What is an industrial element and how does it work?

What is an industrial element and how does it work?

Industrial Heating Element is a device that converts electrical energy into thermal energy. This process is based on the principle of "Joule Heating"; Where the passage of electric current through a conductor with high resistance leads to the production of heat.

The main difference between industrial elements and domestic models is in the output power, sheath material, temperature tolerance and their lifespan in hard working conditions. A standard industrial element must be able to continue operating in acidic environments, under high pressure or at temperatures above 1000 degrees Celsius, without quality loss.

Technical structure and components

Designing and manufacturing a high-quality industrial element requires high engineering accuracy. The main components are:

1. Resistance wire: nickel-chromium (Ni-Cr) alloys are usually used to withstand high temperatures.
2. Electrical insulation: magnesium oxide (MgO) which has the function of transferring heat and preventing electrical connection to the body.
3. Sheath: made of steel (304, 316, 321), incoloy (Incoloy) or copper, depending on the user environment.
4. Terminals and connections: The connection point of electric cables that must be resistant to vibration and heat.

Types of industrial elements based on application

To know which model is suitable for your needs, you should familiarize yourself with the main categories:

1. Tubular Element

It is the most widely used type of element in the industry. Due to its high malleability, it can be produced straight, bent or U-shaped.

• Application: heating of water tanks, oil, ovens and industrial dryers.

2. cartridge element (Cartridge Heater)

These elements are designed to focus the heat in a specific point and are usually placed inside the mold holes.

3. Flanged Element (Flanged Heater)

These heaters consist of several rod elements that are welded on a steel or steel flange.

• Application: Rapid heating of large volumes of liquids in boilers and large tanks.

4. Element with fins or fins (Fired Heater)

In order to increase the contact surface with air, fins are installed on the sheath of these elements.

• Usage: Unit heaters, resistance banks and duct heaters.

5. Band & Ceramic Heaters

These elements are designed in a circular form and are closed around nozzles or cylinders.

The industrial element is used in various industries, wherever controlled heating, melting, drying or temperature maintenance is required.

The most important industries are:

• Plastic and polymer industries: plastic injection machine, extruder, molding, nozzle and cylinder
• Food and beverage industries: cooking tanks, fluid heating, production lines, dryers
• Oil, gas and petrochemical: heating tanks, pipes, fluids, heaters Explosion-proof
• Steel and metal industries: industrial furnaces, heat treatment, preheating
• Packaging industries: sewing, shrinking, sealing and heating machines
• Pharmaceutical and laboratory industries: precision heating equipment, incubators, temperature control devices
• Wood and MDF industries: Dryers, hot press, thermal equipment of production lines
• Textile industries: dryers, thermal stabilization, dyeing and finishing machinery
• Chemical industries: heating of chemicals, tanks and reactors
• Industrial heating and ventilation systems: channel heaters, hot air heaters, unit heaters

Construction materials and applications of industrial elements in various industries

Application of industrial element in parent industries

Thermal elements are used in a wide range of industries due to their ability to produce uniform and controllable heat. Each industry uses a specific model and capacity of this equipment depending on the type of process.

1. Plastic, polymer and packaging industries

The largest consumer of thermal elements is the plastic industry. In plastic injection machines, extruders and polymer pipe production lines, cylinders must reach a certain melting temperature. Belt and ceramic elements play a vital role in this sector. Also, in packaging and shirring devices, cartridge and rod elements are responsible for thermal sewing and cutting of cellophanes.

2. Oil, gas and petrochemical industries

In sensitive petrochemical and refinery environments, it is very important to maintain the temperature of heavy fluids such as crude oil and compressed gases for transportation in pipelines. In this section, flanged immersion heaters equipped with Ex-proof covers are used to prevent any sparks in explosive environments.

3. Food, pharmaceutical and chemical industries

In food and pharmaceutical production lines, hygiene and lack of chemical reaction of the material is very important. For pasteurization, heating of formulation tanks and industrial dryers, 316 steel elements with high sanitary standards are used.

4. Smelting, furnace and heat treatment industries

Ceramic firing furnaces, metal melting furnaces and steel heat treatment systems require temperatures higher than 1000 degrees Celsius. In this equipment, refractory ceramic elements and special alloy wires with extremely high thermal power are used.

