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Introduction
This Article takes an In-depth look at Electric Heaters
You will learn more about topics such as:
Why Have An Electric Heater?
How Does An Electric Heater Work?
How to Choose An Electric Space Heater?
Types of Electric Heaters
Why Have An Electric Heater?
The idea of an electric heater seems to be out of place in modern society since most buildings have a sophisticated central heating system. That may be true, but electric heaters can be a helpful way of saving energy while providing efficient heating. Electric heaters are a creative method to support a central heating system, because they can be personal and maintain a set temperature much like a central heating system while using less energy. The true asset of an electric heater is how it can save on heating costs.
There are times when the temperature is not sufficiently cold to activate the heating system but still uncomfortable. In some cases, putting on layers can help overcome the discomfort but impractical for certain activities. In those instances, an electric heater can provide a comfortable and pleasant work or play environment.
On other occasions, when there is one person in the house, an electric heater can be cost savings since it would be impractical to start the central heating system. Such situations could be working in a home office, alone in the bedroom, or preparing food. Since modern electric heaters are light and portable, they can be easily adapted to fit any type of location.
According to the United States Department of Energy, more than half of an electric bill goes to heating and cooling. A practical solution to lowering those costs could be the use of an electric heater. The energy department estimates that approximately $1800 is spent on the use of an electric furnace each year. If the cost of electricity is $0.12 per kilowatt hour, an electric heater could be run, in a single room, for 12 hours per day from November to the end of March at a cost of $315, a significant savings.
One of the factors regarding electric heaters is the climate where it is used. In parts of California, for example, houses can go for years without the need for heat due to the mild climate. Areas, such as Minnesota, Wisconsin, Idaho, and North Dakota, where the temperature can be well below freezing for weeks, can see significant savings from using an electric heater. As beneficial as they are, it must be kept in mind that they are designed to heat one room and supplement a central heating system.
There are very practical steps to take when using an electric heater as a support for a central heating system. The advantages of keeping heating costs down while increasing convenience and comfort are some of their major attractions. There are practices and steps to take when deciding to use an electric heater to reduce energy costs.
Installing a programmable thermostat is an excellent first step toward heating cost reduction. These efficient cost saving devices are known as setback or clock thermostats. They can be adjusted to change the temperature at different times during the day when heat is not necessary or when an area is unoccupied. A programmable thermostat can be set to lower the temperature during those times by 10 to 15 degrees. This simple step can lower heating costs, according to the U S Department of Energy, by 5 to 15 percent.
Lowering the temperature in a building when only a few rooms are being used is an additional method. Electric heaters could be used in occupied rooms keeping them comfortable and warm. To implement such a system, it would be necessary to check the rooms that are being used and have the appropriate electric heater for the space.
Electric heaters are ideal in this era of environmental consciousness. They heat a specific area and use less energy. None of the energy used to operate a portable heater is wasted. Since they do not use natural gas or oil, they do not produce any form of air pollutants. Infrared type heaters are especially popular as an environmentally safe device.
How Does An Electric Heater Work?
An electric heater is much like a central heating system in miniature. There is a wide variety of heaters to choose from, which all work on the same basic principle. It is very important to choose a heater that is best for you and your situation. Purchasing at random, on the spur of the moment, is not the best decision.
The basic part of all heaters is an electrical resistor, which converts electrical energy into heat energy. The term resistance, in many cases, is taken as a negative term since it is an indication of fighting back. In the case of electric heaters, resistance is what produces heat. An electrically resistant material does not pass electrical current easily. An electric current has to fight to get through the resistant material, which produces heat. The more the resistance, the more heat, and an increase in temperature.
The resistor is the central piece of an electric heater and serves several functions. It controls the flow of electric current in a circuit and is normally made of carbon. They ensure that the components of a heater receive the proper amount of voltage and protect against spikes. The quality of the resistor determines the effectiveness of the heater and how long it will last.
There are different kinds of resistors such as ceramic cylinders, mica-embedded wires, coiled in ceramic, tubular core, or coiled insulated with magnesium oxide powder. Ceramic is used as an insulator and is an excellent heat conductor. When a resistor is made with ceramic, the resistor can use low to moderate power without the need to reheat. A mica embedded wire resistor is an economical solution that provides high resistance for low power applications. Tubular core resistors can come in several diameters depending on how it is to be used and can handle high power loads. One version of a tubular resistor is magnesium oxide powder insulated, which insulates the electric wiring and conducts thermal energy.
