Tubular heater

Types of tubular heaters

A tubular heater is an electric heater with flexible heating coils within a metal tube. The surface temperature of the tubular heater can be increased to warm up the surroundings or to heat the objects by placing them within the heater. Tubular heaters that are accustomed to twisting and bending into different shapes are particularly useful for providing localized heating in industries. Various types of tubular heaters are available.

• Refractory Cement

  Ceramic insulation is made of either alumino-silicate or silica and is attached by inserting it into a high-temperature cement pot. This method's primary advantage is that it can withstand incredibly high temperatures, shrinking, and expanding without damaging the heater or the insulation. However, this will operate at lower watt densities because the insulator must be larger in diameter than the heater. This is an effective insulation method for applications like heat treatment furnaces, kilns, molten metal heaters, and crucibles.

• Industrial Concrete Tubular Heater

  A specific type of refractory insulator that is engineered for high-temperature use is alumina-silicate refractory cement. This cement is built to endure extreme temperatures, making it an excellent insulator for tubular heaters employed in high-temperature industrial applications. Because of its superior capacity to resist heat, this kind of insulation enables the tubular heater to operate at higher watt densities and temperatures than other types of insulation. Moreover, it prolongs the insulation's and tubular heater's functional lives. This may lead to reductions in expenses for maintenance and equipment replacement over time. Refractory cement for tubular heaters can be used in heat treatment furnaces, kilns, and molten metal heaters, and crucibles, among other high-temperature industrial applications.

• Silicone Rubber

  A silicone rubber sheath insulates the heater, making it more insulated and protecting it from various environmental conditions. Shock and moisture resistance is high, but many waterproof silicone rubbers can narrow the allowed watt density. Silicone rubber can operate at a lower watt density and higher temperature than standard rubber. Its temperature range is often between 220 and 250 degrees Celsius. This is in addition to its greater comfort and flexibility. Silicone tubular heater applications include climate control, de-icing, drying, heating, thawing, thawing, sterilization, sterilization, humidity control, and heating blankets for a wide range of industrial uses.

• PTFE Tubular Heater

  PTFE, sometimes known as Teflon, is a thermoplastic polymer that offers significant resistance to chemicals, abrasion, and high temperatures. PTFE's electrical insulation characteristics, chemical resistance, and temperature tolerance create various uses in laboratories, the pharmaceutical industry, semiconductor manufacturing, and chemical processing. Tubular heaters with PTFE insulation are effective solutions in these demanding settings, providing dependable heating even in the most challenging industrial applications.

Specification & Maintenance

• Voltage and Power Rating:

  Tubular heaters come in various voltages, such as 120, 240, 400, or 480 volts, with power ratings generally between 100 watts and 10,000 watts. Selecting the appropriate voltage and power for the intended application is critical for proper operation.

• Length, Diameter, and Watt Density:

  Heaters' lengths and diameters will vary according to the specific application requirements. In addition, watt density is an important consideration. It refers to the number of watts per square inch of the heater's surface area. When selecting tubular heaters, ensure that the specific size and watt density match the heating needs of the application to avoid overheating or insufficient heat.

• Mounting Method:

  These heaters can be mounted in different ways based on the requirements of the application, such as clamping, bolting, or using brackets. The mounting method chosen should ensure that the heater is securely installed and that good heat transfer is achieved.

• Wattage and Operating Temperature:

  Tubular heater wattage is the amount of power it consumes, typically between 100 watts and 5,000 watts. The operating temperature determines how high the heater can safely reach. Different applications require different wattages and operating temperatures. When selecting a heater, make sure the wattage and temperature are appropriate to meet the needs of the application while ensuring safety and efficiency.

• Heating Element Material:

  The materials used, such as nickel-chromium alloy, stainless steel, etc., will provide different features and advantages. Choose the right material for the heating element according to the requirements of the application and the operating environment to ensure optimal performance.

Maintenance tips

• Regular cleaning: Use a soft cloth and warm soapy water to clean the surface of the tubular heater. Avoid using abrasive cleaners or scrubbers to prevent scratches or damage to the surface. Also, make sure the power is off before cleaning.
• Keep ventilation: Ensure that the installation location of the tubular heater maintains adequate ventilation. This helps avoid overheating and improve the service life. For example, do not block or seal the vents of the heaters.
• Check the power cord: Periodically check the power cord and plug of the tubular heater. Ensure there is no damage, such as breakage, peeling, or abnormal loosening. If there is any, it should be repaired or replaced in time to ensure electrical safety.
• Avoid prolonged use: Prolonged use of tubular heaters may cause overheating and shorten their service life. If conditions permit, it is better to turn off the power and allow it to cool down for a while during the heating process.

