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Cast-in circulation heaters

The CETAL-developed Cast-In Circulation Heater Technology offers a safe and precise integrated solution for your process heating requirements

This technology enable to cover many applications such as heating of:

  • Natural gas, butane, propane, N2, CO2, H2
  • Oxygen: Special designs
  • Hydrocarbons, solvents and paints
  • Sensitive fluids and gas applications
  • UHP applications: Semi conductors applications on request
  • Agri-food: pasteurisation / sterilisation

The design is based on customer process conditions : fluid to heat (type and properties), in/out temperature, pressure, flow, and environment conditions (ATEX or not, onshore or offshore …).

Reliability and robustness are key drivers for our engineers.

Product overview

  • Power: 1,5kW up to 32kW
  • Voltage max. 690 V
  • Indirect heating
  • ATEX or non-ATEX
  • Integrated solution

Advantages

  • Less expensive than a conventional heater
  • Compact design, smaller footprint
  • Precise, even heating
  • Easy cleaning
  • Operates at very high pressure
  • Standard wide range sized according to flow rate and power output

Operating conditions

  • Normal (non-ATEX)
  • Hazardous areas (ATEX/IECEx) and NEC 505
  • Operating temperature: from -196 °C to +350 °C (-273 °C on request)
  • Operating flow rate: from 10 Nm³/h to 12000 Nm³/h max. depending on operating pressure and gas
  • Up to 100 bar operating pressure as standard
  • Very high pressure up to 420 bar on request

Oil

  • Machine oil SAE 10, 30, 40 & 50, max load 2,0 – 3,5 W/cm², material: 316L
  • Mineral oil , max load 0,5 – 3,5 W/cm² acc to temp, material: 321, 316L
  • Lube oil, max load 2,3 W/cm², material: 321, 316L

Gas

  • Air, max load 0,1 – 8W/cm² acc to sheath temp, material: 321
  • Circulating air, max load 0,1 – 8 W/cm² acc to sheath temp, material: 309
  • Natural gas, max load 0,1 – 8 W/cm² acc to sheath temp, material: 321, 316L
  • Argon, nitrogen, W/cm² acc to sheath temp, material: 321, 316L, inc 825, inc 600
  • Propan, Butane, W/cm² acc to sheath temp, material: 321, 316L
  • Oxygen, Hydrogen, W/cm² acc to sheath temp, material: 316L

Technical description

Maximum thermal exchange and precise heat control with increased safety

Operating principle

This system is the ideal solution for heating gaseous, liquid or two-phase fluid at a specific flow rate.

Cast-in heaters consists of a cylindrical cast aluminium block which is heated.

The fluid to be heated circulates through an helical coil which is embedded in the cast aluminium block. The heat is precisely and efficiently transferred to the gas or liquid.

To minimise heat losses, the aluminium block is thermally insulated and protected by a casing.

As the system is highly flexible, the heater can be connected in series or in parallel, according to power requirements.

Technical advantages of indirect heating

  • No direct contact between the fluid to be heated and the heating elements
  • Optimized heat exchange
  • Homogeneous heating, no hot spots during system start-up and temperature rise phase
  • Easy cleaning

Regulation and control

A temperature probe is fitted as standard to monitor and control the skin temperature of the heating elements.

Other temperature probes are available as optional extras (for the aluminium block or at the heater inlet and outlet).

A control cabinet is used to control the heater.

ATEX and non-ATEX versions available

The entire system is available in an explosion-proof version for the ATEX T1 (450°C) to T6 (85°C) environment or for other “safe” environment applications.

A compact alternative Cast-in circulation heaters are excellent alternatives to conventional heaters consisting of an immersion heater mounted in a body.

They save space, have lower costs and are very competitive for high pressure applications.

System maintenance is also considerably reduced.

CETAL flexibility

CETAL heaters are available for specific flow rates and process power requirements.

The range starts at 1.5 kW to 32 kW as standard and is available with either a 230 V single-phase, 400 V three-phase to 690 V three-phase power supply.

