- 1. Overall Structure Selection
- Pipeline type: Long cylindrical structure, directly connected in series in the process pipeline, suitable for large flow rate and medium-low pressure conditions, available in horizontal or vertical installation.
- Container type: Vertical closed tank with multiple heating tube bundles inside, suitable for small flow rate, high temperature & high pressure conditions, and scenarios with strict requirements on temperature uniformity.
- 2. Core Heating Unit
- Main body adopts sheathed electric heating tube: internal nichrome resistance wire + crystalline magnesium oxide powder (for insulation and heat conduction) + metal protective sleeve.
- Material: 304 stainless steel for temperature ≤400℃; 316L or Incoloy 800 high-temperature alloy for 400~800℃.
- Surface load is strictly controlled at 2\3W/cm²; heating tubes are evenly arranged, with spacing of 1.5\2 times the tube diameter.
- 3. Fluid Flow Equalization Design
- Inlet and outlet pipe diameters match the process pipeline to avoid sudden changes in flow velocity.
- Baffle plates or flow equalizing plates are installed inside to force nitrogen flow through the heating zone in an "S" path, eliminating gas flow short-circuiting and heating dead zones.
- 4. Pressure-Bearing and Sealing Structure
- Shell is designed in compliance with pressure vessel standards, with a 1.2~1.5 times safety factor reserved for wall thickness.
- Flat flange + temperature-resistant gasket for low pressure; welding neck flange + metal spiral wound gasket for medium and high pressure; full welded seal is available for ultra-high pressure conditions.
- Removable flange blind plate is set at the end for easy maintenance and replacement of heating tubes.
2、 Main technical features
Firstly, the heating response is fast, with a heating rate of up to 10 ℃/s, and the power can be adjusted in real-time according to the process load to avoid fluctuations in flue gas temperature.
Secondly, the thermal efficiency is relatively high. By combining fin enhanced heat transfer with low wind resistance flow field design, the thermal efficiency can reach over 95%, which is 15% to 30% energy-saving compared to the light pipe structure.
Thirdly, it has a wide temperature coverage range and can achieve multiple operating conditions including low temperature (≤ 160 ℃), medium temperature (≤ 260 ℃), and high temperature (≤ 600 ℃). The power range can be customized from 10kW to 1000kW.
Fourthly, the electric heating method has no combustion emissions, does not produce secondary pollutants such as sulfur dioxide and nitrogen oxides, and is easy to operate and maintain.
- 5. Thermal Insulation and Outer Protection
- Aluminum silicate wool insulation layer (50~200mm thick) is filled outside the shell to keep the outer surface temperature ≤50℃.
- Outer layer is wrapped with metal protective plate for waterproof, dustproof and anti-scald protection.
- 6. Electrical and Control System
- Junction box with standard protection grade IP54~IP65; flameproof junction box is required for explosion-proof scenarios.
- Temperature sensors are installed at inlet, outlet and heating section respectively, with PID closed-loop temperature control and accuracy of ±1℃.
- Standard protections include over-temperature, overload and leakage protection; optional flow/pressure abnormal linkage shutdown.
- 7. Special Design for Explosion-Proof Type (Chemical Industry Scenarios)
- Wiring chamber is completely isolated from heating chamber; flameproof enclosure complies with GB 3836 standard.
- Common explosion-proof grade: Ex d ⅡC T4 Gb; the whole equipment is reliably grounded (grounding resistance ≤4Ω).
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Post time: Sep-23-2026
