A combustion-based process heating system uses fuel combustion to produce heat, then transfers that heat to a process or location where it’s needed. Most manufacturers use some form of process heating in their operations, including direct heat used for drying or indirect heat used to maintain specific facility and process temperatures.

At Custom Thermal Applications, we’re a proud industry leader in custom process heating equipment and combustion systems used to support manufacturing processes. Our product line includes:

• Heat treating ovens
• Paint drying ovens
• Ovens and other cooking equipment
• Burn-off ovens
• Water heating systems

Industries & Applications

Process heating accounts for more direct energy use than any other manufacturing element. Some of the industries, applications, and products that benefit from these systems include:

• Automotive
• Appliances
• Computer chips
• Cosmetics
• Electronics
• Farm and heavy equipment
• Food processing
• Medical products
• Paint/coating drying
• Paper products
• Ship building
• Textiles

Regardless of industry, it’s critical to keep your system(s) updated and maintained. Load management, blowdown and temperature optimization, and regular cleaning all help contribute to long-lasting equipment.

Process Heating System Types

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Process heating systems may rely on numerous methods for generating and moving heat. Here are some of the most common system types.

Fuel-Based Systems

These systems generate heat energy by combusting liquid, solid, or gaseous fuels. They transfer heat energy to processes using:

• Direct heating via convection
• Indirect heating via a radiant heat transfer

Some popular examples of fuel-based process heating systems include kilns and ovens.

Electric-Based Systems

Electric-based process heating systems may also use either direct or indirect heat transfer methods. While direct heating methods may pass an electric current directly through the substrate or workpiece, indirect methods may include radiation, convection, or conduction. Electric-based process heating systems are usually reserved for operations like melting, drying, heating, and forming. Common examples include infrared ovens and electric arc furnaces.

Steam-Based Systems

These process systems use either direct heating or indirect steam application to complete an operation. Direct steam heating will inject steam directly into the process, while indirect steam heating uses steam to heat pipes or tubes that are in contact with the process fluid to facilitate heat transfer. Steam-based process heating systems are popular in low-temperature industrial applications.

Hybrid Systems

Hybrid process heating systems rely on a combination of process heating technologies. They may use different heating sources and heating methods in order to optimize energy use. Some examples include:

• Hybrid boiler systems that combined fuel-based and electric-based boilers
• Penetrating electromagnetic (EM) energy and convective hot air combinations that help accelerate drying processes

Process Heating Systems From Custom Thermal Applications

At Custom Thermal Applications, we develop, manufacture, install, and maintain a broad range of process heating systems for manufacturers and industrial businesses. We have extensive experience working with:

• Process ovens for bakeries
• Process cooking equipment and high-volume water heating for meat and other food processors
• Heat treating and burn-off ovens for metallurgical process applications
• Thermal oxidizers for metallurgical process applications
• Paint drying lines for automotive and other parts manufacturing sectors

Process Heating Equipment Experts

At Custom Thermal Applications, we’ve worked diligently since 1984 to position ourselves as an ideal partner for process heating equipment manufacturing and service. Our experience allows us to help our customers overcome any obstacle, and our custom capabilities ensure that we can tailor our solutions to meet unique application needs.

All our systems meet CSA and TSSA standards. If you’re interested in learning more about our systems, contact us or request a free quote today.

Industrial Process Heating Methods

Process heating systems deliver heat to liquid, gas, and solid materials in various industrial settings. Depending on the application, multiple types of heating methods can be used. We will explore several of these industrial heating methods as well as their benefits and applications to help you determine the ideal solution for your application.

The Different Industrial Process Heating Methods

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Process heating systems rely on different fuel sources and heating methods to deliver indirect or direct heat to the process material. Here are a few common heating methods.

Combustion or Fuel Based Heaters

Combustion process heaters burn gasses, liquids, or solids to produce and transfer heat to the process material indirectly or directly. Oil, natural gas, coal, charcoal, wood chips, cellulose, and ethanol are common fuel choices. Air or oxygen is introduced to the fuel to achieve combustion. In direct heating, the combustion gas makes direct contact with the process material. In indirect heating, the process material is heated in a vessel away from direct contact with the combustion gas.

Electric Process Heaters

Electric process heaters rely on resistive heating elements through which electric current is passed to generate heat. The heating elements can then be used to directly or indirectly heat processes in tanks, ducts, or circulation vessels.

Heat Recovery and Exchange Systems

Heat recovery and exchange systems rely on a heat exchanger to transfer heat from one process material to another. For example, a manufacturing facility can use a heat exchanger to recover the heat produced by an exothermic chemical reaction and use it to provide heat to another application.

Boilers and Thermal Fluid Heating Systems

Boilers use fuel combustion to produce steam. This process heating method offers simplified transportation, low toxicity, high heat efficiency, and low cost. Boilers are one of the most prevalent process heating solutions in manufacturing facilities. They can be complex and require consideration of various factors to deliver efficiency and performance.

Thermal fluid heating systems utilize a heat transfer medium in the liquid state that is pumped through the heater and out to the heat transfer consumers. These systems commonly use organic or synthetic oils that allow for operation at high temperatures with little or no pressure when compared to boilers.

Hybrid Systems

A hybrid system utilizes multiple energy sources to heat material. For example, a paper manufacturer can use a fuel-based dryer in combination with an electric infrared heater to dry paper.

What Are the Benefits of Industrial Process Heating Systems?

When you partner with an experienced process heating system manufacturer and select the right system, you can enjoy the following benefits:

• Cost Efficiency: A suitable process heating system delivers optimal heat transfer and generation, improving efficiency, reducing energy consumption, and producing a higher quality product at an overall lower operating cost.
• Simple Installation: Quality process heating systems provide an all-in-one solution for heating and control. An experienced heating system manufacturer can deliver a custom solution that meets the specified space requirements and can be quickly assembled and installed on-site.
• Centralized Control: Process heating systems can be managed remotely with advanced instrumentation and controls.

Applications of Industrial Process Heating Systems

Process heating systems are ideal for a variety of flowing liquids, gasses, and air. They are used in the following process heating and industrial applications.

• Caustic Solution Heating
• Fuel Gas Heating
• Hydraulic and Heat Transfer Oils
• Lube Oil and Fuel Oil Heating
• Molten Salts
• Process Air and Gas Heating
• Process Chemical Reactors
• Steam Superheating
• Water Heating
• Water-Glycol Solution Heating

Process Heating Systems From Sigma Thermal

Industrial and manufacturing facilities have a range of choices for process heating methods. There are several types of heating systems available for solid, liquid, and gas materials, with either direct or indirect heating. Working with a knowledgeable and capable partner is vital to selecting the ideal process heating system for your application that delivers optimal performance and efficiency benefits.

Sigma Thermal offers custom and standard process heating solutions for gasses, solids, and liquids. We offer a selection of combustion, electric, heat recovery and exchange, boiler, and hybrid process heaters, all of which can be customized for your specific needs. Sigma Thermal is ISO 9001:2015 certified and serves a worldwide market.

Contact us or request a quote for your application’s ideal process heating solution.