Circulation Heaters

Table of Contents/Introduction
Engineering Information
Before selecting a standard circulation heater from the Oil Heating Example:
catalog listings, or customizing a design with any of the Application data: SAE 30 lubrication oil with a flow rate of
options and accessories, check the engineering information to 135 GPM, an inlet temperature of 45 F and an outlet tem-
assure proper heater design and performance for your applica- perature of 55 F. First, convert the flow rate to Lbs/Hr.
tion.
135 Gal 1 Ft3 60 Min
Calculating KW Requirements x x = 1083 Ft3/Hr
Min 7.48 Gal 1 Hr
When calculating the power required to heat a material flow- Obtain the specific heat (Cp) and density from Table III.
ing through the circulation heater, the KW equation shown
below can be applied. This equation is based on the criteria 1083 Ft3/Hr x 55.4 Lbs/Ft3 = 60,000 Lbs/Hr
that there is no vaporization occurring in the heater. The KW
equation incorporates a 20% safety factor, allowing for heat Now calculate KW:
losses of the jacket and piping, variation in voltage and watt-
age tolerance of the elements. 60,000 Lbs/Hr x (55-45)F x .45 BTU/LbsF x 1.2
KW =
3412
M x T x Cp x S.F.
KW = KW = 95
3412

Where: Gas Heating Example:

KW = power in kilowatts Application data: Air is flowing at 187 ACFM and 5 PSIG pres-
M = flow rate in Lbs/Hr sure. The inlet temperature of the air is 90 F and the outlet
T = temperature rise in F temperature is 250 F. First, convert the flow rate to SCFM.
(The difference between the minimum inlet temperature
and maximum outlet temperature.)
Cp = specific heat in BTU/Lb F PSIA 530R
SCFM = ACFM x x
S.F. = safety factor, 1.2 14.7 PSIA (TF+460R)
3412 = conversion of BTU to KWH
Where:
Water Heating Example: T = Inlet temperature in F
ACFM = Actual cubic feet per minute (This is the actual
Application data: 8 GPM flow with an inlet temperature of
volume flow rate value at inlet temperature and
65 F and an outlet temperature of 95 F. First, convert the
operating pressure, PSIA.)
flow rate to Lbs/Hr. SCFM = Standard cubic feet per minute (This is the volume
flow rate value at 70 F and atmospheric pressure,
8 Gal 1 Ft3 60 Min 14.7 PSIA.)
x x = 64.17 Ft3/Hr
Min 7.48 Gal 1 Hr PSIA = Pounds per square inch, absolute
PSIG = Pounds per square inch, gauge
Obtain the specific heat (Cp) and density from Table III, PSIA = PSIG + 14.7 (Note: If value is given as psi, it is
page 7. implied to be PSIG.)

64.17 Ft3/Hr x 62.4 Lbs/Ft3 = 4004 Lbs/H 19.7 PSIA 530R

187 ACFM x x = SCFM
14.7 PSIA (90F+460R)
Now calculate KW:
241.5 = SCFM
4004 Lbs/Hr x (95-65)F x 1 BTU/LbsF x 1.2
KW =
3412 Now convert to Lbs/Hr.
KW = 42
60 Min .073 Lbs
241.5 SCFM x x = 1057.7 Lbs/Hr
1 Hr Ft3

Reference Table I for the density and specific heat (Cp) of air.

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 Circulation Heaters
Watt Density & Sheath Selection
Engineering Information (continued)
Properties for Gases Example:
Table I Flow rate: 100 GPM
Density Specific Heat Liquid: SAE 30 lubrication oil
Gas (Lbs/Ft3) (BTU/Lb F) Inlet Temperature: 60 F
Air 0.073 0.24
Nitrogen 0.073 0.25 First, select the vessel size by determining the KW rating and
Steam 0.037 0.49 watt density and referring to the oil heater listings. For this
Densities and specific heats are at atmospheric pressure (14.7 PSIA) and 70 F,
example, we will select a 5 flange heater.
except the temperature for steam is 212 F. From the water pressure drop curves, we get a 2 psi pressure
drop, then we multiply that value by the correction factor
Now calculate KW: (Specific heat of air at average tempera- for SAE 30 lubrication oil. This gives a 3.2 psi pressure drop
ture of 170 F is also .24.) through the heater for this application.
1057.7 Lbs/Hr x (250-90)F x 0.24 BTU/LbsF x 1.2 The viscosity of oil can change dramatically with a 30 F change
KW = in temperature. If your inlet temperature is different than 60
3412
F, or the graphs indicate a pressure drop is too high for your
KW = 14.3 system, please contact Heatrex. We can evaluate your exact
requirements and offer alternatives to meet your needs.
Pressure Drop
Pressure drop through the heater is a function of many vari-
ables, including type of liquid or gas, flow rate, temperature Chart A
and vessel size. Use the information on this page as a guide-
line for common applications where water, lube oil, fuel oil, or
ethylene glycol are heated from 60 F. For other applications,
including heating gases, contact Heatrex, and we will deter-
mine the pressure drop for you.
The curves on Chart A indicate the pressure drop for the dif-
ferent diameters of catalog listed heaters. The curves are
based on water at 60 F, and the heaters having the standard
inlet and outlet sizes as listed on page 10.
Table II gives correction factors for Chart A when these other
liquids are being heated from 60 F.