When a heater is turned on, the electrical current heats up the nichrome wire component, the heating coil. As the electrical energy goes through the resistor, heat is produced, which gives electric heaters the name resistance heating units. The fan on a heater will pull air into the heater, which is forced over the heating elements and into the room like a hair dryer. The process of drawing in air and passing it over heating coils is known as convection heating.
When a fan is not present, air goes over the coils and makes its way out of the heater, which is radiant heating. This type of heater is designed for small areas since it heats the air around it and would take time to heat a large room. The main type of radiant heaters are electric baseboard, which are inexpensive and use natural convection.
When purchasing an electric heater, you have the choice of one with a thermostat or one without a thermostat. Electric heaters without a thermostat heat up and send heated air into a room. They are simple devices with an on and off switch. Electric heaters with a thermostat may have a digital display or a knob that permits you to set the desired temperature and automatically turn off when the desired temperature is reached. The majority of modern day electric heaters come with a thermostat. It is a selling feature that manufacturers emphasize in their literature.
How to Choose An Electric Space Heater?
The term electric heaters or space heaters has gained a negative reputation due to the types that were produced years ago. The poor quality of the early version of electric heaters has been enhanced and improved. Modern technology has taken electric heaters and radically advanced them into the present. There is a diverse assortment of them available on the market today making choosing one more difficult than it was fifty years ago.
Prior to shopping for a new electric heater, it is important to determine how much heat will be required. The size and type of heater depends on the dimensions of the room where it will be used. The traditional type of heater can heat a room of approximately 400 square feet while more powerful ones can heat areas up to 1000 square feet. A careful measurement of the space can save time and money helping to avoid having a heater too powerful for the space or not powerful enough. For practical purposes, unless you plan on heating a milking barn, a small compact heater is usually sufficient.
Once the size of the room is determined, the next step is to decide on the characteristics of the heater. Most electric heaters advertise having some form of energy saving feature that carefully monitors the flow of electricity through the unit. A programmable timer can be a huge convenience since it allows the user to set it to activate automatically. This can also be included as a function of the thermostat.
The more features an electric heater has naturally increases its price. It is highly recommended to purchase a heater with a thermostat even though heaters without a thermostat are less expensive and use only radiant heat. In many ways, a thermostat provides greater control of the heater and ensures safety since it will turn off when it has reached the preset temperature.
One of the things that cannot be determined when purchasing an electric heater in a store is the amount of noise it produces. Some manufacturers will have information regarding noise on the box or in their literature. If the heater is purchased online, good quality heaters will have noise information in the content of their site while stores may not have it. Baseboard heaters and other forms of radiant heaters produce the least amount of noise since they do not have a fan.
The key to getting an electric heater is to be well informed. Though it may seem like an impulsive purchase, planning and preparation are two factors that can lead to having a device that can save energy and lower electric bills. It is important to use all available resources to get the essential information to make a wise purchase.
Leading Manufacturers and Suppliers
Types of Electric Heaters
The design of an electric heater has to fit the space that it will heat. Much of this part of the decision depends on the importance of aesthetics. A tower heater can sit in the middle of the room and rotate, producing heat but may not add to the appearance of the room while a stove heater sets against a wall unnoticed. In many ways, this part of the selection process can be enjoyable and creative.
Air Heaters
Air heaters are defined as electric heaters that provide heat for industrial and residential purposes by way of air circulation or a blower mechanism. Air heaters can be rectangular or barrel shaped, large in size, and portable, but other models of air heaters that vary in size and shape are also available.
Air heaters are constructed by installing a heating element in an enclosure. The heating element remains stationary, while its air ducts expose sections of the heating element to the circulating air by rotating alternately. Heating elements vary from heater to heater, but most of them are found in the form of wires or coils. Wire heating elements are commonly used for industrial and commercial drying applications, and are most commonly found in machines such as kilns and surface treatment heaters.
Since air heaters are used for a variety of applications, they come in a wide range of configurations and utilize different heating elements. Residences use air heaters every day to warm homes and heat food and water, and industries rely on electric air heaters to maintain a certain temperature for various processes. Therefore, it is important to consider all aspects of the heating system and the application for which the heater will be used in order to ensure maximum efficiency and safety.