CETAL manufactures its own heating elements which are the key components (active parts) of all electric heating systems. The design is defined according to customer specifications.

The watt density, tube diameter and the tube sheath are chosen to optimize the reliability and robustness (corrosion, temperature) of CETAL equipments.

Technologies

  • Tubular heating element

Tube diameter & material

  • Tube diameter: 6.5 / 8.5 / 10 / 13.5 / 16 mm
  • Tube material:
    • Stainless steel: AISI 321 (1.4541) / AISI 316L (1.4404) / AISI 309 (1.4828)
    • Others: Incoloy 800 (1.4876) / Incoloy 825 (2.4858) / Inconel 600 (2.4816)
  • Specific coating: TeflonTM (PTFE) / Halar
  • Tube type: sealed tube, seamless tube (on request)

Manufacturing

  • 100% of the components come high quality supplier from Europe
  • 100% manufacture within CETAL factory

  1. Connection terminals
  2. Tube
  3. Insulation : magnesia oxyde (Mg O), to secure optimized heat transfer and electrical insulation.
  4. Resistance wire: Made of Nickel Chrome 80/20, it is the active part of the heating element (Joule effect)
  5. Cold length
  6. Sealing material: Keeps out external moisture. Different types (silicon, resins, cement) are used depending on the industrialapplication, the external medium and temperature.
  7. Output insulation: Made of steatite ou corundum, it provides dielectric insulation (creepage distance, distance in the air).
  • Non ATEX connecting box
    • Stainless steel IP66/67 connection box
    • Two nickel-plated brass cable glands for power and control
  • ATEX/IECEx connecting box
    • Aluminium explosion-proof box with protective paint, Ex d IIC or stainless steel Ex e II C increased safety box
    • Two nickel-plated brass cable glands for power and control
  • Options :
    • Anti-condensation heating tape
    • Cable gland
  • Three-wire PT100 probe for monitoring the heating element temperature
  • Options :
    • Safety thermocouple or safety limiter thermostat or thermal fuse
    • Temperature regulation of the aluminium cast-in unit by PT100 probe, thermocouple or thermostat
    • Process regulation with temperature monitoring by PT100 probe at the outlet or thermocouple (in a separate housing)
    • Temperature measurement at the heater inlet by PT100 probe, thermocouple or thermostat (in a separate housing)
    • 4-20 mA transmitter with or without HART protocol for PT100 probes or thermocouples (ATEX version if an Ex e housing is used)
  • Power: 1.5 kW to 32 kW per unit
  • 230 V AC single-phase or three-phase
  • 400 V AC three-phase and up to 690 V three-phase optional
  • Other voltages available on request
  • Fluid circulation and heating in a 316L stainless steel coil
  • Pickled, passivated seamless tube for better mechanical strength
  • 6.35 mm to 48.3 mm diameter
  • Options : Incoloy or inconel coil / Coil electro polishing
  • Foamglas® / rock wool / ceramic insulation depending on operating temperatures and the fluid being heated
  • Protective aluminium jacket
  • Horizontal foot mounting
  • Options : vertical foot mounting or wall bracket
  • Available option : Vertical mounting configuration
  • Gas bleed and complete drain down
  • Documentation
  • Supplied according to standards and codes
  • Standard smooth welding end
  • Options:
    • 1/2″ to 2″ ASME/ANSI B16.5 stainless steel RF flange, 150 lbs to 600 lbs
    • PN 40 or PN 100, DN15 to DN50, RF flange. Other seal bearing on request for ASME or DIN flange
    • Stainless steel female 1/8″ to 1 1/2” diameter standard NPT or gas or 3000 lbs union fitting
    • Back flange, nuts and bolts and PTFE or spiral wound graphite seal
  • Standard documentation
    • Certificate of conformity to the order
    • Heater wiring diagram
    • Instruction manual
  • On-request documentation
    • Supplied according to directives, standard and construction code
    • Welder qualifications (QS)
    • Welding qualifications (QMOS)
    • PED documentation
    • Material certificate 3.1 according to NF EN 10204
  • Conforms to Pressure Equipment Directive 2014/68/EU
  • ATEX (option)
    • Ex d IIC T1 to T6
    • Ex IIC 2GD Ex tD A21 IP67
    • Ambient temperature: -50°C ≤ Ta ≤ +60°C
    • According to EC type LCIE 04 ATEX 6094X examination certification

