The 7 Best Ways to Use Tubular Heaters in 2023

It is very important to keep your energy bills low for one business owner. With the cold weather months upon us, finding an energy-efficient solution to keep your facility warm without breaking the bank is essential. Tubular heaters are an excellent choice for those looking to save money on energy costs while maintaining a comfortable temperature in their commercial or industrial space.

 

In this article, we’ll explore the many benefits of tubular heaters, including their design, construction, and energy efficiency ratings. We’ll also discuss various uses and types of tubular heaters, such as Hi-Density Miniature Cartridge Heaters, Convector Heaters, and Masonry Heaters, and their unique features, such as built-in temperature sensors and flexible leads.

 

Introduction to Tubular Heaters

 

What is the tubular heater? Tubular heaters consist of tubular elements housed in a metal tube and are designed to be energy efficient, making them an excellent choice for commercial and industrial use. They offer quick response, excellent energy efficiency, and low energy costs. Tubular heaters are corrosion-resistant, have excellent thermal inertia, and can be designed as custom heaters to fit any specific needs.

 

There are various types of tubular heaters, such as Hi-Density Miniature Cartridge Heaters, Convector Heaters, and Masonry Heaters, each with unique features and applications. For example, Hi-Density Miniature Cartridge Heaters are perfect for applications where space is limited, while Masonry Heaters are designed to provide efficient and long-lasting heat for large commercial or industrial spaces.

 

Whether you’re looking for an energy-efficient solution to keep your commercial or industrial space warm during the cold weather months, consider tubular heaters, with their excellent energy efficiency, low energy costs, and various types and applications. Tubular heaters are an excellent investment for any business looking to save money on energy bills while maintaining a comfortable temperature in their facility.

 

Seven Ways to Use Tubular Heaters in 2023

 

Tubular heaters are essential in various industrial applications, providing a reliable and efficient means of heating air, liquids, and surfaces. These electric heaters consist of tubular elements enclosed in a metal tube, making them highly durable and versatile. In this article, we will explore tubular heaters’ industrial applications and their benefits.

 

Hot Water Systems

One of the most common applications of tubular heaters is in hot water systems. Tubular heaters are used to heat water pipes, especially during cold weather. They can be used in hot water heaters, baseboard heaters, and similar systems. The design of tubular heaters can be customized to suit specific applications, such as with built-in temperature sensors, to provide accurate temperature control.

 

Tubular heaters can operate in various temperature ranges, making them suitable for applications requiring high temperatures. They can be used in furnaces, ovens, and other high-temperature applications requiring precise temperature control.

 

Industrial Processes

Tubular heaters are used in various industrial processes, including chemical and food processing. They can heat oil or other liquids, such as in reactors, distillation columns, and heat exchangers. In addition, tubular heaters can be designed to operate in hazardous environments, making them ideal for use in explosive atmospheres.

 

Tubular heaters are highly durable and corrosion-resistant, making them suitable for use in harsh environments. They are commonly used in industrial applications, such as oil and gas refining, chemical manufacturing, and wastewater treatment.

 

Wastewater treatment

Tubular heaters are an essential component of wastewater treatment systems, as they are used to heat the water and maintain the temperature required for the treatment process to work effectively. The use of tubular heaters in wastewater treatment provides several benefits. Firstly, it helps to ensure that the treatment process is effective by maintaining the proper temperature of the water. Secondly, it can help to reduce the time and energy required for the treatment process, as water can be heated more quickly and efficiently using tubular heaters.

 

Heating Air and Gas

Tubular heaters are also used to heat air and gas in industrial and commercial settings. They are commonly used in HVAC systems to heat the air that is circulated throughout a building. Tubular heaters are also used in industrial processes that require hot air or gas, such as drying, curing, and annealing. They are effective at providing uniform heat distribution and can be designed to operate at high temperatures.

 

Freeze Protection

Tubular heaters are used to protect pipes, tanks, and other equipment from freezing in cold weather. They are commonly used in outdoor applications, such as water supply lines, storage tanks, and sewage treatment plants. Tubular heaters can be designed with a variety of sheath materials, such as copper, stainless steel, and Incoloy, to withstand harsh outdoor conditions.

 

Comfort Heating

Tubular heaters can be used to provide heat in commercial and residential buildings. They are commonly used in areas that require supplemental heating, such as basements, garages, and warehouses. Tubular heaters can be mounted on walls or ceilings to provide radiant heat, which is more energy-efficient than forced-air heating systems.

 

Process Heating

Tubular heaters are ideal for process heating applications that require precise temperature control. They can be designed to operate at specific watt densities, voltages, and temperatures to meet the requirements of various processes. Tubular heaters can be used for applications such as heating liquids, gases, and solids in laboratory and industrial settings.

