All posts by Nadine LAURET

Small summary, in words and images, on the milestones of 2018 and the beginning of this year in Aeronautic market

THERMOCOAX equips Airbus A220 with 2 drainage mats for front / rear galleys. With already 536 planes in the AIRBUS orderbook, we are working our ramp up organization. With an ambitious target of several thousands of aircrafts over the next 20 years, the A220 platform would be one of the most successful program THERMOCAX invested in.

 

At the ILA Berlin event at the end of 2018, Stéphane Fourrez, as part of the European NIPSE programme, presented the results of work on a new fire detector for the next generation of avionics engines. Stéphane presented the methodology and the technical results before an audience of international experts and answered many questions.

THERMOCOAX was invited to participate in the “Passive Component” symposium organised by the European Space Agency at the end of 2018.

Among thirty odd posters, the one made by Alexis Brodin and Xavier Potiron won the grand prize-what a proud achievement for them both, and for THERMOCOAX.

 

In Autumn, 2018, at the CAMX event, the THERMOCOAX US team presented the heating products for composite applications designed for aviation and other industries in general.

 

 

High-end thermal solutions for wafer processing operations

In the semiconductor sector, machine-manufacturers at different stages of the wafer manufacturing process are looking for high-performing heating solutions that meet cutting-edge specifications in terms of design, uniformity, repeatability and lifetime but that are also able to withstand very corrosive environments under ultra-high vacuum and with ambient temperatures above 100°C.

THERMOCOAX’s expertise is in responding to strict specifications and in designing tailor-made high-performing thermal solutions from mineral insulated cables.

Our engineering know-how, our prototyping capacity and our knowledge of mineral insulated cables allow us to offer unique solutions to our customers.

We are also able to develop complex mechanical parts that incorporate our heating elements.

Our strength is that we master all these processes internally with a factory certified “Copy exact” dedicated to SEMICON applications for wafer manufacturing processes: high precision machining, welding, soldering, tests and qualifications, control, ….

Over the last few months, THERMOCOAX has developed an innovative, reliable and efficient solution to heat a system inside a vacuum chamber.

The challenge of this project was combining two thermal systems that had to be integrated into the customer’s final system, in an ultra-high vacuum and corrosive environment at high temperature.

The first thermal system that we had to develop was a kind of heating element coiled on a mandrel

The solution was complex because we had to meet critical specifications such as:
• The limitations and dimensional tolerances of the heater
• Critical operating temperature of 800°C
• Achieving a 10% power distribution uniformity – Several heating areas have been designed with different power densities
• Operational guarantee > 5 years, in ultra-high vacuum with a corrosive environment

We designed 6 different concepts and compared these solutions in order to select one.

THERMOCOAX chose a design with EC wound / brazed on a metal support which was mass-produced in line with a specific process.

Progress achieved – results achieved – originality of the chosen solution

This design, which at first glance looks like a heating cartridge, is innovative in its design because it has a fully wound heating element integrated in a mandrel by a process developed by THERMOCOAX.

The expected performances and lifetime results were validated during the qualification phase of the prototypes.

This all-encompassing design by THERMOCOAX targets many areas, with its performance advantages, its low cost design and its long lifetime performance.

The second thermal system is a complex assembly of a 3D design metal part with high temperature heating elements

Problems to solve

Being able to assemble complex metallics with a demanding dimensional specification and an operating temperature that can reach up to 800-900°C.

This temperature is near critical, especially when specifying a lifetime greater than 5 years.

We had to resolve the problem of complex machining.

It was also necessary to take the deformations caused by the machining into account, as well as the deformation from the welding and brazing processes.

The design and manufacturing method was developed entirely by THERMOCOAX to achieve a feasible design suitable for high volume manufacturing and minimizing the risk of non-compliance with dimensional or functional specifications.

We worked on raw material (304L) and evaluated and selected the material that was the most cost / quality / time effective.
For the metallic parts we evaluated: Full mass / forged / foundry material.

The other challenge with these pieces was treating them on the surface so that the highly corrosive liquid in the vacuum chamber would not stick to them.

