As the global energy demand increases and government and environmental regulations tighten, Chromalox is the proven performer in providing integrated heat supply and control technologies for the optimization of sustainable conventional and renewable power generation plants. Our solutions are implemented with deep process know-how, innovative design and engineering expertise, and best-in-class products. Our reliability as a partner is supported by qualified project management, experienced commissioning, and responsive support for maintenance efficiency, optimization, and replacement parts across the lifetime of the plant.
Energy
No matter the complexities of your heating and control needs, Chromalox is adept in providing systems that can help maximize efficiency and reduce emissions, all while providing rugged, exacting, reliable heat exactly where it’s needed.
Power Generation
Assuring Your Process Performance with Chromalox
The Chromalox Difference
Some companies build heaters and controls. Chromalox does more.
Chromalox brings a dual focus to the marketplace. We focus on precision in the design and manufacture of our products and precision in their performance in order to provide the finest products for your application. And we focus on your specific application with the insight to help maximize its performance and efficiency, and the technical support to help you achieve it.
Chromalox Understands Every Facet of the Process
We provide precision heat and control systems for more processes than anyone in the world. Our expertise, combined with the most stringent material and manufacturing standards you’ll find in the industry, provides you with an array of products you can count on to perform at each critical process phase. Among them are process air heaters for inlet housings, circulation heaters for superheating, flanged immersion heaters for sulfur reduction, self-regulating cables and controls for freeze protection, and explosion-resistant comfort heaters that keep process equipment warm for quick starts on peaker plants and free from moisture and freeze-ups.
Chromalox Meets Your Specific Challenges
With that kind of experience behind us, Chromalox understands the unique challenges that power plant builders, managers, and maintenance personnel face. And we have the knowledge, experience base, local support, and technical skills to meet those challenges with you.
Technologies That Reflect an Understanding Of Power Generation
Chromalox Can Save You Time and Money
Our standardized designs can reduce your installed cost as well as your eventual replacement cost. Our electric process heaters require minimal cleaning and calibration. Using Chromalox thirdparty-certified electric package systems results in reduced insurance premiums for you-lower than those offered to competitors using fuel-fired systems.
Chromalox Can Improve Your Process Efficiency
Chromalox control panels, coupled with the precision and reliability of Chromalox heaters, optimize temperature control and shrink variations in efficiencies, allowing a better burn. Chromalox power controls, SCRs, and proprietary software precisely sequence heaters, balance electrical loads, control soft starts, and correct power factors, flattening out electrical fluctuations.
Unrivaled Design, Engineering, and Manufacturing Capabilities Focused On Your Complete Heat and Control Application
Front-End Engineering Design Assistance
Chromalox has more experience in process design than anyone else in the industry. Prior to construction, let us put that experience to work for you. Accurate planning and sound engineering are keys to any process. Our engineering support staff can help to properly specify equipment that will get the job done right the first time so when you enter the construction phase, you can be sure that the specified equipment will operate as desired.
Comprehensive Engineering Capabilities
From heater assemblies and skid fabrication to integration with controls and sensors, our complete engineered systems reduce installation labor, reduce starup time, and ensure proper operation to specification. Chromalox provides engineering assistance with integrating our products into your application, offering a full range of engineering capabilities. Our in-house engineering and software capabilities allow us to design simple operator interfaces. These advanced designs can reduce your business’ training time and expense, as well as increase repeatable operation. In addition, Chromalox has training tools and resources to assist you with installation, startup, and operation.
Custom Design and Manufacturing for Unique Requirements
If an element, sensor, control, or packaged system that we carry in stock doesn’t exactly fit your needs, we’ll custom-build it-either by expertly adapting an existing product or by designing and manufacturing a completely new one. Our design engineers have won industry awards for innovation and rapid turnaround of custom designs. They bring expert knowledge in process engineering design together with a flair for innovation to help you produce prototypes of new products and systems, developing an innovative design in the shortest possible turnaround time.
Manufacturing That Leads the Industry
Chromalox maintains four state-of-the-art manufacturing plants throughout the United States, Mexico, Europe, and Asia. In the U.S., Chromalox has more than 325,000 square feet of manufacturing and warehousing space in Utah and Tennessee. Our manufacturing capability features computer-controlled, automated machinery to help quality. With ASME welding capability in-house since 1953, Chromalox has gained more in-plant experience than any other electric heater manufacturer for high-quality welding. Our large-volume ASME production of high-pressure systems gives Chromalox the experience base to perform ASME welding at a level of excellence unsurpassed in our industry.
