Electric heaters for industrial process heat

Precise control, high efficiency, and emission-free operation

Electric heaters offer an efficient, emission-free and, above all, low-wear option for providing industrial process heat. They are used wherever there are high demands on control accuracy, operational reliability, and environmental compatibility – and, in particular, where fossil fuels are not available or direct firing / combustion is not permitted. CAW develops and manufactures robust electric heaters for continuous industrial operation, precisely designed for the respective heat transfer media, power ratings and temperature ranges.

Our electric heaters can be seamlessly integrated into existing process heating systems or operated as stand-alone heat sources. They are particularly well-suited for applications involving thermal oils, warm and hot water, and other liquid heat transfer media.

How does an electric heater work?

An electric heater converts electrical energy directly into heat and transfers it to a heat transfer medium. Heat is transferred without a combustion process, which means there are no exhaust gases, emissions, or fuel residues.

Structure and process steps

Heating elements: Electric heating rods or heating coils, essentially electric immersion heaters or resistance heaters, are heated by the flow of electricity and transfer the heat generated directly to the surrounding medium.
Heat transfer circuit: The medium heated in a forced-through flow heater is conveyed to the connected consumers in a closed system by means of circulation pumps.
Temperature control: The heating output is controlled continuously or at discrete power levels and precisely adjusted to the process.
Safety and monitoring systems: State-of-the-art, control and regulation technology that complies with applicable standards monitors the temperature, flow rate, and safety of the system.

Technical features of CAW electric heaters

Nealy 100 % efficiency in converting electrical energy into heat – standard operating voltages range from 400 to 600 V at 50 or 60 Hz, although virtually all country-specific voltages are supported.
Very precise temperature control, especially during rapid load changes.
No exhaust venting, no chimney system, and no fuel storage required.
Designed for continuous operation and high thermal loads.
Suitable for various heat transfer media such as mineral and synthetic thermal oils, warm and hot water.

Where are electric heaters used?

Electric heaters are used as a primary or supplementary heat source in a wide variety of system designs. CAW designs electric heaters as stand-alone solutions, as an integral part of existing or newly planned complex process heating systems, or as temporary heating systems during modernization and renovation projects.

Typical system types and operating environments

Thermal oil circuits

Electric heating of thermal oil for high-temperature processes.

Warm and hot water systems

Emission-free heating of closed water circuits.

Hybrid systems

Combination of electric heaters and fired / combustion-based systems to cover peak loads.

Decentralised process heat

Local heat supply without a central combustion plant.

Renewable energy plants

CO2-neutral use of electricity from photovoltaics, wind or hydroelectric power.

Use as a component of complex energy systems

In conjunction with thermal oil systems for zero-emission process heat generation.
As a supplement to combustion plants for flexible power adjustment.
In combination with ORC systems for the efficient use of electrical energy.
In plants with stringent requirements for emission control and permitting regulations.

Industries in which electric heaters are used

Electric heaters are in demand wherever clean, precise and low-maintenance process heat is required. Thanks to their flexibility, they are suitable for numerous industrial applications in the power range from 100 to approx. 10,000 kW.