Electric process heaters: types and fields of application

In this article, we'll delve deeply into integrated electric heating systems for the process industry, clarifying what process heaters are and their relevant fields of application.

The process industry

The process industry is a fundamental sector that deals with the transformation of raw materials into finished products through the management of a series of continuous chemical, physical, or biological processes. "Continuous processes" refers to the uninterrupted production of material flows, without significant breaks.

This characteristic clearly distinguishes it from the manufacturing industry, which focuses on the production of "discrete" goods, meaning products that can be divided into single, well-defined units. Striking examples of the process industry include oil refineries, chemical plants, the pharmaceutical industry, and various types of food industries.

Electric heaters: What they are

Electric process heaters represent a specific subcategory of process heaters, distinguished by their use of electrical energy as the primary heat source.

While they perform the same general function as other process heating units (i.e., providing heat to a medium within an industrial process), their distinguishing characteristic is precisely the use of electricity to generate the necessary heat.

Specific functions and fields of application

Similar to process heaters in general, electric process heaters are used in a wide variety of industries and for diverse applications, thanks to their precision and cleanliness. Their main functions and areas of use include:

• Fluid Heating: They're ideal for raising the temperature of liquids like water, oils, chemical solutions, and gases, ensuring accurate thermal control for reactions, processes, or simply to maintain operating conditions.
  
  
• Temperature Maintenance: They're essential for preventing temperature-related problems, such as freezing, solidification of substances, or loss of fluid viscosity, which could compromise process efficiency or functionality.
  
  
• Space Heating: They're used to provide heat in specific spaces like industrial warehouses, laboratories, or production areas, where climate control or supplementary heating is needed.
  
  
• Drying and Curing Processes: They're fundamental for removing moisture from materials or for inducing specific chemical reactions, such as the polymerization of resins or the curing of coatings, thanks to their ability to provide controlled and uniform heat.

Electric process heaters offer numerous advantages, including energy efficiency, zero emissions, and ease of control, making them a preferred choice in contexts where precision and cleanliness are stringent requirements.

Circulation heating systems

Circulation heating systems are advanced technologies designed to heat a fluid (liquid or gas) by circulating it through a heating element. In practice, the fluid is pumped or pushed into a circuit where, once heated, it is then distributed to the point of use or to the industrial process that requires heat. This approach ensures efficient and controlled thermal transfer.

Zoppas Industries technology for the process industry

Zoppas Industries stands out as a leading supplier in the sector, offering tailor-made integrated electric process heating systems. These solutions are designed to meet the specific needs of industrial clients, providing complete, "turnkey" systems for heat transfer. The systems are skid-mounted to ensure easy installation and management in any operational context.

The solutions offered by Zoppas Industries are conceived to ensure reliability, efficiency, and safety even in the most critical industrial processes, with a particular emphasis on customisation for each individual application.

Versatile applications

Zoppas Industries' electric heating systems are suitable for a wide range of applications, including the heating of:

Gases
Nitrogen
Hydrogen
Fuel oil
Water
Hydrocarbons
Petroleum
Steam

Key performance and characteristics

We're able to provide various industrial heating solutions, with power capabilities of 10 MW and beyond, thanks to a modular design that facilitates adaptation. Our systems are engineered to operate at temperatures up to 750 °C, offering optimal performance across a wide variety of processes, and they support supply voltages up to 690 Volts.

Integrated and tailored Sìsolutions

In addition to electric process heaters (such as heat exchangers or electric heater batteries), Zoppas Industries offers a global range of integrated components for building complete and high-performing systems. This includes:

• Control and shut-off valves: For precise fluid flow management.
  
  
• Pumps for fluid handling: Essential for efficient circulation of liquids and gases within the system.
  
  
• Accurate temperature measurement systems: For constant and reliable monitoring of operating conditions.
  
  
• Pre-wired and customized electrical control panels: Designed for intuitive and specific management tailored to client needs.
  
  
• Self-supporting structures: Ensuring easy and safe installation of the entire system.
  
  
• "Turnkey" solutions fully assembled and tested: For quick and smooth commissioning.
  
  
• Safety systems with cut-outs: For automatic protection in case of anomalous temperatures, ensuring maximum operational safety.
  
  
  

Options

Zoppas Industries' systems are also available in ATEX / IECEx certified versions for hazardous areas, ensuring maximum safety even in explosion-risk environments.

The company also offers start-up and commissioning services to ensure optimal initiation and efficient, uninterrupted operation of the systems.

Choosing Zoppas Industries means relying on an experienced and certified partner for integrated electric process heating solutions. Our technologies are high-quality, customized, and developed in co-engineering with the client to optimise industrial processes and promote production models increasingly oriented towards environmental sustainability and decarbonisation values.