The term “heating elements” refers to any and all heat generation equipment in electric heaters. Found in equipment of all shapes and sizes and with a variety of configurations and materials, heating elements all have the same goal: to convert electrical energy into heat energy up to 1300°F, and then distribute said heat energy through or to solids, liquids or gases (including air) via convection, conduction or radiation. Heating element varieties used in industrial, commercial and consumer applications include: immersion, quartz, flexible, infrared and tubular heating elements, among many others.
Immersion heating elements are used to heat gasses and liquids; they have the special ability to be immersed in the materials they heat without malfunctioning. Immersion heaters are further characterized by their fast, efficient and cost-effective heating solutions. Types of materials they typically heat include plating baths, mild acids, oils, water, salts, air, and chemical solutions. These services are primarily performed for applications like process systems, boilers, water heaters, heat transfer systems, oil heaters, and storage tanks. Read More…
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Quartz heating elements convert electrical currents into infrared rays by running them through special resistors. In doing so, they provide rapid heating. These fast process speeds make them very popular for use with industrial applications like film curing, thermoforming, powder coatings, adhesive sealing, and paint drying, as well as zone control applications in automotive, print, petrochemical, textile, glass and electronic industries.
Flexible heating elements are able to bond to a variety of compounds and shapes and provide direct heating. This versatility is possible because they are very thin and bendable.
Infrared heating elements emit heat in the form of infrared waves, which are a type of electromagnetic radiation known for transferring heat efficiently. Infrared heating elements are used in conjunction with radiating heaters like duct, immersion, and tubular heaters, which heat air or liquid on the large scale. They support industrial ovens, pressure vessel heating, storage tank heating, boilers, water treatment plants, steam generation and more.
Named for their tubular shape, tubular heating elements are found in ovens, dishwashers and more, depending on their form; they may be manipulated into a standard shape or they may be take on a custom shape for a specific application. Usually consisting of an inner conductive material like steel, aluminum, nickel, copper or brass, tubular heating elements are often encased in a protective coating or sheath made from a ceramic.
Most appliances that use heat, use some sort of heating element. Commonly, heating element, whatever their type, are found in the form of coils or wires. In fact, wire heating elements are among the most widely used heating elements for industrial and commercial drying. They are found in surface treatment heaters, kilns, and many other dryers. Another type of heating element, the ceramic heating element, is utilized in convection heating; ceramic elements are built into space heaters, furnaces and semiconductors. Electric heating elements are quite prevalent as well, especially in the service of industrial electric heaters. Cartridge heaters supply localized heat to equipment parts in metal fabricating, foam fabricating, plastic fabricating, food processing and packaging. Coil heaters, band heaters or strip heaters help extruding channels and hoppers maintain the plasticity of materials as they are being extruded.
Before purchasing a new heating element or elements, it’s important to note a few things. First of all, note that heating elements usually have a shorter lifespan than the item they are serving, so expect to replace them from time to time. Generally, manufacturers will offer options stock purchasable or custom made replacement elements, depending on customer needs. More often than not, this replacement process has a fairly quick turnaround time and is considered a part of a regular maintenance schedule. If a heating element goes out in an end-user item, like a hairdryer, however, it’s probably more economical to replace the whole item rather than its heating element. Also note that in order to achieve safe and effective operations, you must correctly pair your heating element and its application. A failure to do so has the potential to result in short circuiting, fires, product damage or equipment loss.
Heating Elements Informational Video