 

Other Applications

Tubular heaters are also used in a range of other applications, including aerospace, automotive, and manufacturing. They are commonly used to heat air or liquids in these applications, providing a reliable and efficient means of heating.

 

In the aerospace industry, tubular heaters are used to maintain critical temperatures in aircraft components, such as fuel lines, hydraulic systems, and avionics. In the automotive industry, they are used to heat engine blocks, oil pans, and transmissions. In manufacturing, tubular heaters are used to heat molds, extruders, and other equipment.

 

Benefits of Using Tubular Heaters in 2023

 

Tubular heaters are electric heaters that are widely used in various industrial applications due to their excellent performance and efficiency. They are designed with tubular elements enclosed in a metal tube, making them durable and versatile. We will introduce the benefits of using tubular heaters in 2023 and how they can improve the efficiency and performance of various industrial processes on this page.

 

Energy Efficiency

The main benefit of tubular heaters is their excellent energy efficiency. They are designed to transfer heat efficiently, providing quick response times and excellent thermal inertia. This means that they can quickly reach the desired temperature and maintain it with minimal energy consumption.

 

Tubular heaters can also be designed to operate in various temperature ranges, making them suitable for high-temperature applications. To improve their performance and accuracy, they can be customized to meet specific requirements, such as with built-in temperature sensors or flexible leads.

 

In addition, tubular heaters are highly customizable, making them suitable for specific applications. They can be designed to operate in various environments, including hazardous areas, making them an excellent choice for many industrial processes.

 

Durability and Corrosion Resistance

Tubular heaters are highly durable and corrosion-resistant, making them suitable for use in harsh environments. TConstructed from premium materials that can resist corrosion, like stainless steel or Incoloy, they are designed for durability. This means they can withstand exposure to corrosive materials, chemicals, and moisture, making them ideal for chemical processing, oil and gas refining, and wastewater treatment.

 

Tubular heaters can also be designed to operate in various temperature ranges, making them suitable for high-temperature applications. The materials used in tubular heaters maintain their effectiveness in the face of extreme temperatures, offering dependable and efficient heating options.

 

Quick Response Times

Tubular heaters are known for their quick response times, which makes them an ideal choice for many industrial processes. They can quickly reach the desired temperature and maintain it with minimal energy consumption, which can help reduce energy bills and improve the energy efficiency rating of a building or facility.

 

In addition, tubular heaters offer excellent thermal inertia, which means that they can maintain the desired temperature even when the ambient temperature fluctuates. This can help reduce the risk of equipment failure and improve the reliability and efficiency of industrial processes.

 

Customizability

Tubular heaters are highly customizable, making them suitable for specific applications. They can be designed with different shapes, sizes, and watt densities to meet the specific requirements of a particular application. This means that they can be used in a wide range of industrial processes, from food processing to aerospace.

 

Tubular heaters can also be designed with various mounting options, including flanges, threaded fittings, or welded connections. This means that they can be easily integrated into existing equipment, making them an excellent choice for retrofitting applications.

 

Safety Features

Tubular heaters can be designed with various safety features to protect against overheating, electrical faults, or other hazards. For example, they can be designed with a temperature fuse or a built-in thermostat to prevent the temperature from exceeding a certain threshold. They can also be designed with a thermal cutoff or a high-temperature limit switch to prevent equipment failure or damage.

 

In addition, tubular heaters can be designed to operate in hazardous environments, making them an excellent choice for use in explosive atmospheres. They can be designed with various certifications, such as ATEX, IECEx, or UL, to ensure that they meet the highest safety standards.

 

Cost-Effectiveness

Tubular heaters offer a cost-effective solution for many industrial heating applications. They are highly efficient, which means that they can reduce energy bills and improve the energy efficiency rating of a building or facility. In addition, they are durable and long-lasting, which means that they require minimal maintenance and replacement costs.

 

Types of Tubular Heaters

 

Tubular heaters are electric heaters consisting of a metal sheath or tube which houses an electrical heating element. The metal sheath or tube can be made from various materials, including copper, stainless steel, and Incoloy, and the heating element can be made from different materials, such as nickel-chromium or iron-chromium-aluminum alloys. Tubular heaters are versatile and can be used in various applications, ranging from industrial heating to residential heating. Different types of tubular heaters are available in the market, and this article will explore some of them.

 

Straight Tubular Heaters

Straight tubular heaters are the most common type available in the market. They consist of a straight metal sheath or tube with a uniform diameter. The heating element is placed in the center of the tube, and the space between the tube and the element is filled with magnesium oxide powder. The powder acts as an insulator and helps transfer heat to the metal sheath or tube, heating up the surrounding environment. Straight tubular heaters are available in various lengths and diameters, making them suitable for different applications.

