MATERIALS HANDLING A
ll process industries face mounting pressure to improve both operational eff iciency and
environmental performance. While electrifi cation is a key component of this transformation, it is only one part of the solution. The real potential for achieving higher eff iciency and sustainability lies in the use of advanced heater technologies in an integrated thermal loop, as Volker Metzger, Applied Thermal Expert at industrial technology company Watlow, explains. This is particularly true for oil and gas. Electrifi cation is no longer a mere
trend but an imperative. Industries are under pressure from regulators, consumers and shareholders to decarbonise, and electric heating systems play a critical role in achieving this transformation.
LEVERAGING ADVANCED HEATER TECHNOLOGY Continuous helical fl ow technology has revolutionised the eff iciency and reliability of electric heaters. Traditional heating systems often suff er from dead zones, leading to hotspots, coking and fouling. These issues reduce eff iciency and increase maintenance needs, causing costly operational disruptions. Continuous helical fl ow technology mitigates these challenges by ensuring uniform temperature distribution across the heating surface, signifi cantly reducing fouling and extending the heater’s operational life. Another key development is the use of medium voltage electric
Modern electric heating systems provide superior performance in high-temperature processes
heaters, which handle the high-power demands of industrial applications while off ering improved eff iciency and safety. Operating at up to 7,200 volts, electric heaters reduce the need for large step-down transformers and minimise the heat generated by cabling, leading to lower installation and maintenance costs.
TRUST IN THE THERMAL LOOP However, the true potential of advanced heater technology is realised when it is integrated into a comprehensive thermal loop that includes not only heaters but also sensors, power management systems and data analytics. This system-wide approach enables companies to fi ne-tune their operations with unprecedented precision, ensuring tighter temperature control, optimised energy use and long-term sustainability. When integrated with proportional-
integral-derivative (PID) controllers and real-time data analytics, modern electric heating systems such as medium voltage solutions, provide superior performance in high-temperature processes. These solutions off er advantages over traditional gas-fi red systems, such as greater temperature control, reduced energy consumption and minimised maintenance costs.
PREDICTIVE AND DATA-DRIVEN The full advantages of electric heaters cannot be achieved without integration of predictive maintenance systems. By continuously monitoring system performance through real-time data analytics, operators can detect early signs of system wear, such as temperature drifts or anomalies, before they escalate into major issues. This approach helps reduce unplanned downtime, extend equipment life and lower maintenance costs. Incorporating digitalisation into the
thermal loop also allows for data-driven optimisation, enabling companies to reduce energy consumption by adjusting power usage based on real- time performance data. By analysing process trends and using predictive insights, companies can optimise energy use, providing a signifi cant competitive advantage in an era where energy eff iciency is paramount. Electrifi cation plays a pivotal role in
improving eff iciency and sustainability in the oil and gas industry. However, the real transformation comes from the integration of advanced heater technologies within a comprehensive and electrifi ed thermal loop. Innovations like continuous helical fl ow technology, medium voltage electric heaters and predictive maintenance systems enable companies to achieve greater eff iciency, lower emissions and enhanced reliability.
For more information visit:
www.watlow.com
A USEFUL LOOP
Volker Metzger from Watlow explores how advanced heater technologies can improve operational effi ciency.
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