Scenarios of tubular heaters

Tubular heaters are versatile and commonly used heating elements in many industries for different purposes.

• Food and Beverage Industry: In the food and beverage industry, tubular heaters are used to heat liquids like sauces, butter, and chocolate. Foods must be kept at a specific temperature to ensure safety and quality. This is where tubular heaters come in handy. They are also used in the baking industry for drying and toasting activities.
• Medical and Pharmaceutical Industry: Tubular heaters are widely used in the pharmaceutical and prosthetic industries. They assist in regulating the temperature of costly medicines, maintaining the temperature of sterilization equipment, and ensuring precise and stable chemical reactions. Tubular heaters play a critical role in maintaining product integrity and compliance with industry standards.
• Chemical Processing and Plastics Manufacturing: In the chemical processing and plastics manufacturing industries, tubular heaters are used for applications like drying, heating molds, and tanks, as well as maintaining the temperature of reactors and extruders. They aid in minimizing viscosity for better flow in plastic processing operations.
• Textiles and Coatings: Tubular heaters are used in the textile and coating industries to heat materials, temper textile fibers, and maintain consistent temperatures in coating machines. They contribute to efficient production processes and high-quality end products.
• Construction and Infrared Heating: In construction and infrared heating industries, tubular heaters are used in applications like infrared heating panels and rails. They provide heat for curing processes, thawing frozen ground, and maintaining temperature in construction activities.

How to choose tubular heaters

Before purchasing tubular heaters for resale, buyers should consider the following:

• Industry requirements

  Buyers should evaluate applications and their specific heating requirements. Consider factors such as the required power, temperature, and dimensions/shape. Determine if they need custom tubular heaters to meet specific industry needs.

• Quality assurance

  Opt for high-quality tubular heaters that enhance performance, longevity, efficiency, and safety. Buyers should research supplier reputation, production experience, certification, etc. They can also request samples for on-site testing and evaluation.

• Wholesale price

  Consider the wholesale price and calculate the potential resale value. Buyers should compare prices among different suppliers and negotiate favorable wholesale pricing. Consider the costs for packaging, shipping, and sales channels to maximize profits.

• Custom options

  If buyers want to offer unique products, they should consider suppliers that provide customization options. They can collaborate with the supplier to develop distinct shapes, sizes, wattages, and temperature ranges that align with their brand.

• Service and support

  Choose a supplier that offers comprehensive services and support. Additionally, customers may require technical assistance and after-sales support. Buyers should evaluate the level of customer service provided and ensure it meets their business needs.

FAQ

Q1: How long does it take a tubular heater to heat something up?

A1: Heating time depends on various factors, including the wattage of a tubular heater, the temperature of the substance being heated, the desired temperature of the heated substance, and whether the tubular heater is in direct contact with the material being heated. Higher wattage tubular heaters will generally heat up substances faster. For example, a 300-watt tubular heater might take 30 to 60 minutes to heat water to a specific temperature, while a 1,500-watt tubular heater could heat the same amount of water in 10 to 20 minutes.

Q2: Can tubular heaters be repaired?

A2: Tubular heaters can be repaired if the damage is not extensive, such as broken leads, burned-out terminals, or damaged threads. Fine cracks in the heater or serious corrosion issues cannot be effectively repaired.

Q3: What are the safety precautions for tubular heaters?

A3: Always store heaters in a dry place. Do not operate heaters in humid or wet locations unless they are suitable for such use. Avoid contact with flammable or combustible materials. Do not attempt to disassemble the heater. Ensure the power supply voltage is within the specified range for the heater.

Q4: Can users install a tubular heater on their own?

A4: Yes, but only if it does not involve dangerous electrical or water elements. In such cases, only qualified personnel should carry out the installation. If users are unsure, it's better to consult an expert.

Q5: Do tubular heaters consume a lot of electricity?

A5: Tubular heaters are not high-power devices, so they do not consume a lot of electricity. However, the electricity they consume depends on their power rating in watts. Users can calculate the electricity consumed by multiplying the heater's power in kW by the hours of use.