Vital materials in the design and construction of industrial elements

The lifespan and efficiency of a heating element depends on the material used in its internal and external components. Choosing the wrong alloy and coating in the vicinity of chemicals or high temperature will lead to immediate burning of the element.

Thermal core of resistance wire (Resistance Wire)

The heat producing part inside the element is made of metal alloys with high electrical resistance:

• Nickel-chromium (Ni-Cr): the most common alloy (such as Ni80Cr20) that has excellent oxidation resistance up to 1150°C.
• Canthal (Fe-Cr-Al): an alloy of iron, chromium and aluminum that is used for very high temperatures (up to 1400°C) in furnaces.

2. Internal insulation of magnesium oxide (MgO)

Magnesium oxide powder acts as an insulator between the live wire and the metal sheath. This material must be of high purity in order to transfer heat in the best possible way while preventing electrical connection and electrocution of the body.

3. Sheath

Element's metal coating protects it from wear, chemicals and moisture. The choice of sheath type is based on the user environment:

• Steel 304 (Stainless Steel 304): suitable for public environments, water heaters and air.
• Steel 316 (Stainless Steel 316): resistant to weak acids and corrosive substances, excellent for food and pharmaceutical industries.
• Incoloy (Incoloy 800 & 840): an alloy extremely resistant to high temperature, pressure and Hard water sediments. Titanium: the most resistant material against the corrosion of strong acids in chemical plating baths: 4. Sealing and final connections

Moisture is the main enemy of magnesium oxide powder. For this reason, the end part of the element (where the wires exit) is completely sealed using fireproof silicone adhesives or epoxy resins. Output wires are also protected against high heat with fireproof varnishes and silicone coating.

The specialized process of designing and manufacturing industrial elements in Celsius

Manufacturing a high-quality thermal element is more than a simple manual production. This process includes a series of precise engineering calculations and machine production steps so that the final product does not lose efficiency or burn under harsh industrial conditions.

Engineering design and calculations unit

The first and most important step is to analyze the customer's needs. At this stage, our engineers calculate the following parameters using specialized software:

• Determination of power (Wattage): Accurate calculation of the amount of heat required to reach the target temperature in a specified time.
• Calculation of surface charge (Watt Density): Determination of the amount of power on the surface (watts per square centimeter); These calculations prevent excessive pressure on the resistance wire and its premature burning.
• Alloy selection: Based on the environment (gas, liquid or solid) and the degree of corrosion, the best material is selected for the sheath and inner wire.

Preparation and coiling of resistance wire

Nickel-chromium alloy wires are wound as springs according to design calculations, with specific diameters and exact distances. Accuracy in the uniformity of spring steps (pitch) is very critical; Because the lack of uniformity causes the creation of hot spots and eventually the wire breaks due to concentrated heat.

Assembly and insulation with magnesium oxide powder (Filling)

The coiled wire is placed in the center of the metal sheath. The empty space between the wire and the tube is filled with high purity magnesium oxide (MgO) powder. This step is usually done by vibrating devices so that the powder fills all the pores in a completely compact and uniform manner and 100% electrical insulation is created.

Condensation and diameter reduction

In order to reach maximum density and ensure fast heat transfer, the elements pass through rolling mills. This process causes the MgO powder to harden like rock and fix the core wire in place. This work significantly increases the lifespan of the element against industrial vibrations.

Bending

If the customer needs special forms (such as U-shaped, M-shaped or spiral), the elements are shaped by hydraulic or manual bending machines with millimeter accuracy. At this stage, care is taken to ensure that the metal sheath does not crack or stretch too much.

H3: 6. Heat treatment and annealing

In order to remove the stresses created in the metal during the rolling and bending stages, some elements are subjected to heat treatment. This makes the body flexible and prevents the sheath from breaking during installation and operation.

Installation of connections and final sealing

In the final stage, the connection screws or fireproof cables are connected to both ends of the element and the opening of the element is sealed using epoxy resins or specialized silicones. This work prevents the penetration of ambient moisture into the insulating powder (which is the main cause of short circuit).

Quality control and safety tests

Before the product leaves the factory, all elements undergo strict tests:

• Hi-Pot test: checking the insulation resistance at high voltages.
• Current leakage test: making sure no current passes to the body.
• Ohm test: Matching the output power to the customer's request.