After much research and testing we identified a substance that has very good anti-wetting properties and could be used for this type of application.

Work has also been done to validate the most suitable deposition process (PVD or CVD).
We finally selected the best deposit solution that operates in up to 600°C.

 

THERMOCOAX Turbines Solutions Long-life Thermocouples

Thermocoax announces a new thermocouple generation :

  • 24 000 operation hours in heavy duty gas turbine
  • Exceptional resistance to vibration, thermal stress, corrosion…
  • Already demonstrated in air-cooled 446MWatt machine
  • 37 gas turbine  already equipped
  • 18 currently under operation
  • 1.2 Million hours cumulated
  • 699 starts

 

Technical application of long-life thermocouples

The gas turbine frames market is a challenging business. On the one hand, the frames are more and more high-tech and expensive and on the other hand, the energy producer is driven by low electricity production prices. To make them both compatible, gas turbine frames have to be reliable to minimize operation disruption and to offer longer periods without maintenance. Therefore, providing thermocouples with an increased lifespan decreases the downtime of the turbine, thereby significantly reducing the maintenance costs.

Required Benefits

One of the key aims of the OEM GT is to find high-accuracy thermocouples on the market that are able to perform in harsh environments and work for 24,000 operating hours without failing.

Thermocouples installed in exhaust gas lines are exposed to corrosion, vibration, thermal expansion and much more.

Thermocoax’s Solution: Design a thermocouple that is out of the excitation bandwidth

Based on the capitalized cumulative return of experience in several fields, such as aeronautical, nuclear and oil & gas, THERMOCOAX has developed a vibration absorber that is secured to the thermocouple to avoid premature breaking when the thermocouple is subject to vibrations and thermal expansion. This solution is protected by a patent.

The invention with the patent number 63638FR/CZ/BB – 17 58061 is a vibration absorber that is secured to the thermocouple cable and is made to fit inside the screen/thermowell.

The number and size of the absorbers depend on the gas turbine specification in terms of vibration, acceleration and thermal cycles.

To demonstrate the advantage of this new design and its ability to reach 24,000 operating hours, THERMOCOAX has undertaken simulation and experimental testing:

1.1 Simulation: Comparison between a thermocouple with and without a vibration absorber

Input data:

  • Ø ≈ 3mm Type K thermocouple with 316L SS sheath
  • Length ≈ 500mm insertion length in SS316L thermowell
  • Temperature 870°C
  • Frequency range: 0 to 250Hz, mean value 100Hz
Long-Life TC Standard TC
Resonant Frequency of the TC 174Hz 68 Hz
Stress produced by the Resonant Frequency of the TC 11.1MPa 450MPa
Number of cycles made before Breaking of TC at its Resonant Frequency 9×109 40
Life-span at the Resonant Frequency of the TC 2.1×109 days 10 days

1.2) Field test results: Comparison between a thermocouple with and without a vibration absorber

  • Ø ≈ 3mm Type K thermocouple with 316L SS sheath
  • Length ≈ 300mm insertion length in SS316L thermowell
  • Temperature 900°C
  • Frequency range: 0 to 1000Hz,
Long-Life TC Standard TC
Resonant Frequency of the TC 68Hz 174Hz
Life-span during the Endurance Test Still works after

20,000h

Stops working before 3000h

 

The test is still ongoing. We can already say that the field results demonstrate the extraordinary positive impact on the reliability of the gas turbine. This new long-life thermocouple lasts 7 times as long as a standard thermocouple.

For the powerplant operator, the cost saving is at least 150,000 euros in thermocouples for every 20,000 hours of operation because there are no costs incurred from the frame shutting for unexpected maintenance.

 

THERMOCOAX Pedigree

For 60 years THERMOCOAX has been a worldwide key player in designing, developing and manufacturing thermocouple temperature sensors for industrial and aircraft gas engines.

