Chromalox Process Heating Systems

Custom Packaged Process Skids

Chromalox leverages its experience from decades of custom process heater engineering into full process control with packaged systems. Designed as plug-and-play units, these packaged skids manage temperature, pressure, flow, and filtration for virtually every application and industry, particularly in the Energy markets. No company has assisted end users with more process solutions than us.

Markets Served

Custom Chromalox process heaters operate in critical markets such as:

• Oil and Gas, both on- and off-shore
• Petrochemical and Refining
• Power Generation
• Industrial Gas
• Textiles
• Pharmaceutical
• Industrial Process

Applications

Common applications include:

• Oil fowarding skids
• Duplex coalescer skids
• Fuel gas conditioning skids
• Lube oil skids
• Wash water skids
• Compressor skids
• Water injection skids

Our process skids operate under the most extreme process conditions, as well as in the most extreme and hazardous environments.

Fuel Gas Conditioning Systems

Fuel Gas treatment for power generating turbines is crucial for optimizing efficiency of the gas combustion and extending the operating life of the turbine.  Proper heating and filtration of the gas stream is accomplished with a Fuel Gas Conditioning Skid.

Applications

Superheating the gas will drive temperature above the dewpoint, eliminating condensate in the system.  Gas filtration will ensure any other contaminant, whether solids or liquids, will be removed prior to entering the turbine.

The Chromalox Advantage

Combining both processes in one skid package saves time, space, and money.  Electric heating provides the best option for superheating as its power is instantly available, has no emissions, and is precisely controlled to only the demand needed.

Chromalox Capabilities

• In-house element manufacturing allows the most efficient, space-saving design possible.
• All welding, pressure testing, and certification are performed in accordance with ASME standards. 
• Chromalox power control can be fully integrated and skid-mounted with the heater for a complete package.
• Engineering design tools include 3D AutoCad, Solid Works, and PV Elite, among others.
• Broadest line third-party certifications available – UL, CSA, ATEX, GOST, INMETRO, IEC, ASME, PED, KOSHA

Electric Steam and Hot Water Boilers

Chromalox Packaged Electric Steam and Hot Water Boilers are safe and versatile heat sources that produce low or high pressure steam or hot water for commercial and industrial processes and for comfort heating applications. Chromalox electric boilers can be used anywhere steam is required and electric power is available. Heating System Boilers are packaged units that operate from existing distribution voltages, making installation simple.

Custom Steam Superheaters

Steam Superheaters

Chromalox leverages its vast experience of manufacturing boilers, vaporizers, and process heaters for water, steam, and other fluids to design and build the best steam superheating systems available. We manufacture all of the major mechanical and electric components of a steam system and perform all skid design and manufacturing in-house.  Nobody in the world can produce such integrated systems while maintaining the quality, performance, and cost structure that Chromalox can provide to our customers.

Unlike most fabricators and packagers who utilize purchased parts and basically assemble their systems, Chromalox is completely vertically integrated.  Our factories build steam systems from the ground up, guaranteeing quality materials and workmanship from the singular tubular heating element and power controllers, through the piping, pressure vessels, and instrumentation, all the way up to the completely integrated package.

Our expertise goes beyond just welding, wiring, and assembling. When you purchase a Chromalox steam system, you can have confidence that it is backed with virtually 100 years of process heating manufacturing and experience, universal third party certifications, and a global network of engineering and service personnel ready to support your system anywhere in the world.

The Complete Package

Chromalox manufactures every element of a steam system:

• Electric steam boilers>
• Steam superheaters>
• Condensate return systems>
• Automatic blowdown systems>
• Control systems & instrumentation>
• Electric heat tracing>

Applications

Common applications include:

• Seal gland preheating at a power plant
• Auxiliary boiler packages
• Steam sparging
• Steam heat transfer systems
• Kettles, reactors, and jacketed vessels
• Steam tracing

Our steam superheaters operate under the highest operating pressures in the industry, as well as in corrosive and hazardous environments.

Hot Oil Heaters - Heat Transfer Systems

Chromalox hot oil and water systems are self-contained heating and cooling packages that provide direct or indirect process heating to temperatures of 750° F. These systems meet ASME codes and are pre-engineered to include temperature and power controls, expansion tanks, heat exchangers, pumps, valves, gauges, and all necessary piping. This eliminates component selection and assembly. Select from oil or water temperature control systems for circulation in a closed-loop process.