Band Heaters
Band heaters, also known as knuckle heaters or barrel heaters, are a variety of heating element that provides direct or radiant heating by clamping around nozzles, pipes, or cylinders. Band heaters are used primarily in metal and plastic forming processes such as extrusion, and are similar to strip heaters in terms of application and configuration. The range of temperature that band heaters provide can vary from 300 to 1400 degrees Fahrenheit. (approx. 149 to 760 degrees Celsius). Strip heaters can also be clamped or bolted in order to achieve the direct transfer of heat to either the air or a solid object.
Band heaters, along with other types of heating equipment, are a necessity for numerous industrial processes, especially extrusion, since the process involves melting materials and maintaining their plasticity in order to prepare the materials for extrusion. The extrusion process generates friction, which in turn generates heat, and the heat that band heaters provide act as a supplement. Band heaters are capable of providing efficient and direct heat in oddly shaped areas that would act as a hindrance for any other type of heater.
Cartridge Heaters
Cartridge heaters are small, cylindrical electric heaters used to provide localized or precision heat to materials and equipment parts in a variety of settings. Similar to immersion heaters, cartridge heaters are usually inserted into a material to heat the surrounding area; unlike immersion heaters, which are usually submerged in water or other liquids, cartridge heaters are inserted into small holes drilled in metal materials and parts that require internal heat. While capable of providing localized high temperature heating, cartridge heaters can also radiate heat throughout the interior of a material or product.
The type of localized, interior heating produced by cartridge heaters is used to heat specific parts of machinery used in packaging, die cutting, mold forming, hot stamping, labeling, sealing, printing, fluid heating, food service and many other industries. Hot plates, platens, semiconductors, shrink wrap machines and labeling machinery often use internal cartridge heaters to heat specific applicator parts. Plastic and rubber forming processes in particular make extensive use of cartridge heaters and other localized heating systems like strip heaters to assist in the plasticization of materials.
Ceramic Heaters
Ceramic heaters are among the most widely used electric heater varieties. Ceramic heaters are used as heating elements in a variety of configurations to provide conductive and radiant heat. Conductive ceramic heaters can be combined with aluminum nitride or other compounds to form warming plates or bonding instruments for medical devices and semiconductor applications. Stand-alone ceramic heating elements may be packed with magnesium oxide and terminated with lead or copper wires for use in a number of industrial applications.
Ceramic space heaters use ceramic insulated heating elements combined with aluminum baffles and fans to provide safe, energy efficient radiating heat as ceramic room heaters. Many other types of electric heaters, including ceramic strip heaters and ceramic band heaters, can use ceramic insulation to conduct heat.
Ceramic-insulated heating coils can be much safer than uninsulated heating coils, especially in the context of industrial and consumer ovens. They protect the coils from contact with dripping grease or other materials, ensuring the coils‘ continued effectiveness and reducing the risk of fire.
Coil Heaters
Coil heaters are electric heaters that generate heat through the use of heating coils. A heating coil is a device that converts electricity to heat. Heating coils are among the most widely used heat generation materials in existence. Across industry, commerce and in the context of consumer products, heating coils are used to generate heat in buildings, equipment, small appliances and in other applications.
These heaters may be bent to a custom size or shape, including round, coiled and spiral wounds, which are used when high temperatures are needed in confined areas. Star wound coils are placed in pipes and ducts to create a turbulent flow in air or liquid. They are used in a number of applications in the heating, plastic manufacturing, food processing, textile, and paper processing industries.
Drum Heaters
There are a few different styles of drum heaters out there in order to accommodate a wide range of applications and industries. While the designs may be different, drum heaters are all manufactured in a way that allows them to increase the overall temperature of a liquid that is being stored within a container, or 55 gallon drum. The reason why the word container is thrown around is that some drum heaters have the ability to heat multiple containers instead of being restricted to one drum at a time. The type of drum heater that you require is all based on the individual needs and requirements that are present in your specific application. Whether you require a large drum heater, such as a drum oven, or a mobile single drum heater, finding the right drum heater manufacturer can save you time and money.
Duct Heaters
A duct heater is a heavy duty modular unit installed in the ventilating ductwork of commercial, residential and institutional HVAC systems, although smaller "duct" heating elements are used in the forced air heating systems of vehicles. Duct heaters can be complementary to a central heating system that utilizes forced air heating, also known as forced circulation heating or convection heating, where air is the medium that transfers heat. Fans and blowers are integral to the transfer of heat; their motion conveys the air through the duct heater.
Duct heaters work with existing central forced-air heating systems to preheat fresh air or returned air. The central air handler filters the air, re-heats it and blows it through the ductwork. The conditioned air is distributed throughout the building and is then returned to the central air handling unit (AHU). Electric heater manufacturers generally construct duct heaters in rectangular or square box configurations, but they can create rounded ones for the best fit in certain sheet metal ductwork.
