Watlow applied thermal expert Volker Metzger gives the low down on advanced heater technologies
All process industries face mounting pressure to improve both operational efficiency and environmental performance. While electrification is a key component of this transformation, it is only one part of the solution. The real potential for achieving higher efficiency 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.
Electrification 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 flow technology has revolutionised the efficiency and reliability of electric heaters. Traditional heating systems often suffer from dead zones, leading to hotspots, coking and fouling. These issues reduce efficiency and increase maintenance needs, causing costly operational disruptions. Continuous helical flow technology mitigates these challenges by ensuring uniform temperature distribution across the heating surface, significantly reducing fouling and extending the heater’s operational life.
Another key development is the use of medium voltage electric heaters, which handle the high-power demands of industrial applications while offering improved efficiency 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 fine-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 offer advantages over traditional gas-fired 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 significant competitive advantage in an era where energy efficiency is paramount.
Electrification plays a pivotal role in improving efficiency and sustainability in the oil and gas industry. However, the real transformation comes from the integration of advanced heater technologies within a comprehensive and electrified thermal loop. Innovations like continuous helical flow technology, medium voltage electric heaters and predictive maintenance systems enable companies to achieve greater efficiency, lower emissions and enhanced reliability.
For more information visit: www.watlow.com