Chromalox Heat Transfer Systems are used in process heating applications requiring closely controlled process temperatures. Systems are furnished complete with heaters, controls, pumps, valves and necessary plumbing.

• Indirect Heating
• Packaged Systems - Heat Transfer Systems
• Water and Water/Glycol Systems
• Non-Pressurized Hot Oil Heaters
• Pressurized Hot Oil Heaters
• Vaporizers

Heat Transfer Systems are used with:

• Jacketed Vessels and Tanks — containing waxes, paraffin, exotic chemicals including those having exothermic reactions, hot melt adhesives, resins, varnishes, paints, dyestuffs, molasses, vegetable oils and many other chemical or petrochemical products.
• Heated Rolls — for coating paper and paper products, spot carbonizing, vinyl bonding, bonding with hot melt adhesives, calendering and laminating.
• Heat Exchangers — for corrosive and noncorrosive fluids.
• Platens, Dies and Molds — for laminating wood and plastics, forming of carbon products, epoxy materials and Fiberglas®, plastics extrusion, injection molding, molding rubber and plastic materials: vinyl bonding and bonding with hot melt adhesives.
• Pipeline Tracing — of viscous materials such as paints, fuel oils, asphalt and many other chemical and petrochemical products for antifreeze protection and/or maintaining pumping temperatures.
• Industrial Systems — such as snow melting, comfort heating and hot water supply and as standby equipment for industrial and commercial applications in case the supply of other fuels is curtailed.

DirectConnect Process Heaters

Medium Voltage Process Heaters

Chromalox DirectConnect Process Heaters utilizing medium voltage technology drastically reduce installation, operation, and maintenance costs for large process heating demands. Medium voltage systems are engineered to provide precise process temperature control and are designed to operate for many years in service at voltages up to 7200 V. As with traditional low voltage systems, DirectConnect immersion and circulation heaters can be adapted to suit virtually any liquid or gas application.

Applications

Common applications include crude oil, natural gas, steam, heat transfer oil, hydraulic fluid, acidic solutions, potable and clean water, glycol solutions, hydrocarbons, industrial gases, hydrogen, oxygen, and superheated air. However, Chromalox has heated thousands and thousands of unique mixtures, solutions, and gas compositions over the years. Nobody has more experience.

Chromalox Technology

Over a century of product development and application experience are delivered in each product we manufacture. Chromalox in-house engineering and fabrication capability allows for an endless possibility of design. DirectConnect medium voltage heating technology is the culmination of our history. Our design innovations, testing, and independent certifications ensure unmatched quality of design with every unit. Electric heating provides the best option for process heating because of its overall efficiency, zero emissions, precise temperature control, and ability to supply exactly what is demanded by the process. Now, these advantages can be leveraged into much larger process heating demands due to the DirectConnect medium voltage technology.

Unique Features

Here are some unique features and advantages of the Chromalox DirectConnect MV technology:

• The only Medium Voltage heating element with third party certification (ETL File # 101361500DAL-001)
• The only Medium Voltage SCR control panel with third party certification (UL 347C)
• The only Medium Voltage heating element that can pass an individual 11,360V dielectric withstand test
• Patent pending SCR panel design with heater soft start algorithm and automatic in-situ dry-out switching capability
• The only Medium Voltage single-end tubular element with isolated terminal design
• Individually replaceable individual Medium Voltage heating elements
• Control panel designed for a minimum short circuit current rating of 50kA
• Separate low voltage enclosure including HMI and PLC control center
• Safety interlock systems utilized in heater and control panel to ensure safe and secured operation
• Full SCR, vacuum contactor, or SCR/Contactor hybrid designs available

Chromalox Capabilities

• In-house element manufacturing allows the most efficient, space-saving design possible.
• All welding, pressure testing, and certification are performed in accordance with ASME and international standards.
• Chromalox power control can be fully integrated and skid-mounted with the heater for a complete package.
• Engineering design tools include 3D AutoCad, Solid Works, and PV Elite, among others.
• The only third-party certified manufacture in the world of medium voltage metal sheathed heating elements