Safety Tips When Using Industrial Heating Elements

In the Philippines, industrial heating elements are not just a component of the manufacturing process; they represent a significant export, accounting for 0.54% of the country's total exports in 2021. This highlights the pivotal role of heating elements in the nation's industrial landscape, particularly in chemical and plastics manufacturing, pharmaceuticals, transportation, and appliances. Besides exports, the COVID-19 pandemic has further underscored their importance, with an unexpected surge in demand indicating a wider adoption across industries.

Beyond the Philippines, the global market for industrial electric heating elements is on a growth trajectory, valued at USD 2855.05 million in 2021 and expected to reach USD 4089.66 million by 2027, growing at a CAGR of 6.17%. This growth is driven by the numerous advantages of electric heating elements, including their ability to provide temperature-controlled and clean heating processes without the need for combustion.

So, what exactly are heating elements, their applications, types, and essential practices for safe use?

Heating elements are crucial components in various industries, functioning to transform electrical energy into heat through a process often referred to as resistive or electric heating. This transformation occurs when an electrical current passes through the element, causing the electrons to move and generate heat due to resistance within the material. This process, fundamentally based on the principle of resistive heating, ensures that the energy input is efficiently converted into thermal energy. Remarkably, this mechanism allows for nearly complete efficiency, with virtually all electrical energy supplied to the element being converted into heat.

And in the dynamic industrial landscape of the Philippines, several types of heating elements are predominantly utilized, including air process heaters, band heaters, and cartridge heaters. Each of these elements serves a specific purpose and finds its application in different settings, tailored to meet specific heating requirements.

Some of the common ones include:

Air heaters, as implied by their designation, are tasked with warming air as it passes through a device. These units essentially consist of a duct or chamber where air enters cool and exits heated, facilitated by coils of heating elements encased in non-conductive materials. Suited for applications requiring high airflow at low pressure, air heaters are commonly employed for processes such as heat staking, plastic welding, laminating, drying, and heat sealing.

Band heaters are uniquely designed to encircle cylindrical metal objects, like pipes, barrels, and extruders, securing tightly with bolted clamps. Within these bands lies a slender resistive wire or ribbon, typically encased in high-grade mica insulation, with an outer sheath of stainless steel or brass. Designed to safeguard the heater from chemical degradation by the processed fluid and prevent potential ignition hazards in oil or lubricant applications, band heaters are commonly employed for applications such as drum heating and oil reclamation systems.

Water heater elements, pivotal for heating liquids to precise temperatures within specific timeframes, utilize immersion heaters controlled either by mechanical thermostats or digital controllers with thermocouples for accurate temperature measurements. These heaters are essential in various settings, providing efficient and controlled heating for various liquid-based applications.

When it comes to industrial applications, the proper selection of a heating element is paramount. To make a well-informed decision, it's essential to grasp the unique demands of your industry. Consider the following factors to navigate the selection process:

When choosing a heating element, the first factor to consider is the power requirement of your application. The heating element must be capable of delivering the necessary amount of heat without overconsumption of energy, balancing operational efficiency with energy costs. Therefore, assessing the wattage and voltage specifications of the heating element in relation to your application's demands ensures optimal performance.

Selecting the right heating element also requires understanding the environmental conditions in which it will operate. Factors such as ambient temperature, humidity, and exposure to corrosive substances can significantly affect the choice of heating element. For environments with high moisture levels or aggressive chemicals, heating elements made from materials resistant to corrosion and degradation are necessary to ensure longevity and safe operation.

The design of a heating element and the materials used in its construction are critical to its safety and performance. Moreover, the choice of material impacts not only the durability of the heating element but also its suitability for specific industrial applications and environments. For example, nickel-chromium is known for its high resistance and heat tolerance, making it ideal for high-temperature applications. Copper, with its excellent thermal conductivity, is suitable for applications requiring rapid heating, while stainless steel offers durability and resistance to rust and corrosion, which is essential in harsh environments.

Abiding by safety standards and regulations is a fundamental aspect when it comes to choosing industrial heating elements. One critical directive to consider is the Restriction of Hazardous Substances (RoHS), which guarantees that electrical and electronic products are devoid of harmful substances, enhancing safety and reducing their ecological footprint. Adhering to these regulations safeguards workplace safety and aligns with global efforts toward sustainable and responsible manufacturing practices.

Ensuring the safe use of industrial heating elements is paramount to preventing accidents and maintaining efficient operations. Adherence to the following safety guidelines is crucial:

• Proper Installation: Follow manufacturer instructions meticulously to ensure that heating elements are correctly installed. Improper installation can pose safety risks and result in suboptimal performance.
• Routine Checks: Conduct regular inspections of heating elements for signs of wear, damage, or malfunction. Detecting problems at an early stage can avert mishaps and prolong the heating element's lifespan.
• Handling Procedures: Always use appropriate safety gear when handling heating elements, especially when they are hot. Establish clear procedures for the safe handling, maintenance, and replacement of elements.
• Emergency Protocols: Develop and train staff on emergency protocols in case of heating element failure or accidents. Knowing how to respond quickly and safely can minimize potential injuries and damage.

When it comes to industrial operations, the safety and efficiency of heating elements cannot be overstated. After all, making informed choices about these essential components is crucial for the smooth running of any industrial process. RS stands ready to support these needs with a comprehensive selection of high-quality, reliable heating elements such as water heater devices, heating filaments, and more, all designed for a myriad of industrial applications.

Our commitment to safety, efficiency, and innovation ensures that businesses can find the perfect heating solution tailored to their specific requirements. Explore our range of other automation and control gear, like thermal overload relays and partner with us to enhance the safety and performance of your industrial heating systems.

Together, let's drive forward with solutions that not only meet but exceed industry standards.