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Freeze Protection
As winter weather extremes can have a major impact on many industrial equipment and production processes and can cause significant financial losses, a situation that Elekheat and many businesses do not want to see, we give some solutions for freeze protection, especially in challenging applications such as wind turbine de-icing and pipe insulation. Helping you choose the right Flexible Heaters, Cartridge Heater and Immersion Heater.
Freeze Protection: Insights from Winter Disasters
In fields such as wind energy, oil and gas, and water management, extreme cold temperatures during the winter months can lead to problems such as frozen equipment, ruptured pipes, and system failures. Are you aware of the following real-life occurrences?
1.In early 2021, Texas in the United States was hit by an extreme cold snap, causing massive power outages and water supply disruptions, with economic losses estimated at more than $130 billion. You can learn more by Texas Tribune.
2.In 2021, the energy crisis in Europe was partly caused by extreme weather-induced declines in renewable power generation, when natural gas prices spiked by more than 200%, directly impacting industrial production costs and residential heating expenses. You can learn more by European Commission.
Industries That Relying on Freeze Protection
- Wind Energy: Because ice disrupts aerodynamics, ice buildup on turbine blades can cause structural imbalances, wear and tear on mechanical equipment, reduce efficiency by up to 30%, and increase downtime, especially in areas where temperatures drop to -4°F (-20°C) or lower.
- Oil and Gas: Waxes in crude oil begin to crystallize around 15°F (-9°C), forming a gel that makes the fuel difficult to transport at lower temperatures. For diesel fuel, gelation occurs below 32°F (0°C), which can clog pipelines and cause severe operational disruptions.
- Water Treatment: Freezing temperatures as low as -13°F (-25°C) can freeze reservoirs, pipes and valves, causing water treatment facilities to shut down. Ice jams can disrupt water flow and damage infrastructure.
- Transportation: At temperatures below -10°F (-23°C), the viscosity of diesel fuel increases significantly, leading to engine failure and inefficiency. Critical hydraulic systems in heavy machinery can seize at temperatures below -5°F (-20°C).
- Agriculture and Mining: In areas where temperatures fall below -22°F (-30°C), irrigation pipes and hydraulic equipment are susceptible to freezing, leading to downtime and costly repairs.
Freeze Protection for Efficient De-Icing
Latest Research Insights into Wind Turbine De-Icing
A groundbreaking study conducted at Northeastern Agricultural University explored the use of electric heating for wind turbine blade de-icing under simulated frost conditions. This study provides insights for optimizing antifreeze heating systems.
Experimental Setup:
Conditions: The tests were conducted at -16°C to simulate the formation of freezing ice under wind speeds of 5 m/s, 10 m/s, and 15 m/s.
Blade Design: The NACA0018 airfoil, a widely adopted blade profile, was used in this study. The first 1/3 of the blade is hollow with a wall thickness of 2 mm and Film Heater elements embedded in the inner surface.
Heating Elements: The heating elements measure 49 mm x 19 mm and are rated at 12 V and 24 W. These elements utilize high-performance metal alloy heating wires and excellent insulation provided by polyimide.
Observations:
Mode I: Thin ice melts, and returning water flows along the ice leaf.
Mode II: At low wind speeds (5 m/s), the melted ice slides backward due to inertia.
Mode III: At high wind speeds (15 m/s), the returning water refreezes at the trailing edge.
Mode IV: Ice is completely dislodged, and there is no water flow, usually at medium to high wind speeds.
Optimal Heat Flux Levels:
5 m/s wind speed: 10 kW/m² for effective de-icing.
10 m/s wind speed: 12 kW/m² for effective performance.
Energy Efficiency:
At 5 m/s and a heat flux of 14 kW/m², energy consumption drops to 0.33 kJ in 1 minute. However, too high a heat flux increases the risk of secondary freezing.
The study proved that Film Heaters are very effective in de-icing wind turbine blades. Optimal heat flux levels (10-12 kW/m²) minimize energy use while ensuring efficient de-icing. Precise control is essential to prevent secondary freezing and maximize system efficiency.