Flexible Heaters
Flexible heaters are great for a wide range of applications as they are able to fit into tight spaces and provide heat to areas or products that other traditional methods may not be able to reach. Flexible heaters are commonly found in applications such as air heating in baking ovens, surface heating, cabinet warming and a number of different other industrial applications. A majority of flexible heaters tend to be made from plastics or metals; obviously this all depends on the requirements of the application and the temperature range that they will be exposed to during the process. Other materials that are commonly used to manufacture flexible heaters include rubber molding, rope, certain adhesives, and polyimide films. These flexible heaters are manufactured in a way that will allow them to conform to a surface which requires heating in a number of different applications.
Foil Heaters
Foil heaters are used in many industries and they can be found in products like car battery warmers, cabinets, defrost applications, heat exchangers, laboratory equipment, incubators, ceiling panels, and wall panels. Most foil heaters are etched using an automated machine. The etching in the foil helps to distribute the heat evenly when the power source is turned on by putting more of the surface in contact with the device being heated. The computer-designed etched foil is sometimes manufactured with a laminated coating on either side to insulate it.
One of the many advantages of foil heaters is that they can heat up rapidly because the foil is highly conductive and very thin. The thin foil sheets can easily be integrated into products that need heating but do not have a lot of excess space. A foil heater requires wider elements, but these elements can be spaced much closer together. Because of this, many elements can be added to the foil and run side by side, producing more heat in less space.
Infrared Heaters
Infrared heating uses electromagnetic waves to transfer heat to an object or material. The process of an infrared heater includes heating the panels until they are sufficiently hot to release infrared radiation. The type of waves of an infrared heater are similar to those that are produced by the sun. The radiant heat travels until it reaches a solid object. In essence, the process is a direct transfer of heat to objects or materials without changing the temperature of the atmosphere around the heater or objects.
The heat transfer mechanism of an infrared heater uses emission, reflection, and absorption of electromagnetic waves. The components of an infrared heater are its heating system and a reflector where the heating system converts electrical energy or chemical energy from a fuel source into thermal energy. The reflector directs the thermal energy to objects that are around the heater and is the component that determines the efficiency of the heater. Materials used for the reflector include aluminum, stainless steel, ceramics, and quartz with some reflectors being made of gold or rubies for improved reflectivity and the ability to focus more heat.
The energy savings and efficiency of infrared heaters make them ideal for industrial use, such as drying coatings, welding, and embossing or laminating. The three basic types of infrared heaters are quartz, ceramic, and metal sheathing, which can quickly reach temperatures of 1300°F to 1600°F (704°C to 871°C). Of the three types, quartz infrared heaters are capable of reaching the highest temperatures while ceramic infrared heaters are the most economical.
Forced Air Heaters
Forced air heaters use a fuel source or electricity to generate heat by increasing the temperature of a heat exchanger over which air passes, absorbs the heat, and is pushed by a fan or blower through ductwork. They are one of the most common types of heaters due to their ability to be used in a wide variety of applications and processes.
The central component of a forced air heater is the heat exchanger, which can be a shell and tube heat exchanger, plate heat exchanger, or air cooled heat exchanger. Each type of heat exchanger is distinguished by its construction. Shell and tube heat exchangers have several small tubes placed in a cylinder that expand and contract with the changes in temperature. Plate heat exchangers have a series of stacked plates that are brazed or gasketed depending on the application and fuel. Air cooled heat exchangers are small and mobile and supply heat and cool air.
The next key element of a forced air heater is the blower or fan that pulls in air to be heated and pushes the air out to circulate. In an electric forced air heater, electricity is used to heat a heating element that supplies heat to the heat exchanger. Once the air is heated, it is forced out by the blower. Where air goes after being heated depends on the type of forced air heater and its use.
Industrial forced air heaters can take several different forms from ones capable of heating a large building to ones small enough to supply heat to a section of a building. The flexibility and mobility of forced air heaters is one of the reasons for their popularity. Additionally, of the various types of heating methods, forced air heaters tend to be the most economical and cost effective.
Fan Heater
Electric fan heaters use the Joule Thomson effect, also known as resistive or ohmic heating, where electric current is converted into heat as it flows through a resistant that is in the form of a solid or liquid. The heat from the process is generated on the microscale when conduction electrons transfer energy to conductor atoms by way of collisions. The heat that is created by the process is spread into the environment by a fan.