 

Electrical tests

  • Power test by cold resistance measurement. Allowed tolerance: -5% and +10% of the nominal resistance value.
  • Insulationtest, direct voltage 500 V, mini cold value is > 100 Megohms
  • Dielectric test, (2U + 1000 V)  x 1,2 during 1 second
  • The stray current and the hot dielectric rigidity can be measured on a sample at operating temperature (on request).
  • 100% of the heating elements are tested before shipment (Final control)

Mechanical tests

  • Visual inspection
  • X-ray test (if required)
  • Liquid penetrant test
  • Pressure control test

Dimensional test

  • Critical dimension are tested

Other tests / operations

  • Helium test (on request)
  • Degreasing
  • Argon cleaning

Third party

  • Third party inspection (on request)

 

Type

Power
(KW)

Max.
flow rate
Nm3/h
at 8 bar

Max. flow rate
Nm3/h
at 80 bar

Max.
liquid flow rate
m3/h

Distance
between
inlet & outlet*
(mm)

Ext. Ø
of helical
coil
(mm)

Tube
thick-ness (mm)

Width*
(mm)

Length*
(mm)

Height*
(mm)

Weight (kg)

Cast-in circulation heater 01-xx kW

1.5/3

10

100

0.2

90

6.35

1.24

240

470

190

30

Cast-in circulation heater 02-xx kW

1.5/3

25

250

0.5

8

1

30

Cast-in circulation heater 03-xx kW

1.5/3/6

40

400

1

10

1

30

Cast-in circulation heater 04-xx kW

1.5/3/6

55

560

1.5

140

13.7

2.24

310

500

220

45

Cast-in circulation heater 05-xx kW

3/6/9/12

120

1300

3

17.2

1.6

45

Cast-in circulation heater 06-xx kW

3/6/9/12/24

180

1900

4

250

21.3

2.11

430

520

275

90

Cast-in circulation heater 07-xx kW

6/9/12/24

320

3300

7

26.7

2.11

95

Cast-in circulation heater 08-xx kW

6/9/12/24

540

5500

11

33.4

2.77

110

Cast-in circulation heater 09-xx kW

6/9/12/24/32

850

8600

19

340

42.2

2.77

540

550

320

240

Cast-in circulation heater 10-xx kW

9/12/24/32

1150

12000

26

390

48.3

2.77

590

550

345

250

* subject to change

Electric heating controls for industrial processes must be designed for the characteristics of the fluid to be heated and also take into account the process specifications.

CETAL offers an economical range of power supply and control cabinets. They are specially designed to control cast-in circulation heaters.

The design of the pre-configured cabinets allows for simplified quick installation and safe commissioning. They are supplied in the form of IP54 sealed metal boxes with a small, space-saving footprint.

Depending on the process, two methods of regulation are available: the standard version with a contactor controlled by a PID controller or, optionally, with a static contactor (thyristor).

The front panel controls are easy to use:

  • General switch-disconnector at the top of the cabinet
  • On / Off switch
  • Fault acknowledgement button
  • Emergency stop button

Technical data

  • Dimensions according to the model: from 600 x 500 x 250 mm to 1200 x 100 x 300 mm
  • Power: 3 kW to 150 kW, 400 V three-phase + earth
  • Three-phase 12 A to 200 A disconnector
  • Right side handle
  • Safety fuse holders + fuses
  • Transformer
  • ON indicator, general fault indicator, illuminated green knob
  • Safety line contactor
  • PID controller
  • SSR output + 1 high alarm
  • Three outputs on potential-free contact
  • Wall bracket
  • Options:
    • Wave train control contactor
    • If required, 230 V fan with filter and thermostat
    • Floor mounting base
    • Top