Babcock Wanson Unveils Innovative Electric Thermal Fluid Heaters

Welcome, Net Zero News readers! Today, we’re excited to share an important development in the quest for sustainable industrial heating solutions. Babcock Wanson, a specialist in industrial process heating equipment, has taken a significant step forward by launching the EPC EL range of electric thermal fluid heaters. This innovative product promises to offer businesses an effective low-carbon heating option devoid of direct emissions, aligning perfectly with the growing demand for eco-friendly technologies.

The need for efficient heating solutions in various industrial processes cannot be overstated. Thermal fluid heaters are essential for providing the high temperatures required for numerous applications. The EPC EL range is designed with key functionalities that include high turndown ratios, low heat flux, precise temperature control, and elevated safety standards, all of which are seamlessly integrated into its design.

At the heart of the EPC EL is a multi-tubular thermal fluid heater, featuring a series of flanged electrical heating elements strategically placed within carbon steel exchange tubes. As thermal fluid circulates at high velocity, the EPC EL ensures an accurate forecast of the fluid temperature at every point along its internal path, eliminating significant internal recirculation. This innovative one-dimensional fluid arrangement not only allows for a more compact design but also enhances the protection of the thermal fluid compared to traditional single vessel designs, thereby improving fluid longevity.

The modular design of the EPC EL electric thermal fluid heaters is particularly noteworthy. These units can be configured in various ways, either in series or parallel, to meet the diverse requirements of different applications and sites. Each single functional unit comprises two thermal heater elements, each capable of delivering a maximum power output of 60kW. Should one of the thermal heater elements fail, the EPC EL can continue to operate at a reduced power level by excluding only the faulty element. This robust design feature ensures minimal disruption and enhanced reliability.

In terms of power control, a single 100 A thyristor manages the power supply, offering flexibility and modulation that can be tailored to specific needs. Additionally, temperature limitation is ensured through the incorporation of temperature sensors directly connected to the surfaces of the heating elements, providing an extra layer of safety and operational efficiency.

Accessibility and ease of use are also at the forefront of the EPC EL design. Each unit is supplied with a separate power and control panel housed in a standard cabinet, facilitating easy access for operators. The panel is equipped with a PLC (Programmable Logic Controller) and HMI (Human-Machine Interface), ensuring a simple and intuitive operator interface.

Durability and maintainability are hallmarks of all Babcock Wanson process heaters, and the EPC EL is no exception. The internal tubing is fully welded to eliminate potential leakage points, enhancing the overall lifespan of the unit. The heating section is secured within a protective steel frame, enclosed by easily removable thermal insulating sandwich panels that allow for straightforward inspection. The front of the heater, where the electric elements are located, features a light cover designed with fast-release bolts and handles, enabling a single operator to lift it with ease.

The EPC EL range represents the latest innovation in Babcock Wanson’s diverse line of thermal fluid heaters, which also includes models with integrated gas, oil, or dual fuel burners to cater to the varied needs of modern industry. This latest offering underscores Babcock Wanson’s commitment to providing efficient, reliable, and environmentally friendly heating solutions that are crucial in the transition towards a sustainable future.

For those interested in learning more about this cutting-edge technology, Babcock Wanson invites you to reach out for additional information. You can contact them at 020 8953 7111 or via email at info@babcock-wanson.com. For further details, please visit their website at www.babcock-wanson.com.

This article originally appeared in the May 2025 issue of Energy Manager magazine. If you wish to keep up with the latest advancements in energy management and sustainability, consider subscribing to stay informed on pivotal updates in the industry.

As we move forward in our journey towards achieving net zero emissions, innovations like the EPC EL electric thermal fluid heaters from Babcock Wanson provide a glimpse into a more sustainable industrial future. Let’s continue to support and promote such advancements in technology that align with our shared goal of a greener planet.