A fan heater operates in a fashion that is similar to that of a forced air heater but makes a different use of the heat generated by electricity. As with a forced air heater, a fan heater draws in air from the surroundings and forces it over the heating element where it is warmed before being released into a room, enclosure, or portable office.
Electric fan heaters have a simple construction, which makes them easier to use and install. They produce heat quickly and efficiently and use a small amount of electricity that is converted into heat without any waste. Since electric fan heaters are expensive to operate, they are used for a limited amount of time.
Modern fan heaters have been upgraded with power settings and thermostats, which switch the fan off when the proper temperature is reached. The mobility of electric fan heaters makes them ideal for use in factories and manufacturing operations where focused heat is required for a process.
Strip Heaters
Strip heaters are direct contact heaters that are bolted, clamped, or fastened onto the surface of an object to be heated. The size of strip heaters makes it possible to use them individually or in groups, depending on the needs of an application. They are flat, straight, and have a shape that is similar to that of a ruler with the addition of fins when they are used to heat the air around them.
The process for a strip heater is that of heat transfer by converting electrical energy into thermal energy using the Joule Thomson effect. The surface of strip heaters make it possible to generate a greater amount of collisions between the electrons and atomic ions that creates vibrations, which is expressed as heat.
Strip heaters have a heating element, sheath or sleeve, and mounting hardware with fins added when they are used for radiant heating. The flexibility of strip heaters makes it possible to bolt or attach them to walls, pipes, objects, and materials to release heat over large areas. They are normally used indoors and attached to baking ovens and ovens for vacuum dehydration. In cold climates, strip heaters are used to heat equipment for moisturizing protection.
The wide use of strip heaters is due to their simple construction, low cost of installation, and portability. They are insulated with mica or ceramic with outer shells made of steel, stainless steel, or nickel alloys. Strip heaters are capable of reaching temperatures of 700°F up to 1400°F (371°C up to 760°C).
Cable Heaters
Cable heaters are made of small diameter cables that can be bent, shaped, configured, and formed to fit any type of heating condition or application. The various types of heating cable are cables through which electric current is passed to generate heat. They are known by several names including trace cable, heat cable, and heater cable. The different types of heating cable are capable of reaching different temperatures for various purposes and processes.
The appearance of heating is that of standard wiring cable but stiffer due to being enclosed in a housing that is used to protect the heating elements. The structure of heating cable makes it possible to cut and trim it to different lengths such that it can be shaped to match the needs of an application.
The two types of heating cable are self regulating or self limiting and constant wattage heating cable. Self regulating heating cable is made such that the temperature of the cable will not rise above a set temperature, which keeps the cable from overheating or burning out. They are on the low end of the temperature range and can reach temperatures up to 250°F (121°C).
Constant wattage heating cable does not have a set temperature and must be attached to a control mechanism. It can reach temperatures up to 500°F (260°C) and run on voltages ranging from 120 V up to 480 V. Additionally, constant wattage heating cable comes in several different types with each type designed to meet the needs of a particular application.
Convection Heaters
Convection heaters, also known as convector heaters, are non-fan heaters that use the natural convection of heat to move heated air. Since they do not rely on fans or blowers, the operation of a convection heater is quieter. The absence of blowers or fans prevents convection heaters from circulating dust, pollutants, or contaminants. The process of a convection heater is built on heating the air inside the heater, which makes the air less dense than the cool air around it. Due to the fact that heated air is less dense than colder air, the heated air from the convection heater rises forcing cold air into the heater.
The components of a convection heater are the heating element and fins. The fundamentals of convection heating are based on the conversion of electrical energy into heat by passing current through resistance wires in the heating element. The convectors of the heating element are metal sheaths that are made with spiral wound resistance wires enclosed in an insulating powder, such as magnesium oxide, which is encased in a metal sheath.
The fins of a convection heater act like a chimney and are added to the element to improve heat transfer. They direct air flow over the heating element and their surface to heat the incoming air. The fins of a convection heater vary according to how the heaters are used. Typical convection heaters have aluminum fins while heavy duty and heavy use convection heaters have explosion proof fins that are made of steel and brazed to withstand the higher demand.
As a control mechanism, convection heaters have an over-temperature sensing device that is located near the heating element that stops the flow of electricity when exceptionally hot conditions occur. This normally happens when an air inlet is blocked and causes heat build up.
