Industrial electrical heating elements are core equipment serving the manufacturing, chemical, energy, metallurgical and other industrial fields. Their design needs to meet the requirements of “high reliability, precise temperature control, and long life” under extreme working conditions (such as ultra-high temperature, high pressure, strong corrosion, and high dust). They are indispensable key components in the industrial production process. Application scenarios include plastic extruder heating, metal heat treatment (such as induction quenching), chemical reactor heating, oil refining pipeline heating, and precision temperature control systems in semiconductor manufacturing.

In terms of material selection, industrial heating elements need to be customized according to specific working conditions: for example, induction heating elements for metal heat treatment (such as induction coils) are mostly wound with rectangular copper tubes, nickel-plated on the surface to prevent oxidation, and used with cooling water systems to cope with the high temperature generated by high-frequency currents; the electric heating module of the chemical reactor needs to use a heating plate made of polytetrafluoroethylene (PTFE) or ceramic to resist strong acid and alkali corrosion; the heating element of the high-temperature vacuum furnace needs to use refractory metal wires such as tungsten and molybdenum (such as tungsten wire), because of its high melting point (tungsten melting point 3410℃), it can work stably in a vacuum environment above 2000℃.

In terms of design, industrial heating elements need to be deeply integrated into industrial equipment to meet customized needs: for example, the barrel heating of plastic extruders usually uses segmented heating elements (such as electric heating wires wrapped in mica sheets), and each section is independently temperature-controlled with an accuracy of ±1°C to ensure uniform melting of the plastic; the radiant tube heating elements of the steel mill rolling furnace need to be designed as a replaceable structure for easy regular maintenance; the heating elements of semiconductor precision annealing furnaces need to use tungsten-molybdenum alloy strips with inert gas protection to avoid metal contamination. In addition, industrial scenarios have extremely high safety requirements (such as explosion-proof and leak-proof), so the components need to pass ATEX explosion-proof certification (for explosive environments) or use dual-circuit temperature control protection (such as main temperature control + backup temperature control) to prevent accidents caused by temperature runaway. A typical example is the pipeline electric heater used in the oil industry, which needs to continuously heat high-viscosity crude oil at an ambient temperature of -40°C to 150°C. The components need to have anti-freezing and anti-coking properties, and the design life is usually more than 10 years.