Tubular Heaters

The flexible tubular heating element can be easily bent by hand and is therefore perfectly adaptable to all contours.

Tubular heating elements are an indispensable part of modern industry. They are used in many manufacturing processes and impress with their powerful efficiency.

What are electric tubular heaters?

Tubular heaters are electrical heating devices that are designed in the form of tubes or pipes. They are used to heat, regulate and check liquids, gases and solids in industrial applications to the desired operating temperature.

How do tubular heaters work?

At the center of a tubular electric heater is a heating element, usually made of a resistant wire material such as stainless steel or nickel-chromium alloys. This wire has a high electrical resistance, which means that it does not allow electric current to pass through it easily and therefore heats up when current flows through it.

The heating wire is surrounded by an insulating tube, which is also often made of stainless steel or another heat-resistant material. This tube serves to protect the heating wire and to direct the heat in the desired direction.

To supply the tubular heater with electrical energy, it is connected to an electrical power source. This then flows through the heating wire inside the tube.

The electrical resistance of the heating wire causes it to heat up and give off heat. As the wire is located inside the insulating pipe, the heat generated is dissipated to the outside. This heat can then be directed to the desired area of application.

In addition, a temperature sensor can be connected, allowing temperatures to be precisely adjusted and monitored.

What can be heated with tubular heaters?

Electric tubular heaters can be used in a wide range of applications, heating materials and media. These include

• Liquids: Tubular heaters are often used to heat liquids in tanks, containers or pipe systems. This can include water, oil, chemicals, solvents or other liquids. A common example is the heating of water for heating and hot water systems.

• Gases: Tubular heaters can be used to heat gases such as nitrogen, oxygen or carbon dioxide. These are used, for example, in industrial drying systems or gas flow applications where a specific temperature is required.

• Solid materials: In some industrial processes, electric tubular heaters are used to melt or heat solid materials such as plastic granulate or bulk material before they are processed further. Metal and glass can also be heated, melted or shaped in ovens using tubular heating elements.

• Working appliances: Tubular heaters are also used to heat appliances such as ovens, boilers, heating systems, reactors or distillation plants and to maintain uniform temperatures.

Types of tubular heaters

To ensure that electric tubular heaters can be used efficiently and safely in any type of application, different and adapted types are required. The most important types include

• Coiled tubular radiators: This type of tubular radiator consists of a heating wire spirally wound around an insulated tube. These flexible tubular heaters can be manufactured in various shapes and sizes. This allows them to be used in tank heating systems, for example, so that the tubular heaters heat water, oil, solvents or chemicals in industrial processes.

• Flanged tubular heaters: These tubular heaters are equipped with a flange, a flat and round component with a hole, which is attached to a tank or other structure. They are often used in industrial applications to heat liquids or gases in tanks or containers.

• Immersed tubular heaters: These are immersed directly in a liquid or gas that needs to be heated. They are widely used in heating applications such as water heaters, chemical tanks and ovens.

• Tubular heaters with integrated temperature sensors: Some tubular heaters are equipped with temperature sensors such as thermocouples or resistance thermometers to monitor and control the temperature in real time. This enables precise temperature control, such as in plastic extrusion or chemical reactors.

What are the advantages and properties of electric tubular heaters?

Due to their many advantages, electric tubular heaters are used in a wide range of industrial applications. Particularly relevant advantages and properties are

• Versatility of application: Tubular heaters are available in different sizes, shapes and materials and can be adapted to the specific requirements of an application. As a result, electric tubular heaters can heat water and other liquids, gases, solid materials and even appliances. This makes them extremely versatile.

• Efficient heat transfer and precise temperature control: Tubular heating elements generate heat directly inside a pipe or conduit, enabling fast, efficient heating. In addition, the precise temperature control of tubular heaters with thermostats and control systems is crucial for industrial processes.

• Robustness and durability: Most tubular radiators are made of high-quality materials such as stainless steel, Incoloy or nickel-chromium alloys, which are corrosion-resistant and offer a long service life. However, flexible tubular heaters are also very durable. As a result, tubular heaters require minimal maintenance under normal operating conditions, keeping their running costs low.

• Simple installation: Tubular heaters are often easy to install and only require a power source and a connection to the medium to be heated.

• Safety: Modern tubular heaters from high-quality manufacturers are usually equipped with protective devices such as temperature sensors, overheating protection and pressure relief valves to ensure safety during operation.