Enclosure Heater
Electrical cabinets must maintain a constant temperature level to ensure proper operation of electrical components. Enclosure heaters raise the temperature in an enclosure to reduce humidity, heat air entering the enclosure, and keep electronic components from freezing.
The types of enclosure heaters vary in accordance with the size of the enclosure where small enclosures can use small ceramic heaters while larger enclosures may use convection heaters or forced air heaters. All enclosure heaters are designed to prevent condensation and evenly distribute heated air. Moisture build up in enclosures can cause corrosion and rust, which results in the failure of vital electronic components, such as circuit breakers, relays, busbars, circuit boards, and transformers.
The range of heaters used in enclosures include fan heaters, convection heaters, surface or strip heaters, cartridge heaters, flexible heaters, and tubular heaters. When choosing an enclosure heater, the first factor that is considered is the dimensions of the cabinet since its height, width, and depth determine the cabinets volume. The second factor is the density of the enclosed instruments, which has an effect on the volume of the cabinet.
An obvious third step, when choosing a heater for an enclosure, is the location of the cabinet, such as locations where there is exposure to harsh weather, the danger of freezing, and the availability of energy sources. Additionally, enclosures on ships, planes, rockets, and satellites have to be specially engineered to fit the conditions.
Kickspace Heaters
Kickspace heaters are installed at floor level near the bottom of cabinets or cupboards. They are a small space saving heating method that is normally out of sight along baseboards. Kickspace heaters are referred to as toe kick heaters due to where they are installed. The operation of a kickspace heater involves drawing cool air onto electrical coils that heat the air and release the air back into the room
The size of kickspace heaters makes it possible to install them in nearly every space regardless of the challenges of the layout or structure of a location. They are an inconspicuous and unseen heating device used in buildings, which is one of the major reasons for their popularity. Their placement in a room does not interfere with the ambiance of a room and allows for more design freedom.
The size of kickspace heaters limits their use and prevents them from heating large areas. Their main function is to heat difficult to reach places such as small rooms, powder rooms, dressing rooms, or kitchens. They are designed to work independently with controls for each individual unit. The unique nature of kickspace heaters makes them capable of working without being connected to the main heating system, which makes it possible for a kickspace heater to control the temperature of a specific room or location without interference from the main system.
Mica Heaters
The functionality of mica heaters or micathermic heaters is a combination of convection heating and radiant heating, which is the reason they are so efficient. Mica heaters have heating elements that are like those of a convection heater that are panels covered in sheets of mica, a material that is known for its ability to generate electromagnetic rays.
Mica is a popular material used for heating applications due to its ability to rapidly reach temperatures as high as 1112°F (600°C). Thin sheets of mica allow for low thermal mass and extremely rapid heat up times. The construction of mica heaters includes etch foil heating elements that are bonded between high temperature mica sheath layers, a design that allows for exceptional heat transfer. For the best efficiency, mica heaters are clamped in place between rigid plates to prevent layer separation.
The inherent qualities of mica include heat resistance, electric conductivity, and chemical stability, qualities that work together to produce a safe, efficient, and safe heat source. The thermal stability of mica helps prevent fire or faults, which makes it possible to mount mica heaters without fear of burning or scorching surfaces.
The unique combination of convection and radiation is the reason for the extremely effective ability of mica heats to heat a location. Since micathermic heaters do not require the use of blowers or fans, they operate quietly to heat any size area, which is unlike traditional infrared and convection heaters that are limited in the areas they can heat.
Electric Heat Pumps
Unlike other heating methods, heat pumps do not generate heat by heating plates or tubes but absorb heat energy from the outside air. The technology of a heat pump is similar to that of an air conditioner in that they remove air that has an unwanted temperature. While an air conditioner only removes warm or hot air, a heat pump is capable of removing cold air and hot air depending on the time of year and how it is set.
The source of heat for a heat pump comes from the ambient air that is pumped over the surface of a heat exchanger. The heat is sufficient to cause refrigerant to evaporate and turn into a gas, which is moved through a compressor that increases pressure on the gas and causes its temperature to rise. The heated gas moves over an internal heat exchanger surface and blown throughout the interior of a building.
Heat pumps extract more heat energy from the environment than the energy they use. They produce two to three times more heat than their electricity input. Hybrid heat pumps are integrated with a traditional heating system. They monitor the outside temperature and choose the best heating method. Unlike other heating methods, heat pumps generate extremely low emissions due to their exceptional efficiency.
