Electric heat exchanger

An electric heat exchanger for media plays a central role in industrial processes in which gaseous or liquid substances have to be brought to a defined temperature. These can be natural gas, biogas, hydrogen, process gas, LNG, nitrogen, air, water or glycol mixtures. The use of such electric heat exchangers is particularly important in the chemical, petrochemical and polymer industries, natural gas extraction, food processing, shipbuilding and in maritime and industrial applications.

Through targeted heat exchange, media can not only be heated efficiently, but also superheated to ensure optimum process control. Depending on the application, the electric heat exchanger can be designed as an electrically heated system, a steam-driven model or a solution supported by heat recovery. Precise temperature control ensures consistent conditions, which significantly increases both energy efficiency and process reliability.

Particularly in sensitive applications, such as gas heating for pressure reduction or liquid heaters for industrial cooling and heating circuits, electric heat exchangers must meet the highest technical requirements. Materials, temperature resistance and control systems are precisely adapted to the respective operating parameters in order to ensure maximum efficiency and durability.

1. chemical industry

1.1 Preheating of process media

• Heating aggressive chemicals (e.g. acids, alkalis) before a reaction
• Temperature control for sensitive chemical processes
• Reduction of viscosity problems through preheating

1.2 Heating solvents

• Avoidance of condensation or solidification
• Uniform temperature control during extraction processes
• Ensuring flowability at low ambient temperatures

1.3 Heating for polymerization reactions

• Generating the optimum starting temperature for reactions
• Preventing undesirable side reactions through uniform heating
• Energy-efficient heat supply in plastics production

2. oil and gas industry

2.1 Preheating heavy oil and crude oil

• Reduction of viscosity for better pumpability
• Avoidance of kerosene and wax precipitation at low temperatures
• Preparation for further processing in refineries

2.2 Gas preheating in high-pressure systems

• Prevention of condensation during gas expansion (e.g. in pressure reducing stations)
• Avoidance of icing effects in valves and control lines
• Efficient heating before gas liquefaction or gasification processes

2.3 Heating lubricating and hydraulic oils

• Ensuring optimum flow properties for machines
• Reduction of wear on pumps and lines
• Use in offshore and pipeline systems for safe operation

3. power plants and energy generation

3.1 Feed water preheating for steam boilers

• Increasing the efficiency of power plant processes
• Reduction of thermal stresses in boiler systems
• Optimization of steam generation through more constant conditions

3.2 Electrothermal heaters for emergency applications

• Provision of heat in situations without fossil fuels
• Use in regions where water is scarce and steam heating is not possible
• Use as a backup system for heat generation in power plants

4. food and beverage industry

4.1 Heating of liquids in production processes

• Heating milk, fruit juices or liquid foodstuffs
• Ensuring hygienic processes through targeted temperature control
• Energy-efficient heating without direct use of steam

4.2 Melting fats, oils and chocolate

• Prevention of crystallization during transport or storage
• Ensuring homogeneous processing temperatures
• Use in confectionery production and the bakery industry

4.3 Heating process water

• Use in CIP systems (cleaning in place) for hygienic cleaning
• Provision of hot water for pasteurization processes
• Temperature control in breweries and dairies

5. pharmaceutical and biotechnology

5.1 Heating of reaction media in bioreactors

• Temperature control for cell cultures and fermentations
• Ensuring optimal conditions for biotechnological processes
• Preventing sensitivity to cold in biological substances

5.2 Heating water for sterilization purposes

• Direct heating of ultrapure water for pharmaceutical production
• Provision of hot water for autoclaves and cleaning systems
• Use in vaccine production and laboratory applications

6. marine and shipping industry

6.1 Heating of heavy fuel oil for ship engines

• Reduction of viscosity for even combustion
• Prevention of deposits and wear in injection nozzles
• Use in container ships, freighters and tankers

6.2 Heating systems for ballast water

• Protection against icing in cold climate zones
• Avoidance of biological contamination through temperature adaptation
• Improvement of water quality for long-distance transportation

7 Hydrogen and alternative energy technology

7.1 Preheating hydrogen gas for fuel cells

• Increasing the efficiency of fuel cells through controlled heating
• Avoidance of pressure fluctuations caused by cold
• Use in vehicles, industrial plants and energy storage systems

7.2 Thermal support for power-to-gas systems

• Heating methane or synthetic gases for conversion processes
• Use in electrolysis plants for hydrogen production
• Improving efficiency through heat recovery

Electric heat exchangers are indispensable in numerous industries that work with the filtration and preheating of natural gas and other technical gases. They are frequently used in the energy and gas industry in particular, where pressure and temperature control is of central importance. Heating the gas before further processing protects sensitive systems and optimizes the efficiency of the entire process.

The chemical and petrochemical industries also rely on electric heat exchangers to ensure the stability and reliability of their high-pressure systems. This ensures that gases are fed into reactions and other processes under optimum conditions without causing unwanted cooling and loss of efficiency.

THIELMANN ENERGIETECHNIK GmbH manufactures electric heat exchangers that are designed to meet the special requirements of these demanding industries. With their robust design and precise temperature control, our electric heat exchangers offer a durable and safe solution for companies that depend on reliable gas preheating.

Electric heat exchangers are designed and manufactured in accordance with specific regulations and certifications in order to meet the requirements of international markets. These include ASME (with or without U-Stamp), EN 13445 for the European market, SVTI for Switzerland, AS1210 for Australia and PD5500. This variety allows the preheaters to be used in a wide range of regions and industries with specific standard specifications.

A decisive factor in planning is the customer-specific approval and testing by renowned companies and institutions such as BASF, OGE, Gascade, Sasol, INGL, ERI, Dolphin, Saudi Aramco, Gasco, MAN, Jenbacher, MAPNA, Siemens, DONG and TEMA. This ensures that the electric heat exchangers can withstand the demanding operating conditions in the respective applications.

Depending on the application, the electric heat exchangers are also suitable for sour gas applications in accordance with NACE to ensure chemical resistance in corrosive environments. They can also be designed for low-temperature operation down to -50 °C, so that even extreme operating conditions can be reliably mastered.

The technical specification also includes a design pressure of up to 300 bar and a design temperature of up to 250 °C, covering a wide range of industrial applications. In addition, a customer-specific nozzle arrangement enables optimum integration of the electric heat exchangers into existing process systems.

The choice of materials for electric heat exchangers depends on the specific requirements of the respective application and the operating conditions. A wide variety of materials enables optimum adaptation to pressure, temperature and medium.

Electric heat exchangers can be made of carbon steel, stainless steel or a combination of both materials. Carbon steel is characterized by high mechanical strength and economy and is preferred in applications with moderate temperatures and non-corrosive media. Stainless steel , on the other hand, offers excellent resistance to corrosion and chemical influences and is particularly suitable for aggressive media or environments with high purity requirements.

By specifically combining both materials, the advantages of carbon steel and stainless steel can be united in one preheater system to achieve an optimum balance between mechanical stability, corrosion protection and costs. Materials are always selected in close coordination with the operating requirements and applicable standards to ensure maximum efficiency and durability.