Broadest Third-Party Approval
Chromalox is the only manufacturer with extensive systems manufacturing in the U.S. and Europe. Approvals and certifications include, but are not limited to, CE, NEC, UL, VDE, cUL, FM, CSA, MSHA, BASEEFA, Cenelec, ASME, PED, ATEX, GOST, and ISO 9001:2008.
Chromalox Service Options Ensure Optimum Performance and Extend Product Life
From startup and training to ongoing maintenance diagnostics and emergency response, we offer customized service options to ensure the quality and continued success of your process.
Startup and Commissioning
New equipment startups can often delay project timelines. Minimize any chance for costly setbacks by having a Chromalox qualified engineer for onsite startup and commissioning the mechanical, electrical, instrumentation, and control equipment for any system we have built, anywhere in the world. They will assist with initial equipment startup and perform a complete review of the installed system to ensure optimized integration into your facility, increasing overall efficiency. You will save time and know that your product was installed correctly.
Chromalox Cold Weather Contracts
Cold weather can be a strain on much of your system’s equipment. To help you avoid unplanned downtimes that can occur due to cold weather Chromalox offers a package of pre-season planning and preventive maintenance services to ensure proper equipment operation before the cold weather strikes. This added degree of security provides confidence that the heat will flow when you need it.
Chromalox Service Contracts
Chromalox Service Contracts deliver efficient emergency response and preventive maintenance, helping to eliminate problems before they arise. Chromalox field service personnel are experts at maximizing the performance of your process heat and control systems with a variety of on-site services including multi-point inspections, guaranteed emergency response times, site reports, and replacement parts availability.
Coal-Fired Power Generation
Precision Electric Heat and Control Systems for Coal-Fired Power Generation Plants
Heat and Control Applications
Construction and Personnel Heating
Blower heaters and air handlers provide comfort heating for personnel, for warming equipment in enclosed spaces, and for curing materials in construction areas.
Air Intake Heaters
Large electric duct heaters warm incoming air that is mixed with pulverized coal for efficient combustion.
Fire Water Storage
Large-tank heaters with replaceable elements ensure operational readiness with freeze protection service.
Hazardous Area Heating
Explosion-certified heaters are rated for hazardous areas and hose-washdown capable.
Coal Hopper Heaters
High-temperature modular heaters installed on the sides of baghouse hoppers between the insulation and the hopper wall provide blanket heat coverage to help prevent acid condensation and corrosion.
High-Pressure Steam Piping
High-temperature metal-sheathed heating cable is used for freeze protection on high-pressure steam piping in hazardous-rated areas.
Service and Maintenance
Yearly service visits ensure optimal operating conditions and help predict needed maintenance.
Auxiliary Steam Generators
Compact, low-pressure electric steam boilers provide on-demand steam supplies for super critical times during start up and peak demands.
Temperature Controls, Sensors, and Control Panels
Thermocouple and RTD sensors, electronic PID DIN temperature control units, and SCR power switching panels minimize temperature swings to increase life of the heaters and tighter control.
Lubricating Oils for Turbines and Compressors
Immersion heaters warm lube oil for lubrication of bearings and moving components of turbines and compressors.
Piping Distribution
Heat trace counteracts the heat loss from process equipment and piping through its insulation, prevents solution precipitation, prevents increase of viscosity or solidification of product, and provides freeze protection.
Cogeneration Power
Precision Electric Heat and Control Systems for Cogeneration Plants
Heat and Control Applications
Fire Water Storage
Large tank heaters with replaceable elements ensure operational readiness for freeze protection applications.
Freeze Protection and Heat-Loss Protection
Heat trace counteracts heat loss from process equipment and piping, prevents solution precipitation, decreases viscosity or solidification of product, and provides freeze prevention on water lines.
Storage Tanks
Storage tank facilities for products such as sodium hydroxide and DI water are heated with hazardous-duty flanged immersion heaters to ensure precise temperatures needed for process conditions.
Lubricating Oils for Turbines and Compressors
Immersion heaters with or without replaceable elements provide direct heating of lubricants for turbines and compressors.