Immersion Heaters
When identifying which immersion heating company to purchase from, consumers should be sure to choose carefully. There are many different types of water heaters on the market today each with different useful applications and abilities. Some of these include pipe (or dry-well) heaters, flange heaters, over-the-side heaters, tubular heaters, and screw plug heaters. Consumers would be wise to choose a vendor who can accurately advise them on exactly which type of product will be most applicable in each of their individual situations. Companies who specialize in manufacturing immersion heating products must take multiple factors into consideration and should use ethical construction practices, high-quality materials, and well-researched engineering techniques.
All types of electric heaters must be manufactured with precision and care in order to ensure a safer and more effective product. Manufacturers should strive to provide high levels of product quality control to ensure client satisfaction and safety. Good manufacturers will have an advanced understanding of the electric heating industry and be able to effectively inform consumers on which type of heating device will best serve their purposes.
Immersion heating comes in many different forms. Consumers may find that they end up needing a different type of immersion heating element than they had previously anticipated. If purchasers are unsure about which specific heating device they will need, knowledgeable industry professionals are able to help companies and consumers alike decide which product will best fit each heating situation.
Industrial Heaters
Industrial heaters are just that, heaters for industrial purposes. This includes a wide range of products from furnaces and ovens to immersion heaters and temperature sensors. Whatever your application may be, we strongly encourage consulting a knowledgeable, trusted industrial heater manufacturer in order to ensure that you receive the right type of industrial heater for your application. There are many different styles of industrial heaters, and each style can be further broken down into even more subcategories.
Certain industrial heater manufacturers specialize in different industries and styles of heater, so if you already know the type of heater you need this can be a great way to filter through different manufacturers until you find the right fit for you. Ovens and furnaces are other forms of industrial heaters that operate similarly to standard kitchen ovens but on an industrial scale. The sub categories include: furnaces, keyhole ceramic insulated elements, and rectangular ceramic insulated elements.
Kapton Heaters
A Kapton heater is a type of electronic heater that uses polyimide film to encapsulate heating circuits. This thin, ultra-flexible and lightweight material makes Kapton heaters a great solution for compact applications. The name" Kapton" comes from the polyimide film that was first developed by the company Du Pont for applications where a thin, flexible housing for heating circuits is necessary. A Kapton heater has the capacity to operate at extremely low and extremely high temperatures. Even though they are flexible, they have incredible tensile strength and durability. During manufacturing, a pattern is etched into the thin foil to help spread heat across a surface. This very thin film or foil can be created using materials like copper, kanthal and constantan.
Pipe Heaters
Pipe heaters range in style and type depending on the application, as pipe heaters can be found in a vast range of industries and applications. There are a number of different forms of pipe heater solutions available in order to prevent your pipes from freezing.
These pipe heaters come in a variety of styles from fiberglass cloth tape to wrap-on pipe heating cables. Each style is better suited for certain types of applications as some products may not be as effective as others in certain conditions. Wrap on heating elements themselves have a lot of variety as each is made with certain applications in mind, some are built for sub-zero temperatures while others are simply meant to prevent your pipes from freezing in below freezing temperatures and may stop functioning properly at sub-zero temps. There are also in-pipe pipe heaters which obviously reside inside of the pipe and are great for use on drinking water and tap water as it allows the water to heat up much faster than wrap on solutions might.
Silicone Heaters
A silicone heater is a flexible heater with an internal wire element and a body made of silicone rubber. These durable heaters can operate at temperatures of up to 450 degrees Fahrenheit. Silicone performs well in environments where there are rapid changes in temperature and it is highly resistant to moisture and chemicals. These durable qualities make silicone the material of choice for heaters that will be exposed to harsh conditions in industrial or commercial settings. The circuit‘s surface can also be chemically etched to create a more even heat distribution pattern. Adhesive backing can be added to the heater if it is being fitted to a flat surface after manufacturing, and fasteners of various sizes are available for many applications.
In most silicone heaters, a fiberglass grid reinforces the silicone sheet making it strong and durable while still allowing it to be thin and light. Thermostats, thermocouples and fuses can be built into the heater and it can accommodate holes if it needs to be fitted with other components. There are two styles of heating circuits that can be used with silicone rubber and each has its own advantages. Wire wound circuits are made by designing a specific pattern to wrap the resistance wire around a fiberglass core. The second style, an etched foil circuit, has a flat circuit that is created by chemically etching a resistant circuit out of nickel alloy resistance foil.