 

Formed Tubular Heaters

Formed tubular heaters are designed to fit into specific shapes or configurations. They are made by bending the metal sheath or tube into the desired shape, and the heating element is placed inside the bent tube. Formed tubular heaters are suitable for applications where space is limited and a custom-designed heater is required. They are commonly used in the medical and semiconductor industries, where precise temperature control is necessary.

 

Finned Tubular Heaters

Finned tubular heaters have fins or ridges on the outside of the metal sheath or tube. The fins increase the surface area of the heater, allowing it to transfer more heat to the surrounding environment. Finned tubular heaters are commonly used in air heating applications, such as duct heating and space heating. The fins can be made from various materials, including aluminum and stainless steel, and can be attached to the metal sheath or tube in different ways, such as welding or brazing.

 

Flange Tubular Heaters

Flange tubular heaters are designed to be mounted onto a flat surface, such as a tank or vessel. They consist of a metal sheath or tube with a flange at one end and a terminal box at the other end. The flange allows the heater to be bolted onto the surface, while the terminal box houses the electrical connections. Flange tubular heaters are commonly used in industrial heating applications, such as oil and gas processing, chemical processing, and water heating.

 

Circulation Heaters

Circulation heaters are tubular heaters that are designed to heat liquids or gases as they flow through a pipe or tank. They consist of a metal sheath or tube with a heating element inside, and a temperature sensor is installed to monitor the temperature of the fluid or gas. Circulation heaters are commonly used in the food and beverage, oil and gas, and chemical processing industries, where precise temperature control is necessary.

 

Process Heaters

Process heaters are tubular heaters that are designed to be used in industrial heating applications, such as furnaces, ovens, and dryers. They consist of a metal sheath or tube with a heating element inside, and they can be designed to meet specific requirements, such as high temperature, rapid heating, or precise temperature control. Process heaters can be used in various industries, including automotive, aerospace, and electronics.

 

Choosing the Right Tubular Heater for Your Application

 

Choosing the right tubular heater ensures optimal performance and energy efficiency in any industrial heating application. With a wide range of available options, it can be challenging to determine which heater is best suited for your specific needs.

 

Nonetheless, you still make the right decision by considering several crucial aspects.

 

One of the best options for a high-quality and reliable tubular heater is HASTECO Heating Technologies. HASTECO offers various tubular heaters customized to meet specific customer needs, including industrial, commercial, and residential heating applications.

 

 

 

 

When choosing the right tubular heater, consider the following factors:

 

Temperature Requirements

The first factor to consider is the temperature requirements of your application. Different heaters are designed to operate at different temperatures. Some tubular heaters can achieve temperatures up to 2000°F, while others are designed to operate at lower temperatures. HASTECO offers a range of tubular heaters that can operate at a variety of temperatures to meet any heating requirement.

 

Watt Density

Watt density is another essential factor to consider when selecting a tubular heater. This refers to the amount of heat that is produced per square inch of the heater’s surface area. High-watt density heaters generate more heat per square inch, which can benefit applications where space is limited. However, they also require more frequent maintenance and have a shorter lifespan. On the other hand, low-watt density heaters have a longer lifespan and require less maintenance, but they are less efficient in terms of heat output. HASTECO offers a variety of watt densities to meet any heating requirement.

 

Material Selection

The material used to construct the heater is also a crucial factor to consider. Different materials offer varying levels of corrosion resistance, thermal conductivity, and strength. Common materials used for tubular heaters include copper, stainless steel, and Incoloy. HASTECO offers a variety of material options to select from, tailored to the unique requirements of your particular application.

 

Heater Size and Shape

The size and shape of the heater must also be considered. The size of the heater will determine the amount of heat that can be generated, while the form will determine how the heat is distributed. HASTECO offers a variety of shapes and sizes to ensure that your heating requirements are met.

 

Voltage and Power

The voltage and power requirements of the heater should also be considered. Different heaters require different voltage and power inputs, and these should be matched with the power supply available in your facility. HASTECO offers a range of voltage and power options to ensure compatibility with your existing electrical system.

 

Customization Options

Finally, consider any customization options that may be required for your specific application. HASTECO offers a range of customization options, including built-in temperature sensors, thermocouples, and specialized lead wires.

Conclusion

Choosing the right tubular heater requires careful consideration of various factors to ensure optimal performance and energy efficiency. HASTECO Heating Technologies offers a range of customizable tubular heaters that meet any heating requirement, making them an excellent choice for industrial, commercial, or residential heating applications.

 

In addition to making the best tubular heater, we also offer a high-quality coil heater and cartridge heater. Contact us to buy top heating elements at the best price.

 

 

Sales representive Luke

Luke

As the devoted CEO of Hasteco, I've spent countless years nurturing my passion for heating elements. Warmly inviting you to connect & collaborate for cozy, tailor-made solutions. Get in touch!

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