With our custom-made Mineral Insulated Cable, we are providing our customers with solutions for:

  • Development applications:
    • R&D programs with institutes
    • Ground, aero & industrial test equipment
  • Production models:
    • Thermocouples in harsh environments with an installed base of over 300,000 thermocouples:
      • Heavy duty gas turbine
      • Stroke engine
      • Steam turbine
    • Thermocouples for helicopter engines with 15,000 units installed
  • Thermocouple characteristics:

Thermocouples are produced with Class 1 custom-made cables with a diameter from 0.25mm up to 6mm.

Single (2 wires) or duplex design (4 wires)
Types K and N are the most used in the industry.

Thermocoax recommends type N thermocouples for a working temperature of between 600°C and 1100°C, which offer a smaller drift compared to type K.

We have several sheath alloys available:

  • Stainless Steel
  • Inconel
  • Haynes
  • Platinum
  • Tantalum

 

 

THERMOCOAX Calibration Lab

100% of the mineral insulated cable and finished thermocouples are controlled in the calibration lab.

  • Capabilities

Fixed points

TEMPERATURE -Thermocouple
Calibration purpose Mesurand Measurement range Best calibration uncertainty Measurement principle/Method reference (*) Calibration tools (reference, Equipement) Activities in Lab and/or on site
Thermoelectric couple Temperature                                                                              Electromotive Force Signal Voltage Melting ice point 0,00°C ±0,3°C Method by comparaison at a fixed point / PP200D010 Rev06 Water triple, Sn, Pb, Zn cells Platinum resistance thermometer multimeter                                                  Melting ice point Lab
Water Triple point 0,01°C ±0,3°C
Sn Melting point 231,928°C ±0,5°C
Pb melting point 327,46°C ±0,5°C
Zn melting point 419,46°C ±0,5°C
Sb freezing point 630,62°C ±0,9°C Sb Cells                                              Thermoelectric couple S Type Multimeter                                              Melting ice point

 

By comparison

TEMPERATURE -Thermocouple
Calibration purpose Mesurand Measurement range Best calibration uncertainty Measurement principle/Method reference (*) Calibration tools (reference, Equipement) Activities in Lab and/or on site
Thermoelectric couple Temperature                                                                                                                                                                        Electromotive Force Signal Voltage -40°C to 0°C ±0,4°C Method by comparison / PP200D022 rev 08 Ethylene/Glycol constant temperature bath                           Platinum resistance thermometer Multimeter                                     Melting ice point Lab
0°C to 80°C ±0,3°C
50°C to 200°C ±0,4°C Oil Constant temperature bath Platinum resistance thermometer Multimeter                                                 Melting ice point
150°C to 400°C ±0,5°C Bath of melted salts Platinum resistance thermometer multimeter
400°C to 500°C ±0,6°C
500°C to 700°C ±1,3°C Tubular furnace                                    S type thermoelectric couple Multimeter                                             Melting ice point
700°C to 1100°C ±1,4°C
1100°C to 1200°C ±1,6°C
1200°C to 1300°C ±2,1°C
1300°C to 1500°C ±2,4°C

Heated cable inlet for climatic chambers

Target market :

Manufacturers and operators of climatic chambers.

Challenge :

Prevention of condensation at the cable inlet inside and outside of climatic chambers.

Description of the problem without a heated cable inlet :

Condensation at the cable inlet due to climatic differences between the inside and the outside of the chamber.

Condensation on the measuring cables inside and outside of the temperature test chamber when using a standard inlet.

Risk :

High financial risk if long-term climatic tests have to be cancelled because of condensation in the climatic chamber. Condensation damages the test materials and affects the climate regulation in the chamber.

Solution :

Heated cable inlet from THERMOCOAX Isopad® GmbH. A standard inlet with geometric properties, the best possible sealing and a heated area inside of the cable inlet.

Test results with a heated cable inlet :

Decrease in the amount of condensation formed inside the climatic chamber by approx. 95% and by 100% outside of the climatic chamber!

The risk of failure is extremely reduced because there are hardly any condensation drops in the chamber (airflow can spread the drops onto the test material).

No water on the floor outside the chamber. The risk of slipping is eliminated, thereby extremely reducing the risk of accidents !