Strip Heaters
Strip heaters are small electric heaters that can be clamped or bolted onto a surface for direct transfer of heat to a solid object or for the heating of air in an enclosure. Strip heaters are usually flat, straight and similar in shape to a ruler, but they are often fined for fuller heat radiation when they are used to heat air. They can also be used to heat tubes, pipes and nozzles, in which case they can be designed as circular bands that clamp around cylindrical objects.
A few of strip heaters' common applications include providing heat for cylinders, platens, process machines, moisture protection, thawing, baking, drying ovens, food processing, control cabinets, acrylic extrusions and space heaters. Strip heaters may be used individually or in groups to provide melting, drying or air heating. Strip heaters can also be used in the formation and shaping of plastics. In plastic extrusion, strip heaters can be used to assist in the plasticization of raw plastic stock while it is processed in a conveyance channel. They are also used to heat plastics in advance of bending processes.
Tubular Heaters
Tubular heating is used primarily in custom heating applications such as plastic injection molding, rubber molding, packaging, plastic welding, and plate heating. Food processing equipment uses the heaters to sterilize low-acid liquid foods, while small animal breeders use them to heat cages. Tubular heaters differ in terms of features and options; some products are corrosion resistant and explosion proof, while others are finned or portable.
Tubular heaters create heat with a coil heating element. These heaters are constructed with a coil centered in the heating element binder; inside the binder, the coil is surrounded by magnesium oxide powder. The powder is vibration loaded to ensure even density throughout the length of the heater. The heater is then reduced to the finished diameter, causing the magnesium oxide powder to compress and "freeze" the coil in the center of the heater. The final step is to place the binder inside a protective sheath. The coil converts electricity into heat and radiates heat through the insulation and sheath. The coil can be straight or curved to fit into smaller spaces, such as a coffee maker. The sheath is usually made from aluminum, copper, rubber or stainless steel and serves as a cover to the actual heating element.
The Best Types of Heaters
ICR Series Heaters
ICR heaters are infrared heaters that produce short radiant wavelengths, which convert 85% of consumed energy into directional heat. They can easily be adjusted to meet the heating loads for a specific area. The ICR series reduces ceiling clearance to remove ceiling clutter to provide a streamline environmental look. The installation of an ICR series heater requires the use of a flush mount kit and fire rated installation enclosure. ICR series heaters can be mounted on walls or ceilings, which allows for design flexibility and heat coverage.
Infinity® 24 Heat Pump
The Infinity 24 heat pump is a highly advanced next level technology form of heat pump. It pairs adaptable speed technology with the Infinity 24’s heat control system and includes a variable speed compressor that allows the system to adapt to the needs of a building. The design of the Infinity 24 makes it possible for it to operate longer, steadier, and to provide exceptional energy efficiency. The temperature controls of the Infinity 24 are the best on the market.
Electric Fired Process Air Heater
Electric fired process air heaters are highly durable heating units used for industrial heating processes, such as ovens, baking, and curing and drying applications. Depending on the application, they can be installed vertically or horizontally with tubular heating elements. Electric fired process air heaters are designed for rugged use in industrial environments and have carbon steel mountings, stainless steel supports, and insulation collars. They can be custom designed to meet the needs of any industry.
EWH5500 Forced Air Heater
The EWH5500 is a powerful heater that can provide 17,060 BTUs in any work space. It has a louver design for directional air flow to enhance heat distribution. The hand held remote of the EWH5500 makes it easy to adjust the unit’s settings. The convenient size of the EWH5500 makes it possible to have the unit be floor or wall mounted. The EWH5500 has spiral wrapped steel heating elements encased in a scratch resistant cabinet. A timer and overheat shut off come standard.
DR998 Infrared Ceramic Heater
The DR998 has a built-in humidifier that adds moisture to the heating process and an oscillating function that evenly distributes heat from the unit. The dual heating system of the DR998 is capable of heating large rooms with temperatures ranging from 50°F to 85°F and uses water bottles as part of the process. The unit has lifetime cleanable easy access filters that can be cleaned with hot water or a vacuum. The dual action of the DR998 includes a ceramic heating element and an infrared heating element and comes with a remote for convenient use.
Conclusion
Energy costs have become a great concern and may seem impossible to control since we depend so much on the convenience of energy consuming devices. A little thought and organized planning can help avoid waste and lead to a more efficient use of energy. A first step to resolve this issue can be a portable electric heater, which can make a dent in electric energy usage.
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