Factors affecting the price of industrial elements

The price of an industrial element is not a fixed number and is determined based on technical specifications, type of application, construction material and order conditions. The more accurate, more resistant and customized the element is, the higher its final cost will be.

Element type

One of the main factors determining the price is the element type. Rod, cartridge, flanged, finned, ceramic and immersion elements each have a different structure, application and production cost. For example, cartridge and ceramic elements are usually more expensive than simpler models due to higher manufacturing accuracy.

Consumable material

The material of resistance wire, outer sheath, inner insulation and connections have a direct effect on the price. The use of alloys such as Incoloy, Inconel or Steel 316 increases the cost of construction compared to conventional materials, but in return provides higher durability and resistance.

Power and dimensions of the element

The higher the power of the element, the amount of resistance wire, the amount of insulation and the amount of material used will also increase. Also, longer, thicker or specially designed elements require more raw materials and production time, and as a result will have a higher price.

Working conditions and operating temperature

Elements that are designed for high temperatures, corrosive environments, high humidity or harsh industrial conditions, must be made with more precision and special materials. This causes the price to increase. For example, an element suitable for a petrochemical or furnace is not the same as a simple element for water or air.

Customization and special design

If the element is designed based on the customer's drawing, sample or specific requirement, the cost of engineering, initial design, prototyping and technical tests will be added to the final price. Custom elements are usually more expensive than off-the-shelf models, but they are made to fit your application exactly.

Type of voltage and electrical power

Single-phase and three-phase elements, or models that require specific powers and precise temperature control, are different in terms of design and construction. The more complicated the electrical and control system, the higher the construction cost.

Type of connections and installation method

The type of terminal, output cable, flanged, threaded or ceramic connections also affects the price. Elements that require more specialized installation or stronger connections are usually more expensive.

Order number

In bulk orders, the price of each element is usually lower; Because the start-up, design and production costs are shared among a larger number. But in single orders or prototyping, the unit price is higher.

Tests and quality control

Elements that undergo specialized tests such as insulation test, ohmic test, leakage current test, high-pot test and detailed quality checks are higher in manufacturing cost. However, these tests increase the reliability and longevity of the product.

Fluctuations in the raw material market

The price of industrial metals and alloys, the cost of importing some special materials and market fluctuations also have a direct effect on the final price of the element. For this reason, the price of the industrial element is usually inquired daily or periodically.

Short summary of this section

In general, the price of an industrial element depends on a combination of product type, material, power, dimensions, working conditions, customization and order number. Therefore, in order to get an accurate price, it is better to check the technical specifications of the project in order to choose the most suitable option in terms of quality and cost.

Important points in choosing the right element

Choosing the right element is not limited to its power or price. In order for the element to perform optimally in real conditions, a set of technical, environmental, and executive factors must be checked properly. The wrong choice can reduce efficiency, increase energy consumption and even burn the element early.

Application type and installation location

The first point in choosing an element is to specify its type of use. The element used for water, oil, air, mold, furnace or chemicals must have a different structure and material. For example, the element suitable for immersion is not the same as the element suitable for hot air.

Required working temperature

It should be determined what temperature the element is supposed to work at. The higher the required temperature, the more important the choice of alloy, sheath and type of insulation becomes. If the element is not selected for high temperature, the possibility of loss of efficiency and burning increases.

Required thermal power

The power of the element should be chosen according to the volume, material and heating speed of the desired environment. Low power causes a delay in reaching the desired temperature, and excessive power can damage the product, device or process material.

Type of work environment

The environment in which the element works plays an important role in its selection. The presence of moisture, steam, dust, corrosive substances, vibration or high pressure makes it necessary to use more resistant elements with more special materials.

Sheath material and resistance wire

The material of outer sheath and inner wire should be selected based on working conditions. For corrosive environments or high temperatures, the use of alloys such as steel 316, Incloy or nickel-chromium can increase the useful life of the element.

The shape and dimensions of the element

Elements are produced in different models such as rod, cartridge, flanged, finned, belt and ceramic. Choosing the right shape should be done based on the installation space, device type and heat transfer method.

Voltage and type of electricity used

Before buying the element, the working voltage of the device must be determined; For example 220 V, 380 V or three phase. If the voltage of the element is not compatible with the electrical system of the device, its operation will be disturbed and it may even damage the equipment.