 

 

 

Successful test campaign on neutron sensors

THERMOCOAX has finalized a test campaign on neutron sensors.

reacto Pool : experimental fixtureReactor Pool : experimental fixture

Despite stringent time constraint, a highly professional IJS team was prompt to react and welcome a team conducted by THERMOCOAX and relying on the best internationally recognized experts from different European nuclear organizations.

Multiple irradiation tests have been carried out.

IJS reactor being very well characterized, results are confirmed to match with our stringent expectations: perfect matching between theory and practical results!

An additional demonstration of the THERMOCOAX mature technology readiness.

 

About THERMOCOAX

THERMOCOAX has over 60 years of expertise in instrumentation and heating solutions. It provides solutions in the world of nuclear, aerospace and semicon industries. It design, qualify and manufactures sensors for harsh environment with a focus on nuclear on temperature and radiation measurement.

 About IJS Jozef Stefan Institute

IJS Jozef Stefan Institute in Slovenia has over 50 years of expertise. Reactor Infrastructure Centre (RIC) department is operating a  TRIGA Mark II reactor. Reactor physics department is directed mostly towards development of new calculation methods for research and power reactors. Several program packages for reactor calculations both for TRIGA research reactor and Krško nuclear power plant. Jozef Stefan Institute also study advanced fourth generation reactors, advanced neutron sources and data and materials for fusion technology are also studied.

 

TRIGA reactor
TRIGA reactor

THERMOCOAX ISOPAD Gas line heating Jackets

Gas line heating jackets for high purity gas delivery systems

 

silicone Jacket
Gas line heater

THERMOCOAX is involved in many levels of the wafer manufacturing processes working with OEM all around the world.

We provide thermal solutions for applications such as lithography, deposition, etching, ion implantation, or annealing.

While developing our business in the ALD deposition processes, we understood the need of our customers to heat the high purity gas delivery systems from the ampoule to the deposition chambers.

Temperature control is extremely important in the deposition process.

This is why industrials need to have a high performance gas delivery system in terms of management of the gas flow rate and temperatures.

Transfer line heating jackets are used for both solid and liquid precursor management in semiconductor deposition processes.

The heating temperature requested is in the range of 80°C to120°C. Typically, the range of thermal solutions is provided by our German subsidiary ISOPAD, specifalist in the development and manufacture of customized silicon heating solutions.

The main concern of our customers was the need to keep the temperature uniform all the way from the gas generation ampoule to the deposition chamber. This complex way includes straight tubes, Tees, elbows (2P,3P), VCR, valves, manifolds and complex components.

Each delivery system is specific to the customer process.

That  was the challenge for THERMOCOAX ISOPAD.

Another limitation of this application is the use of jackets that must be installed, positioned as easily as possible in an environment with limited space.

ISOPAD has a lot of experience in high performance silicon jackets.

The silicone jacket is a well-known product for our company, all the expertise we have gained from working with our other OEM customers have been used to design and construct a high volume production solution.

All core competencies are in house, only the raw materials are bought in.

Many years ago, we developed filter heating jackets for the biotechnology industries, built with seamless silcone rubber that does not need affixing.

 

Isopad Silicone Jacket
Silicone Jacket

These jackets have a real advantage on the market because of the flexibility they provide  in terms of positioning and ease of cleaning.

The one-piece molded design is formed out of a two-component silicone rubber compound that fits around the filter housings without any affixing methods that may  not be compliant for use in those production processes.

 

The target for THERMOCOAX ISOPAD to adapt this solution to the SEMICON applications was:

  • to adapt this technology to smaller diameters, and to complex shapes.
  • To achieve the customer specifications on uniformity over the full line assembly
  • To find good materials for clean-room use and respond to the SEMICONDUCTOR requirements in term of low contamination properties.

Due to our expertise, we quickly managed to design and prototype a full line assembly responding to our customers’ demanding specifications.

 

The advantages of our solution:

These heating jackets provide an innovative design on the market with short delivery time.

