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Electric vs. Non-Electric Heating in Processing Applications

Electric heating technology is often the preferred choice when considering safety, design standards, reliability, controllability and environmental regulations. The keys to proper performance are superior engineering practices and application expertise to ensure good design.

Electric heating provides little installation and maintenance hassles to many process applications compared to the tradional choices of gas and steam. Electric heat is cost effective regardless of temperature range because it runs at high efficiencies without emissions concerns. The physical size of an electric heater is also more compact than a gas-fired system.

Consider these advantages when specifying your process heating needs.

Increased Efficiency:
Direct immersion is typically going to be the most efficient way to heat in processing applications. This includes specifying the energy level required for heating and precise temperature control of the system. This is often more economical because of the cost to control and the temperature need. Additional expenses are also required for venting exhaust gases.

Safety:
Electric heating is safer as it relates to fire hazards and exhaust gases.

High Elevations:
Electric heaters can still be utilized efficiently and cost effectively above three stories. It is difficult to pipe steam at this level. If steam is used, booster electric heaters may be needed to reheat or superheat the steam for certain processes.

Remote Site Locations:
If a heat source is required away from the main complex, it becomes too costly and difficult to pipe steam or to lay oil and gas lines for burners. Electric heat is a preterable option because it is easier to move around, set it up, connect the wires and go.

Very Tight, Accurate Process (Temperature) Control:
Electric heat is much easier to control and safeguard than oil or gas fired heat. As temperature controls are developed, they become better and better. Refineries are even beginning to use electric heat to meet the demanding requirements of today's refinery processes.

Small Size/kW Rating:
When small amounts of heat are required, electric heathers are more efficent than bulky gas tanks or piped in stea.

Hazardous Area Classification:
Electric heater enclosures and switching cabinets are far easier to design and build to conform to hazardous areas than any other heating method.

High Process Temperatures:
In processes requiring very high temperatures (mostly gas heating), it is much safer and more efficient to heat with direct immersion of electric elements versus using a heat exchanger set up with steam or gas fired heat sources. There comes a point in steam heating when raising steam temperature requires very high pressures. This dramatically increases heat exchanger system costs, thus making electric heating more attractive.

Emission Issues:
When an electric heater is used, emissions are rarely a concern because they are not located in the same area, like with gas and oil.

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