Type of temperature control

If temperature accuracy is of utmost importance, an element must be selected that is compatible with a thermostat, thermocouple or temperature controller. In sensitive industries, accurate temperature control has a direct role in the quality of the final product.

. Build quality and production standards

High-quality element should be checked in terms of insulation, sealing, ohmic test and highpot test. Low build quality, even if it costs less, in the long run creates more repair and replacement costs.

. Possibility of customization

In many industrial projects, the element is not ready to respond to the real need. In this situation, choosing a custom element based on drawings, samples or technical specifications of the device is the best option. This work increases the accuracy, efficiency and longevity of the system.

Short summary of this section

To choose the right element, the type of application, working temperature, power, environmental conditions, material, dimensions, voltage and quality of construction should be checked at the same time. Choosing the right element saves both energy consumption and increases the life of industrial equipment.

Common mistakes in buying or ordering industrial elements

Purchasing industrial elements is a specialized process. Many buyers make mistakes due to lack of familiarity with technical details that lead to financial losses, production line stoppages, or even safety risks. In the following, we discuss the most common errors:

. Ignoring surface density (Watt Density)

The biggest mistake is asking for too much power (watts) for a small element. Each element can repel a specific power based on its level. If the "Watts per square centimeter" is more than the allowed limit, the internal resistance wire will melt within a few hours and the element will burn. Engineers must observe the balance between the power and the length of the element.

Incorrect choice of sheath alloy (Sheath Material)

Many buyers are only satisfied with the "steeliness" of the body, while there is a big difference between steel 304, 316, 321 and alloys like Incoloy. For example, the use of normal steel in acidic environments or heavy water will lead to rapid corrosion and perforation of the element sheath.

Not paying attention to the installation environment (humidity and pollution)

Elements are very sensitive to moisture. If your work environment is humid or the element is subject to splashing of materials, special seals (silicone or resin) must be used in the output part of the wires. The penetration of moisture into magnesium oxide powder is the main cause of short circuit and fuse jumping.

Error in voltage calculations

Ordering the element without specifying the type of electricity (single-phase or three-phase) is a common mistake. Connecting an element designed for 220 V to 380 V electricity will cause it to burn instantly, and on the contrary, connecting a 380 V element to municipal electricity will reduce its thermal power greatly.

Inaccurate measurement of dimensions and tolerances

In elements such as Cartridge Heaters, even half a millimeter distance between the element and the mold hole can be disastrous. If the element is not completely fit, the air layer prevents heat transfer and causes overheating and burning of the element.

Prioritizing price over quality

Buying a cheap element made of low-purity porcelain wires or low-quality insulating powder will end up costing you more. The short life of these elements and the costs related to stopping the production line and replacing them again will be several times the initial savings.

Providing ambiguous information to the manufacturer

Phrases like "I want a strong element" or "to heat the water tank" are not enough. For a successful purchase, you must provide the sales experts with detailed information including: type of fluid, starting temperature and final temperature, optimal time for heating, dimensions of the environment and available voltage.

1. "To avoid these mistakes and get free expert advice before placing an order, contact the technical experts of Celius Industrial Group right now."

Why choosing a quality element is an investment?

In this article, we learned that the industrial element is the beating heart of many production processes. Choosing a suitable element that is designed with accurate engineering calculations and made of high-quality material (such as nickel-chromium wire and high-purity insulating powder) not only reduces energy costs, but also prevents sudden stoppages of the production line and heavy damage to machinery.

Don't forget that technical details such as watt density, case alloy type and proper sealing define the line between a durable element and a low-quality consumable.

Expert advice and online order from Celsius Industrial Group

With years of experience in the design and production of various types of thermal elements, Celsius Industrial Group is ready to be a technical consultant alongside the large and small industries of the country. We are not the only manufacturer; We design optimal heating solutions for your industrial challenges.

Benefits of cooperation with Celsius:

• Free consultation before purchase: Our engineers suggest the best material and power based on the exact needs of your project.
• Custom manufacturing: Accurate production of all types of rod, cartridge, ceramic and flanged elements according to the drawing or sample sent by you.
• Quality assurance: Performing all standard tests (high-pot and ohm) before delivery. Goods. Competitive price: elimination of middlemen and direct purchase from the production unit.

Are you looking to optimize the heating system of your devices?

Contact our experts right now to benefit from free expert advice in addition to daily price inquiry. We help you to ensure the longevity of your equipment by making the right choice.