Built with seamlessly-molded silicone rubber, these jackets offer a better thermal performance due to a close-fitting design and a high uniformity over the complete line.

With a product that has demonstrated a longer service life than existing solutions, we can deal with any installations of new deposition systems, but also spare parts for installed systems.

Applications that addresses our offer:

PeCVD, PVD, ALD, Epitaxy, ETCH, Wafer packaging, cleaning chamber processes etc.

 

THERMOCOAX KEY DIFFERENTIATION FACTORS:

 Technical Performance

. Custom-built line assembly

. Seamlesly-molded silicone

. Close-fitting design

. Better thermal performance, heat 68°F (20°C) up to 275°F (135°C)

. Reduced installation faults

. Lower overall risk of production downtimes

. Longer service life

. Easy to install & remove

. Outgassing according NASA standards

 

THERMOCOAX is a certified for Copy Exact:

 Specifications

  • Thermal gas flow uniformity: ± 5°C in the complete line assembly
  • Better thermal performance, heat 68°F (20°C) up to 275°F (135°C)

(minimum 1 meter of length)

  • Reduces installation faults
  • Lower overall risk of production downtimes

 

  • Jacket: silicone rubber, seamlessly molded, easy to clean, IP68 standard
  • Minimum gas line diameter: ¼ inch OD
  • Affixing technology: ” snap-on ” design by molding, easy to install and remove
  • temperature:   200 °C
  • UL-V0 standard, FDA-approved ultra-low emission material

 

Heater design to fit standard components used in weldments

  • Straight tube
  • Elbows (2p, 3p)
  • Tee
  • VCR fitting, etc.
  • Specially-formed and customised heaters for valves, manifolds and complex components

This high purity gas line heater development has been combined with the development of ampoule and canister heaters which are used in all deposition processes and with RF thermocouples used in the plasma environment to control the temperature in the deposition chamber.


Ampoule heater

THERMOCOAX meets the requirements of the SEMICON market in terms of repeatability, temperature uniformity, production control, quality monitoring, and COPY EXACT high volume manufacturing.

For high volume manufacturing, THERMOCOAX works with a continuous improvement strategy for:

  • Design
  • Manufacturing process
  • Cost reduction

 

THERMOCOAX is highly adaptable to specific customer requests

 

 

 

 

Heating System for SMA actuators

You are looking to replace your pyrotechnic actuators with shape memory alloy technology for your space applications ? We have the most advanced industry-proven solutions.

Spacecrafts require variety of mechanisms to accomplish the mission. The typical functions are deployment, articulation, positioning, displacement.

Pyrotechnic separation nuts, paraffin actuators and others devices are hazardous for the satellite, regarding shocks waves generation and potential risk of contamination.

Shape Memory Alloy ( SMA ) technology equipped with inner heating element, offers smooth and slow behavour, higher cleanliness result and good vibration & shock resistance.

Thermocoax addresses this new market with miniature and powerfull heating element, same components already demonstrated on propulsion and thermal management on board satellite.

Main applications are single one time used valve, Hold Down & Relieve Mechanism (HDRM), Pin Puller, deployment Hinge.

Heating SMA
Heating coil

THERMOCOAX heating space products with Spacecraft Electrical Propulsion System

New Generation of Pre-Heating Solution for : Hall-Effect Propulsion Thruster

heating ring ring

THERMOCOAX Pedigree

For 15 years, THERMOCOAX has been a worldwide key player in designing, developing and manufacturing heating systems for the space market.

We provide solutions for :

Ground applications :

  • R&D programmes with institutes
  • Ground equipment

Flying models :

  • Heating management systems at 50 & 100 volts for Satcom
  • Catalyst bed heaters for chemical propulsion
  • Heating solutions for Hall-effect thrusters

Scientific Mission :

  • Heating systems on Curiosity Rover
  • Heating elements on ISS for MSL
  • Heating elements for pyrolysor on Cassini-Huygens Titan probe

heating technology THERMOCOAX heating solution

Technical Application of pre-heating ring

The new generation of communication satellites is improved with more power available (13kW for E3000 platform) and allows the use of electrical propulsion systems for orbit raising and for all station-keeping manoeuvres, wheel offloading, station relocation and final re-orbiting for disposal.

