In industrial and commercial settings, tubular heaters are among the most widely used types of electric heating elements. They can be used to heat liquids, gases, solids or surfaces, and come in a wide range of models to suit virtually any requirement.
But what factors should you consider to make the right choice? From heater type and voltage to installation environment, we’ll guide you through everything you need to know !
The right heater is about efficiency, durability, and matching the element to your environment.
How are Tubular Heaters Made?
The way a heater is manufactured plays a crucial role in determining its longevity and efficiency.
How are Tubular Heaters Made- ohmvo.comA NiCr resistance wire is carefully wound into a precise coil, which is then positioned at the center of a metal sheath. Terminals are securely attached. The assembly is packed with high-grade magnesium oxide (MgO) powder then compacted to reduce its diameter and compress the MgO into a dense, solid mass. At this stage, the heater is placed in a furnace to soften the metal sheath, allowing it to be bent into custom shapes. Finally, the tubular heater is shaped into its final configuration and ready for quality inspections and performance testing.
Importance of Selecting the Right Tubular Heater
The performance, efficiency, and lifespan of a heating system depend greatly on selecting the right finned tubular heater for the intended application. The right choice can lower operating costs, boost productivity, and enhance product quality.
What to Look for Before Buying a Tubular Heater ?
The Type
Tubular heaters are generally classified into four main types :
- Finned tubular heaters. Equipped with fins to increase surface area and enhance heat transfer efficiency. Commonly used for heating air and gases in ovens, dryers, and various types of ducts.
- Straight tubular heaters. A simpler design, best suited for immersion heating in tanks, boilers, vats, and similar applications.
- U-shaped tubular heaters. The curved form makes them ideal for use in molds, dies, and platens, as well as for immersion heating.
- M-shaped tubular heaters. Compact in design, making them well-suited for tight spaces or irregularly shaped installations.
The Size and Shape
The size and shape of a tubular heater directly influence its heating capacity and heat distribution.
For example, the diameter affects both the rate of heat transfer and dissipation, as well as the curvature radius. A larger diameter results in greater heat transfer, faster dissipation, and a wider curvature radius. Conversely, a smaller diameter reduces these factors.
Likewise, increasing the length of the finned heater enhances its heating capacity. Depending on your application, you may choose a curved heater. While this option requires a more complex installation, it provides more uniform heat distribution.
The Material
The choice of material will affect the heat transfer rate, dissipation efficiency, and overall lifespan of your tubular heater. Common options include:
Material of Tubular Heater – ohmvo.comStainless Steel. A widely used material known for its excellent heat transfer properties.
Incoloy / Inconel. A nickel–iron–chromium alloy that provides exceptional corrosion resistance and an extended service life.
The Wattage
Be mindful of power and voltage mismatches, as these can impair heating performance or cause premature equipment failure ! For industrial applications, account for the volume and type of material being heated, as well as any potential heat loss. Power density is typically expressed in watts per square inch or per square centimetre.
The Environmental Conditions
Environmental Conditions – ohmvo.comWhen selecting a tubular heater, it is also important to consider the operating environment, including exposure to corrosive substances, humidity, and harsh chemicals. These factors may influence the choice of material, as well as the need for additional features such as overheating protection or explosion-proof enclosures.
About the Thermostat
It can be mechanical, digital, smart, or capillary. The latter uses a sensor bulb connected to the main unit by a tube filled with a fluid that expands when heated, triggering a switch. This design allows the sensor to be positioned at a distance from the control dial.
Choose one that is compatible with the required electrical current and offers the features and precision your application demands.
Do I Need Customization Options ?
From size and shape to power, every aspect of a tubular heater can be customized to suit your needs, ensuring the perfect installation even for highly specific applications.
Common options include the integration of thermostats or thermocouples, enhanced corrosion-resistant coatings, and specialized housings for operation in humid environments. Installation is equally adaptable, with various mounting configurations available, such as flanges, brackets, clamps, or threaded fittings. These choices are essential for extending the lifespan of your system and ensuring consistent heat distribution.
Installation and Maintenance
Correct installation is essential to ensure both safety and optimal performance. As for maintenance requirements, they remain also crucial for reliable operation and longevity.
How to Install the Tubular Heater – ohmvo.comAfter disconnecting power, mount securely and horizontally your tubular heaters, and make sure to maintain clearances. Air must be able to circulate properly through the installation, and flammable materials must be kept at a safe distance.
Final Thoughts on Choosing the Right Tubular Heater
As we’ve seen, tubular heaters are an excellent choice thanks to their high thermal efficiency, uniform heat distribution, and wide range of customization options. Just as important, selecting the right tubular heater also means relying on the proven reliability of a reputable manufacturer.
Explore OHMVO’s full range of heating solutions and discover how our expertise, quality materials, and customizable designs can meet the exact needs of your application !