Pressure Drop Correction Factors

Table II
Liquid Correction Factor
SAE 30 Lubrication Oil 1.6
No. 2 Fuel Oil 1.4
Ethylene Glycol (50% Solution) 1.7

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 Circulation Heaters
Table of Contents/Introduction
Watt Density and Element Sheath Material Selection
Selecting the proper watt density (watts per square inch of The standard vessel material is carbon steel. A stainless steel
element surface area) and the proper sheath material is vessel may be required at higher temperatures or for better
critical to heater life and fluid integrity. If the watt density corrosion resistance.
is too high, the fluid may carbonize, break down chemically, Table III gives watt densities and sheath material guidelines for
or the elements may burn out. If the sheath material selec- a variety of liquids.
tion is incorrect, it will corrode, destroying the element.
The watt density and sheath material guidelines shown in this
In general, watt density is determined by three factors: table should not be interpreted as a recommendation
1) maximum outlet temperature 2) type of fluid heated and 3) for all applications because there are many other factors
fluid flow rate. that can affect the selection of the appropriate watt density or
Sheath material depends on the type of fluid and maximum sheath material. Use this information as an initial guide along
temperature. with knowledge of the actual conditions which exist
in the heating application.

Maximum Watt Densities, Sheath Materials and Properties for Liquids

Table III
Sheath Sheath
Max. Max. Specific (1) Materials Max. Max. Specific (1) Materials
Fluid Watt Density (1) Heat, Cp Fluid Watt Density (1) Heat, Cp

Stainless Steel
Stainless Steel

Liquid Liquid
Temp. Density (Lbs/Ft3) (BTU/ Temp. Density (Lbs/Ft3) (BTU/
(F) (W/In2) Lbs F) (F) (W/In2) Lbs F)

Incoloy
Copper
Incoloy
Copper

Steel
Steel

Acetic Acid (2) 221 40 65.4 0.51 C C Heat Transfer Oils

Alkaline Solutions 212 50 62.0 1.00 B Syltherm XLT 475 12 52.6 0.40 A A A
Asphalt 500 6 132.0 0.22 A A A Syltherm 800 725 12 58.7 0.38 A A A
Ethylene Glycol- A B A A Thermalane 600 575 12 50.7 0.52 A A A
300 50 65.8 0.76
50% Solution Thermalane 800 675 12 50.1 0.57 A A A
Fuel Oils Therminol 44 400 12 57.8 0.47 A A A
No. 1* 575 20 50.5 0.50 A A A Therminol 55 560 12 55.2 0.46 A A A
No. 2 375 20 53.9 0.47 A A A Therminol 59 575 20 60.6 0.41 A A A
No. 5 375 12 58.9 0.45 A A A Therminol 60 560 20 62.6 0.39 A A A
No. 6 375 8 58.9 0.44 A A A Therminol 66 630 20 63.0 0.38 A A A
Heat Transfer Oils Therminol 75 675 20 68.8 0.38 A A A
Caloria HT 43 475 12 52.0 0.43 A A A Therminol FR-1 575 20 85.5 0.28 A A A
Chemtherm 660 675 20 63.7 0.38 A A A Therminol LT 475 20 53.7 0.43 A A A
Dowtherm A 725 20 66.0 0.38 A A A Therminol VP-1 725 20 66.7 0.37 A A A
Dowtherm G 675 20 68.6 0.37 A A A UCON 500 475 12 64.8 0.47 A A A
Dowtherm HT 625 20 60.6 0.37 A A A Machine or
Dowtherm J 575 20 54.1 0.43 A A A Lubrication Oils
Dowtherm LF 575 20 63.0 0.40 A A A SAE 10 275 20 55.4 0.45 A A A
Hitec 875 20 126.2 0.37 A A A SAE 20 280 20 55.4 0.45 A A A
Marlotherm L 675 20 58.7 0.45 A A A SAE 30 285 20 55.4 0.45 A A A
Marlotherm S 675 12 60.8 0.43 A A A SAE 40 290 12 55.4 0.45 A A A
Mobiltherm 600 550 20 58.4 0.43 A A A SAE 50 295 12 55.4 0.45 A A A
Mobiltherm 603 550 20 53.9 0.44 A A A Vegetable Oil 380 30 50.6 0.58 A A
Mobiltherm 605 550 20 53.9 0.44 A A A Water
Mobiltherm Light 550 20 61.3 0.42 A A A Process 212 50-80 62.4 1.00 A A A
Multitherm PG-1 565 12 54.2 0.45 A A A Deionized (2) 212 50-80 62.4 1.00 B
Multitherm IG-2 575 20 54.8 0.47 A A A (1) Densities and specific heats are at or near room temperature.
(2) Stainless steel vessel may be required.
* Kerosene

Rating legend:
A Good
B Fair
C Conditional, solution concentration and temperature will affect suitability.

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