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:: Circulation Heaters ::
 
MTRUSREE ELECTRO HEATS Circulation Heaters are designed and manufactured in a wide range of models, ratings, and watt densities for many applications. Circulation Heaters consist of either a flanged or screw plug heater which is mated to a casing with inlet, outlet, vent, & drain options to meet your specifications.
The packaged system with a Matrusree Circulation Heater is designed to supply the right amount of energy to heat the process fluid to the desired temperature, for a given flow rate. Circulation heaters with brazed or welded construction, center core baffles for increased velocities available. Standard Circulation Heaters are furnished with high temperature insulation and steel jackets. Standard pressure vessels are up to 24" pipe and are Carbon Steel. MATRUSREE Electric Circulation Heaters have universal or custom mounting brackets available. These Circulation Heaters have inlets, outlets, drains, or extra openings in your choice of female coupling (standard), threaded male pipe stub, or flanged. Ciculation Heater overall and immersed lengths, and inlet and outlet dimensions, can be varied to suit your application.
Standard Circulation Heaters are furnished with high temperature insulation and steel jackets. Standard pressure vessels are up to 24" pipe and are Carbon Steel.
MATRUSREE Electric Circulation Heaters have universal or custom mounting brackets available. These Circulation Heaters have inlets, outlets, drains, or extra openings in your choice of female coupling (standard), threaded male pipe stub, or flanged. Ciculation Heater overall and immersed lengths, and inlet and outlet dimensions, can be varied to suit your application.
Design Feature:
"General purpose terminal housing is standard. Moisture proof and/or explosion resistant housings are optional. A set of installation and maintenance instructions along with a wiring diagram can be found inside the terminal housing of each unit.
" Heating source-11/4" and 21/2" Screw Plug Heaters are used on smaller units. 3" to 14" size heaters use Flanged Immersion Heaters. The flanges are made from forged steel rated for 150 lbs with raised face
"Supplied with threaded eyebolts for ease of handling and installation.(Optional stainless steel flanges or 300 lb ratings available).
"Inlet-outlet connections are NPT pipe threads for 3" to 8" Circulation Heaters (flanges are optional). Standard inlet-outlet connections on 10" and larger units are 150 lb. rated flanges.
"Double-pole non-indicating bulb and capillary type thermostat is an optional feature and can be located in the terminal box or attached to the insulation jacket as pictured. Solid state temperature controllers and indicating thermostats are available. Over-temperature protection can be provided by attaching a thermocouple to one of the elements
"Threaded mounting lugs to support the unit are welded to the steel vessel. Custom supports can be designed to fit your structure.
"Wide selection of heating element sheath materials for maximum corrosion resistance to the medium being processed. On smaller circulation units with screw plug heaters, the element diameter is .315" or .475". On larger units with flanged heaters, the element diameter is .475".
"The vessel is surrounded with 1" thick insulation rated to 750F (399C) to minimize heat loss. Additional insulation or a high temperature ceramic fiber insulation is optional. Vessels can also be supplied
"Vessel material is SA53B or SA106B steel. Good for up to 750F (399C) operating temperature. For drainage and cleaning purposes, a drain plug is located in the base of the tank. Optional: Stainless steel vessel.
"Outer steel sheet metal jacket protects and keeps the insulation dry from the environment. It is painted with rust and corrosion resistant paint. Optional: Stainless steel outer jacket and rain-tight seal.
Circulation Heater Specifications
Wattage:0.5 to 800 kilowatts
Voltage:Up to 600 volts, Single or 3 phase
Flange sizeANSI up to 24 Inch & Custom Sizes
Screw Plug size:2" NPT, 2-1/2" NPT, 3" NPT
Pressure rating:Up to 1500 PSIG
Vessel size:Up to 24" Pipe
Flange Material:Carbon Steel, Various Stainless Steels, Incoloy
Screw Plug Material:Steel, Various Stainless Steels
Flange Material:Carbon Steel, Various Stainless Steels, Incoloy
Immersed length:Up to 160 inches
Typical Application:
Heating of liquid materials, in large storage tanks, to pumping temperatures. Maintaining an entire tank of viscous fluids such as water, molasses etc., or other Liquide Mixtures at pumping temperatures is very costly. In many applications it is not practical or economical because the tanks are located underground or are not insulated.Type, Circulation Heaters are a cost-effective solution to this problem. Circulation heaters are specifically designed to heat only that amount of material that is to be pumped from a large storage tank. The outlet nozzle is attached to the pump suction. The heater heats the material inside the heater pipe body which is then drawn through the heater into the suction side of the pump. This technique saves substantial energy costs since it is not necessary to heat the entire contents of the tank to draw off relatively small amounts of viscous materials. Complete weather-proof construction makes these heaters perfect for installation in large outdoor storage areas. Large heater inlet provides smooth, full-flow through the heater.
Some of the applications in brief:
  • Clean water,
  • Aqueous solutions
  • Lubricating Oils
  • Fuel oils
  • Light and Medium weight oils
  • Heat transfer oils
  • Degreasing solutions
  • Liquid paraffin
  • Forced air
  • Caustic solutions
  • Processed water
  • De-ionized water
  • Circulation Heater Section
    Matrusree Circulation Heaters will provide long life and reliable trouble free service and trustworthy-provided the sheath materials, watt densities and operating temperatures are properly matched for the medium being heated.

