiberglass grid reinforces the silicone sheet, enhancing its strength and durability while keeping it thin and lightweight. These heaters can incorporate thermostats, thermocouples, and fuses and can be designed with holes to fit additional components. There are two types of heating circuits compatible with silicone rubber, each offering distinct advantages. The first, wire-wound circuits, involve wrapping resistance wire around a fiberglass core in a specific pattern. The second, etched foil circuits, are created by chemically etching a resistance pattern from nickel alloy foil, resulting in a flat circuit.
Strip heaters are small electric heaters that can be clamped or bolted onto a surface for direct transfer of heat to a solid object or for the heating of air in an enclosure. Strip heaters are usually flat, straight and similar in shape to a ruler, but they are often fined for fuller heat radiation when they are used to heat air. They can also be used to heat tubes, pipes and nozzles, in which case they can be designed as circular bands that clamp around cylindrical objects.
A few of strip heaters' common applications include providing heat for cylinders, platens, process machines, moisture protection, thawing, baking, drying ovens, food processing, control cabinets, acrylic extrusions and space heaters. Strip heaters may be used individually or in groups to provide melting, drying or air heating. Strip heaters can also be used in the formation and shaping of plastics. In plastic extrusion, strip heaters can be used to assist in the plasticization of raw plastic stock while it is processed in a conveyance channel. They are also used to heat plastics in advance of bending processes.
Tubular heating is used primarily in custom heating applications such as plastic injection molding, rubber molding, packaging, plastic welding, and plate heating. Food processing equipment uses the heaters to sterilize low-acid liquid foods, while small animal breeders use them to heat cages. Tubular heaters differ in terms of features and options; some products are corrosion resistant and explosion proof, while others are finned or portable.
Tubular heaters create heat with a coil heating element. These heaters are constructed with a coil centered in the heating element binder; inside the binder, the coil is surrounded by magnesium oxide powder. The powder is vibration loaded to ensure even density throughout the length of the heater. The heater is then reduced to the finished diameter, causing the magnesium oxide powder to compress and "freeze" the coil in the center of the heater. The final step is to place the binder inside a protective sheath. The coil converts electricity into heat and radiates heat through the insulation and sheath. The coil can be straight or curved to fit into smaller spaces, such as a coffee maker. The sheath is usually made from aluminum, copper, rubber or stainless steel and serves as a cover to the actual heating element.
ICR heaters are infrared heaters that emit short radiant wavelengths, converting 85% of the consumed energy into focused heat. They can be precisely adjusted to meet the specific heating needs of an area. The ICR series minimizes ceiling clearance, reducing clutter for a sleek, streamlined appearance. Installation requires a flush mount kit and a fire-rated enclosure. These heaters offer versatile design options as they can be mounted on either walls or ceilings, providing flexible heat coverage.
The Infinity 24 heat pump represents cutting-edge technology in HVAC systems. It combines adaptable speed technology with an advanced heat control system and features a variable speed compressor, enabling the unit to adjust to a building's specific needs. Its design allows for longer, steadier operation and exceptional energy efficiency. The Infinity 24 also boasts top-of-the-line temperature controls, setting a new standard in the industry.
Electric fired process air heaters are highly durable heating units used for industrial heating processes, such as ovens, baking, and curing and drying applications. Depending on the application, they can be installed vertically or horizontally with tubular heating elements. Electric fired process air heaters are designed for rugged use in industrial environments and have carbon steel mountings, stainless steel supports, and insulation collars. They can be custom designed to meet the needs of any industry.
The EWH5500 is a robust heater capable of delivering 17,060 BTUs to any workspace. Its louvered design directs airflow to improve heat distribution. With a handheld remote, adjusting settings is effortless. The compact size allows for both floor and wall mounting options. The EWH5500 features spiral-wrapped steel heating elements housed in a scratch-resistant cabinet, and includes a timer and overheat shutoff for added safety.
The DR998 features an integrated humidifier that adds moisture to the heating process and an oscillating function for even heat distribution. Its dual heating system efficiently warms large rooms within a temperature range of 50°F to 85°F, using water bottles in the process. The unit includes lifetime washable filters that can be cleaned with hot water or a vacuum. Additionally, the DR998 combines ceramic and infrared heating elements and comes with a remote control for added convenience.
Energy costs have become a great concern and may seem impossible to control since we depend so much on the convenience of energy consuming devices. A little thought and organized planning can help avoid waste and lead to a more efficient use of energy. A first step to resolve this issue can be a portable electric heater, which can make a dent in electric energy usage.
A band heater is a heating device that clamps onto objects to provide external heat using radiant and conductive heating. The different mounting methods of band heaters makes it possible to secure them tightly and...
A cartridge heater is a cylindrical tubular heating device that provides concise and precise heating for various forms of materials, machinery, and equipment. Unlike an immersion heater, a cartridge heater is inserted into a hole in the item to be heated to furnish internal radiant heat...
Ceramic heaters are electric heaters that utilize a positive temperature coefficient (PTC) ceramic heating element and generate heat through the principle of resistive heating. Ceramic materials possess sufficient electrical resistance and...
Electric heating is produced by using a known resistance in an electric circuit. This placed resistance has very few free electrons in it so it does not conduct electric current easily through it. When there is resistance in...
A flexible heater is a heater made of material that can bend, stretch, and conform to a surface that requires heating. The various forms of flexible heaters include polyimide film, silicone rubber, tape...
An immersion heater is a fast, economical, and efficient method for heating liquids in tanks, vats, or equipment. Known as bayonet heaters, they have heating elements that can be directly inserted into a container of water, oil, or other material in order to heat the entire contents...
Infrared heating is a heating method used to warm surrounding bodies by infrared radiation. Thermal energy is transferred directly to a body with a lower temperature through electromagnetic waves in the infrared region...
A heating element is a material or device that directly converts electrical energy into heat or thermal energy through a principle known as Joule heating. Joule heating is the phenomenon where a conductor generates heat due to the flow of electric current...
Radiant heaters are systems that generate heat internally and then radiate it to the nearby objects and people. The sun is a basic example of a radiant heater. When we feel warm on our bodies on a sunny day...
An AC power cord is a detachable way of providing an alternating current of electric energy from a mains power supply to an electrical appliance or equipment. Serving industries like...
Electrical plugs, commonly known as power plugs, are devices responsible for supplying and drawing current from a receptacle to the circuitry of an electrical appliance...
A NEMA connector is a method for connecting electronic devices to power outlets. They can carry alternating current (AC) or direct current (DC). AC current is the typical current found in homes, offices, stores, or businesses...
A power cord is an electrical component used for connecting appliances to an electrical utility or power supply. It is made from an insulated electrical cable with one or both ends molded with connectors...
Thomas Edison developed the power distribution system in 1882. He wrapped a copper rod in jute, a soft shiny fiber from plants, as an insulator. The jute wrapped copper rod was placed in a pipe with a bituminous compound...