The electrical propulsion system allows a significant reduction in spacecraft mass. A disadvantage is the average length of 8 months to raise the final orbit in comparison to a few days for chemical propulsion.

The first platform to be equipped with the THERMOCOAX pre-heating ring is the EUTELSAT172B, produced by Airbus Defense and Space, equipped with Russian FAKEL EPS.

Space electrical propulsion hall effect thruster

For faster startup and to protect the thruster from premature erosion, a pre-heating system is installed around the electrical thruster. Each pre-heating ring supplies 28 watts.

Technical Description of heated Ring

We use our best mineral-insulated cable.

Mineral-insulated cable with 2 resistive wires welded together at the tip to make one electrical loop.

Redundancy can be reached by using 2 separate heating cables with an outer diameter of 1mm or only 1 cable with 4 wires for 2 heating loops with a minimum outer diameter of 1.5mm.

drawing of heating element heating element

 

The cables are installed and brazed in the metallic ring.

To get the perfect dimensions and tolerance, the ring is reworked and then polished.

3D drawing of heating ring ring

 

3D drawing of polished product Finished product cleanless

 

Catalyst Bed Heater :

  • 2 redundant electrical loops
  • Nominal power supply: 28 to 55 volts
  • Power version per loop:
  • 30 watts under 70VDC
  • 60 watts with 2 loops activated
  • Max exposed temperature:
  • 1000°C with Inconel

Other power and voltage available.

Mineral-Insulated Cable :

Version exposed to 1000°C :

  • Inconel 600 sheath
  • 4 nickel-chromium wires

Xray cable Xray four wires heater

 

Lead Wires :

  • 4 wires
  • Color code for each loop
  • AWG24 or 26
  • Strength 1.4kg

Acceptance Test Criteria of the catalyst bed heater :

  • Helium Leak Test
  • X-ray of the ring
  • X-ray of the junction MIC/lead wires
  • Lead attachment strength test
  • Visual and mechanical examination
  • Overvoltage
  • Line resistance
  • Insulation resistance under 500 volts
  • Burn-in test
  • Dielectric 100/300/500VAC, 60Hz/60s
  • Weight
  • Final Manufacturing Report

 Test List for Qualification Program

THERMOCOAX manages and conducts the qualification test programme in accordance with our customer’s specification.

Our engineers write the QTP for customer approval prior to running the test.

Most of the tests (thermal, humidity, electrical, etc.) on the space grade heating solutions are performed in THERMOCOAX’s labs.

Tests requiring heavy equipment (vibration, acceleration, shocks, etc.) are subcontracted to external laboratories or supported by our customers with the complete propulsion system.

List of Typical Qualification Tests on Catalyst Bed Heater :

  • Vibration
  • Acceleration
  • Mechanical shock
  • Pyrotechnic shock
  • Helium leak
  • Burn-in
  • Humidity
  • Hot firing
  • Electrical cycling
  • Thermal cycling
  • Lead attachment
  • Dielectric
  • Destructive physical analysis
  • X-ray Examination

 

vibration qualification graph Example of vibration spectral

Packaging and Cleanness :

Packaging is designed specifically to ensure excellent condition of the catalyst bed heater during transportation and storage :

packaging vacuum packaging

 

packaging marking packaging

 

THERMOCOAX supplies the new Hall-effect thruster with 1500 and 5000 watts, here are a few examples :

  • SMART1
  • Alphabus
  • Alphasat

To come :

  • SSL1300
  • E3000e
  • Boeing 702 platform

 

THERMOCOAX is the major player for onboard heating solutions for electrical thrusters and is proud to participate in challenging international space programmes.

THERMOCOAX’s focuses on high-quality heating products for maximum stability and repeatability during operation. We have understood our customers’ challenge to manufacture spacecrafts for over 20 years for a better life for human beings.

New large constellation programmes are currently in construction, THERMOCOAX is now ready to support the market with high-reliability and high efficiency heating ring for electrical thruster.