Advanced heating technology from Elekheat Freeze Protection
Heat loss is shaped by a combination of ambient temperature, wind speed, and humidity. While water solidifies at 0°C, oils behave unpredictably, thickening or congealing at varying temperatures—a challenge that calls for customized heating strategies. Furthermore, insufficient insulation or poorly positioned heating elements often results in uneven heat distribution and wasted energy, undermining both efficiency and performance.
Based on these findings, Elekheat has developed a range of heating solutions suitable for a variety of industrial applications. Elekheat heating elements are carefully designed for reliability, energy efficiency and adaptability to extreme conditions.
Proper insulation is essential to minimize heat loss and maintain a constant temperature in extremely cold environments. By reducing heat dissipation, insulation increases the efficiency of heating elements and ensures that energy is directed where it is most needed. At Elekheat, we deliver:
Designed to withstand extreme temperatures with high performance insulation and customized insulation solutions tailored to the specific dimensions of your infrastructure, provides excellent heat resistance for pipes, tanks and equipment to ensure maximum efficiency.
Flexible Heaters
Flexible Heaters, refers to heaters made with flexible materials, including Polyimide Heating Membrane and Silicone Rubber Heater.They can be adapted to different shapes and sizes, and are widely used in scenarios where localized or specific area heating is required. They can be bent and cut, are lightweight and thin, and provide uniform heat distribution. Applications include medical devices, aerospace, industrial, consumer electronics and more.
1.Elekheat Polyimide Heating Membrane
Made of lightweight polyimide material with excellent flexibility and thermal conductivity, ideal for uniform de-icing of wind turbine blades and other precision applications.
If you need to order Elekheat Polyimide Heating Membranes, click here to request a quote.
2.Elekheat Silicone Rubber Heater
Made of silicone or polyimide, the pads accommodate irregular surfaces and provide even heat distribution for tanks, piping and other challenging applications.
If you need to order Elekheat Silicone Rubber Heater, click here to request a quote.
How to select the right flexible heater for my application?
| Feature | Polyimide Heating Membrane | Silicone Rubber Heater |
|---|---|---|
| Material | Polyimide | Silicone Rubber |
| Thickness | Very thin (approx. 0.1-0.2 mm) | Relatively thick (approx. 1-3 mm) |
| Operating Temperature Range | -200°C to 200°C | -60°C to 250°C |
| Flexibility | Very high | High |
| Applications | Localized heating in precision equipment | Heating in industrial equipment and harsh environments |
| Durability | Moderate (better for static use) | Very high (resistant to mechanical damage and environmental corrosion) |
Polyimide Heating Membrane is ideal when an extremely thin design, precise heating and high performance insulation is required.
Silicone Rubber Heater is more suitable when greater mechanical durability, water resistance, and operation in harsh environments are required.
3.Elekheat Cartridge Heater
Made of high-grade ceramic insulation and nickel-chromium resistance wire, cartridge heaters provide targeted heating in compact spaces such as hydraulic systems and small tanks.
If you need to order Elekheat Cartridge Heater, click here to request a quote.
About cartridge heaters, you may want to know
| Question | Answer |
|---|---|
| Which cartridge heater is best for high-temperature applications? | Choose heaters with high-quality materials like Incoloy or stainless steel sheaths, high watt density, and insulation materials such as magnesium oxide (MgO) for durability and efficiency at extreme temperatures. |
| How to choose a cartridge heater for corrosive environments? | Use heaters with corrosion-resistant materials such as Inconel or stainless steel. Ensure they have moisture-resistant features and compatibility with the specific chemicals or substances in the environment. |
| What type of cartridge heater is suitable for food processing equipment? | Select heaters with FDA-approved, food-grade stainless steel sheaths for corrosion resistance and hygiene. Ensure uniform heat distribution and compliance with safety standards for food processing applications. |
| Are there explosion-proof cartridge heaters available for hazardous areas? | Yes, explosion-proof heaters are designed for hazardous areas with flammable gases or dust. Look for heaters with ATEX or IECEx certifications, sealed connections, and reinforced construction for safety. |
4.Immersion Heater
Made of durable stainless steel or Incoloy, they provide direct heat transfer to water and oil-based media, ensuring consistent performance in extreme environments.
If you need to order Elekheat Immersion Heater, click here to request a quote.
How to choose a corrosion-resistant material for an immersion heater in corrosive environments?