    Following are some points worth to be considered while selecting the proper Circulation Heater:

  • Match your process to the most suitable heater alloy sheath material
  • Do not exceed the maximum allowable heater watt density (w/in2) and recommended operating temperature for the material being heated. Consult MATRUSREE with your requirements.
  • Pressure-Temperature Rating.
  • Select the proper terminal enclosure to protect the heater wiring and provide safety to personnel and equipment.
  • For uniform heat distribution and reduction of power in large storage tank applications, several smaller circulation heaters are recommended rather than a single large unit.
  • Sheath Material Selection:
    CORROSION: Apart from selecting a sheath material that is companionable with the heated medium, other factors that affect corrosion need to be considered.

    The temperature of the corrodent. As temperature increases the degree of corrosion increases. Also remember that the element temperature is usually higher than the material it is heating.

    Velocity of the corrodent. Increased velocity can increase the corrosion rate.
    Sheath Materials:
    Incoloy 800 A Nickel (30-35%), Chromium (19-23%), Iron alloy. The high nickel content of this alloy contributes to its resistance to scaling and corrosion. Used in air heating (also see Incoloy 840 on page 10-3) and immersion heating of potable water and other liquids that are not corrosive to an Incoloy 800 sheath. Sheath temperatures to 1600F (871C).

    Low Carbon Steel Applications include fluid heat transfer media, tar, high to low viscosity petroleum oils, asphalt, wax, molten salt, and other solutions not corrosive to a steel sheath. Sheath temperatures to 750F (399C).

    316 Stainless Steel A Chromium (16-18%), Nickel (11-14%), Iron Alloy with Molybdenum (2-3%) added to improve corrosion resistance in certain environments, especially those which would tend to cause pitting due to the presence of chlorides. Applications include deionized water. Sheath temperatures to 1200F (649C).

    316L Stainless Steel A Chromium (16-18%), Nickel(10-14%), Ferrous alloy with Molybdenum (2-3%) With carbon percentage slightly less than 316 SS is used in most marine applications

    Copper Mainly used in clean water heating for washrooms, showers, rinse tanks and freeze protection of storage tanks. Sheath temperatures to 350F (177C)
    Optional Element Sheath Materials:
    304 Stainless Steel A Chromium (18-20%), Nickel (8-11%), Iron Alloy used in the food industry, sterilizing solutions, air heating, and many organic and inorganic chemicals. Sheath temperatures to 1200F (649C).

    321 Stainless Steel A Chromium (17-20%), Nickel (9-13%), Iron Alloy modified with the addition of titanium to prevent carbide precipitation and resulting intergranular corrosion that can take place in certain mediums when operating in the 800-1200F (427- 649C) temperature range. Sheath temperatures to 1200F (649C).
    Sheath Metal Surface Treatment:
    Circulation Heater surfaces in contact with the material being heated can be passivated or electro-polished to improve their resistance to corrosion.

    Passivation removes surface contamination, usually iron, so that the optimum corrosion resistance of the stainless steel is maintained. Surface contamination would come from the small amount of steel that may be worn off a tool during the manufacturing process.