 

In-Core water level detector

Over the last decade, THERMOCOAX has developed a range of Ex-Core accident resistant cabling systems and In-Core instrumentation assemblies for Gen 3 reactors.

Based on THERMOCOAX unique expertise and taking profit of the extreme robustness of its MIneral Cable technology, THERMOCOAX has developed, tested and qualified a Reactor Pressure Vessel Level (RPVL) detector.

Before making the detector commercially available, THERMOCOAX has partnered with SIET (www.siet.it) to verify detector functionality at normal and abnormal conditions.

Some results have been published during the latest BEPU 2018 Conference. Click here to read an abstract

THERMOCOAX Nuclear team remains available for further information.

Innovative flange immersion heaters for liquid fuel

FLANGE IMMERSION HEATERS FOR LIQUID FUEL

The project to develop a high-efficiency immersion heater started a long time ago at Thermocoax with a particular R&D project for high purity aluminium foundries.

HEAVY FUEL STORAGE

Then we decided to adapt our technology to heating applications for the storage of heavy fuel. We designed an innovative flange immersion heater offering longer lifetime than existing solutions.

The technology is based on THERMOCOAX Mineral Insulated Cables that offers high reliability, high resistance, long lifetime and a fully insulated heating solution.

A COMPLETE RANGE OF IMMERSION HEATERS

A full range of Flange Immersion Heaters low density is now available with a total length above the flange of maximum 2 meters.

To respond to the needs of fuel storage applications in tanks where the accessibility is reduced and where small footprint heating systems are requested, we limited the length of the immersion heaters and made our design with DN100 & DN200 flanges only.

The challenge was to develop a design with high total power, a Low power density and a small footprint while offering a natural movement of the fluid through the heater.

Another challenge was to make a comfortable maintenance design, with a strong mechanical resistance and that can resist the immersion in petroleum-based liquids with 100% energy efficiency.

THE THERMOCOAX IMMERSION HEATERS DESIGN

We based the design on a strong mechanical stainless steel structure with mineral insulated heating cable spiralled and firmly fixed on the structure.

In the middle of the heater, a stable Stainless steel square tube is welded to the flange. Another construction is fixed on this tube so that a solid essential strength is created.

The heating cables are held by particular carrier profiles which are connected to stainless steel discs and fixed to the middle tube.

We managed to make a design where each heating cable is independent, and due to an innovative assembly, each heating cable can be replaced independently for easy maintenance of the Immersion Heater on site.

Mineral insulated cables with 316L stainless steel sheath are used to offer to the heater a high resistance for immersion in main petroleum-based liquids and also asphalt, tar or other dense or highly viscous components.

We also wanted to offer a solution with better fluid circulation through the heater and with more contact between the fluid and the heating surface than with existing solutions on the market.

To meet this need, THERMOCOAX ISOPAD Immersion Heaters can have up to 3  layers of heating elements while keeping enough space for fluid circulation. The multilayer design increases the contact surface between the fluid and the heaters for a better heat transfer efficiency.

The clearance between two spires for the movement of the fluid through the heater is between 9mm and more than 15mm depending on the total power of the Immersion Heater.

All our immersion Heaters can be manufactured with an integrated thermocouple or PT100 for temperature control, with flange with screw plug and junction box.

THERMOCOAX IMMERSION HEATERS APPLICATIONS :

  • Fuel, light diesel fuel, standard diesel fuel, maximum load 1 – 2 w / cm², materials: 321, 316l
  • Heavy fuel, maximum load 0,5 – 3,5 w / cm² according to grade, materials: 316l
  • Diesel, kerosene, maximum charge 3 – 3.5 w / cm², materials: 316l
  • Machine oil, maximum load 2 – 3.5 w / cm², materials: 316l
  • Mineral oil, maximum load 0,5 – 3,5 w / cm² according to temperature, materials: 321, 316l
  • Lubricating oil, maximum load 2,3 w / cm², materials: 321, 316l
  • Asphalt, tar and other heavy or highly viscous components