For high temperature applications, preference is given to materials such as Incoloy or stainless steel. ELekheat experts recommend the High-Temperature Immersion Heater or Flanged Immersion Heater in Incoloy 800/840 for plastics processing equipment, mold heating, and high-temperature industrial furnaces.
In corrosive environments, choose a heater with corrosion-resistant materials and moisture-proof seals. ELekheat experts recommend Corrosion-Resistant Immersion Heater or Teflon-Coated Immersion Heater made of Inconel 600/601 or 316L stainless steel. They are suitable for chemical equipment, heating in marine environments, and in areas with acidic gases.
For food processing equipment, choose FDA-compliant, corrosion-resistant and easy-to-clean heaters made of food-grade 304 or 316 stainless steel, recommended by ELekheat experts for food roasters, beverage heating equipment, and dairy processing.
In hazardous areas, explosion-proof heaters with certified safety standards are needed to prevent accidents, ELekheat experts recommend Inconel or Incoloy materials with sealed joints design for oil and gas industry, mining heating equipment, chemical flammable gases environments.
Calculating Heating Requirements for Freeze Protection
Formula for Water Heating
Kilowatts required=372(Gallons)×(Delta Temperature in °F)×(Hours)
Formula for Oil Heating
Kilowatts required=860(Gallons)×(Delta Temperature in °F)×(Hours)
How much power is required for freeze protection?
To determine the amount of power needed for freeze protection, consider the example of heating a 20,000 gallon tank. The calculations are shown below:
Determine the Temperature Differential (ΔT):
Initial water temperature: 50°F
Target temperature: 90°F
ΔT: 40°F
(20,000gallons)×(40°F)÷(372)×(24hours)=86kW/hour
This means that over a 24-hour period, the temperature inside the tank will rise by approximately 1.67°F per hour.Without proper insulation, significant heat loss can occur, especially when the outside temperature drops below freezing.
Without insulation, as much as 35-40% of the heat may be lost through the walls of the tank, resulting in a drop in water temperature of approximately 28°F per hour In this case, the heating system will have difficulty maintaining the target temperature and may freeze within a few hours.
The Importance of Insulation in Freeze Protection
Insulated tanks can significantly reduce heat loss and improve efficiency and reliability. Here is an example:
With insulation: heat loss is reduced to about 5%, which means a 90°F tank loses only 2°F/hour. with an 86 kW heater, the temperature rises 1.67°F/hour and the net loss is reduced to only 0.33°F/hour, which keeps operations safe.
Without insulation: the same tank can lose as much as 28°F per hour, which quickly leads to icing unless a more powerful heater is used.
FAQ:
1. What is freeze protection, and why is it important?
Freeze protection prevents freezing in water, oil, and other fluids in extreme cold, avoiding equipment failure and downtime in industries like wind energy, oil and gas, and water treatment.
2. How does insulation affect freeze protection?
Insulation reduces heat loss, improving heating efficiency. Without insulation, up to 40% heat loss can occur, leading to freezing.
3. Can silicone rubber heaters prevent freeze damage?
Yes, they provide even heat distribution for freeze protection in tanks, pipes, and irregular surfaces.
4. How does wind speed affect de-icing in turbines?
Wind speed affects heat efficiency. At 5 m/s, 10 kW/m² is needed; at 10 m/s, 12 kW/m² ensures effective de-icing.
5. How do immersion heaters work?
Immersion heaters directly heat liquids inside tanks, preventing freezing even in extremely cold conditions.
Contact Elekheat today by dialing 008618914757574 or use our contact form to discuss your heating element needs and improve your business’s efficiency and bottom line.
References
- Li, X., Chi, H., Li, Y., Xu, Z., Guo, W., & Feng, F. (2024). An Experimental Study on Blade Surface De-Icing Characteristics for Wind Turbines in Rime Ice Condition by Electro-Thermal Heating. Coatings (Basel), 14(1), 94.https://doi.org/10.3390/coatings14010094
- Richard L. Snyder, Extension Biometeorology’s, University of California, Atmospheric Science, Davis, CA 95616, U.S.A. https://biomet.ucdavis.edu/doc/Principles_of_Frost_Protection–UCDavis_Biometeorology_Group.pdf