    Electro-Polishing is an electrochemical process that removes surface imperfections and contaminants, enhancing the corrosion resisting ability of the stainless steels. The resultant surface is clean, smooth and bright. Many medical and food applications require this type finish.
    Flow Control Baffles:
    Used on circulation tank heaters to aid heat transfer by forcing the liquid or gas back and forth across the elements. Baffles can be custom designed and positioned for you application.
    Temperature Control:
    Thermostats:
    Thermostats are an optional feature on flanged immersion heaters. This type of control operates by expansion and contraction of a liquid in response to temperature change. Liquid contained within the sensing bulb and capillary flexes a diaphragm, causing the opening and closing of a snap action switch. For heating applications the contacts are normally closed and open on temperature rise.

    Do not use the thermostat as a power switch. Use some other means of disconnecting power to the heater for servicing. Thermostats are not a failsafe device. Use an approved high temperature limit control and/or pressure limit control for safe operation.
    Thermocouples:
    Type K (Chromel-Alumel) or Type J (Iron-Constantin) thermocouples can be supplied for process temperature or over-temperature control.

    Type J is reliable and accurate for temperatures up to 1000F (539C). Type K should be used for higher temperatures. For measuring process temperatures the thermocouple can be mounted in a thermowell in the center of the element bundle. Note that a location somewhere away from the heater may give a more accurate measurement of process temperature.

    For over-temperature protection the thermocouple is usually attached to one of the elements and any unusual rise in element temperature would shut the heater down. This thermocouple may also be mounted in a thermowell, which is then attached to one of the heating elements if desired. This protects the thermocouple from the solution being heated and allows you to replace it without removing the heater but does increase its response time.
    Installation Procedures:
    1. Flange heaters are supplied with two drilled and tapped holes for threaded eye bolts, providing ease of handling during installation and flange removal during maintenance cleaning or heater replacement.
    2. Replacement of heater is inevitable. Therefore, provide adequate space for installation, allowing ample room to remove the flange heater for cleaning or replacement.
    3. In applications requiring the circulation heater to be fed by an inline pump, install the pump at the inlet end.
    4. To maintain the lowest possible temperature at the terminal box, place the outlet at the end opposite to the terminal box. If your process temperature is circulating at 450F (232C) or above (at the nozzle closest to the flange), stand-off terminal box construction is recommended.
    5. To prevent temperature and/or pressure buildup on closed loop circulation heater systems, adequate and strategically located thermocouples for temperature controllers and pressure relief valves should be installed. Never over-rate pressure relief valves beyond the pressure temperature rating of the flange being used.
    6. During the process cycle, flow rate of the medium being heated should never be interrupted or reduced, thus creating an overheating condition. Excess temperature can result in damage to the medium being processed and premature heater failure.
    7. Make sure that your circulation heater is equipped with the proper terminal housing for the environment in which the heater is being used.
    Mounting:
    Vertical:
    In this type of mounting the inlet is on the bottom side and terminal housing on the top ensuring that the elements are immersed in at all times to prevent premature failure
    Horizontal:
    Here the heaters are always mounted with inlet-outlet pipes facing up to make sure that the heating elments will be immersed at all times to prevent premature failure. For liquid heating outlet may be at either end. When heating gases the inlet should be closest to the terminal enclosure to minimize terminal box wiring temperatures.
    Maintenance:
    1. Never perform any type of service on the unit earlier to disconnecting all electrical power and closing all intake lines.
    2. Remove sludge deposits through the drain plug.
    3. Check flange bolts for tightness.
    4. Check terminal connections for tightness.
    5. Check thermocouple or thermostat bulb for response to temperature changes. If defective, change immediately.
    6. Check for leaks.
    7. Depending on operating conditions and medium being processed, the flange or screw plug heater should be periodically removed for physical inspection and cleaning of the element bunch.
    Wiring:
    1. All heater installations must be properly earth grounded to eliminate electric shock hazard.

    2. All power to heaters must be disconnected before removing the terminal housing cover and performing any type of service.

    3. Electrical connections on heater terminals must be kept tight. Loose connections will create arcing, over-heating, and eventually will destroy the heater terminal and cause premature heater failure.

    4. If the amperage rating of your circulation heater exceeds the amperage capacity of the supplied thermostat, mercury relays or magnetic contactors should be used with the thermostat.

    5. Over-temperature protection thermocouples require a separate conduit to the control panel for the thermocouple wire.
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