Auxiliary Steam Generator
Compact, low-pressure electric steam boilers supply on-demand steam for super critical times during startup and peak demands.
Fuel-Gas Conditioning and Dew Point Heaters
Electric inline circulation heaters preheat and dry out supply gas streams to prevent corrosive condensation from forming and damaging expensive turbine blades.
Exhaust Stack and Accessory Modules
Hazardous-duty convection and forced-air heating units provide safe heating in places like turbine and vent fan enclosures, exhaust stacks, and accessory modules.
High-Pressure Steam Piping
High-temperature metal-sheathed heating cable is used for freeze protection on high-pressure steam piping in hazardous-rated area locations such as the Heat Recovery Steam Generator (HRSG).
Turbine Air Intake
Large electric duct heaters warm incoming air to prevent icing on turbine blades in cold climates.
Motor and Enclosure Heaters
Component strip heaters and silicone laminate heaters for medium to large sized motors and enclosures prevent condensation agents from decreasing life and performance.
Temperature Controls, Sensors, and Control Panels
Thermocouple and RTD sensors, electronic PID DIN temperature control units, and SCR power switching panels minimize temperature swings, increase life of the heaters, and provide tighter control.
Service and Maintenance
Yearly service visits ensure optimal operating conditions and help predict needed maintenance.
Maintenance Facilities and Wash Water Skids
Convection and blower units heat enclosed spaces to warm both equipment and personnel.
Pollution Control
Precision Electric Heat and Control Systems for Power Generation Pollution Control Systems
Heat and Control Applications
Service and Maintenance
Start-up, commissioning, and yearly service visits ensure optimal operating conditions and help to predict needed maintenance.
Urea Tank Heaters
LTFX-style immersion heaters maintain urea concentrations above their freeze temperatures.
Aqueous Ammonia Vaporizer
Immersion heaters with SCR power control used to vaporize ammonia for NOx reduction.
Anhydrous Ammonia/Urea Piping
Heat trace counteracts heat loss from process equipment and piping and provides freeze protection.
Ammonia Storage Tanks
In-line circulation heaters stand by, ready to warm ammonia for injection into the pollution control stream and maintain system pressure.
Fire Water Storage
Large tank heaters with replaceable elements ensure operational readiness with freeze protection service.
Construction and Personnel Heating
Blower heaters and air handlers provide comfort heating and aid in curing materials in construction areas.
Catalyst Regeneration
High-temperature inline heaters heat air to preheat catalyst beds.
Selective Catalyst Reduction
Process air duct heaters superheat air to inject with ammonia particalized stream.
Fly Ash Dust Collection Bins
Hopper heaters eliminate moisture in baghouse collection systems.
Limestone Slaker Water
Large inline electric preheaters heat and maintain make-up water for slurry mix.
Nuclear Power Generation
Vertical integration in manufacturing capabilities.
Heat and Control Applications
Glycol / Water Heating
Circulation heaters are used to warm coolant for stand-by / emergency generators.
Fire Water Storage
Large-tank heaters with replaceable elements ensure operational readiness for freeze protection applications.
Process Air
Duct heaters can be used for applications such as air heating or iodine absorbers.
Fuel Pre-Heating
Circulation heaters pre-heat #2 fuel oil for stand-by / emergency generators.
Lube Oil Heaters
Immersion heaters warm lube oil for lubrication of bearings and moving components.
Construction Areas
Blower heaters and air handlers provide construction comfort heating and aid in the curing of concrete in construction areas.
Boric / Boron Heating
Precipitate heaters maintain temperature to prevent solution from solidifying or freezing.
Hydrogen Storage
Immersion heaters provide heat input to ensure precise temperatures needed for process conditions.
Process Lines
Mineral insulated cable is used for high-temperature pipe heating, such as steam, boron, sodium, or lead bismuth.
Personnel Comfort Heating
Blower, convection, and radiant heaters provide comfortable temperatures for staff.
Pressurizer Heaters
Pressurizer heaters heat and maintain water in the primary loop at the operating temperature and pressure required by the pressurized reactor vessel.
Recirculation Heater
Circulation heaters prevent the freezing of the liquids used in the containment cooling system and storage tanks.
Demineralized Water Storage
Immersion heaters provide freeze protection and temperature maintenance.
Process and Heating Control
Panels, controllers, and sensors direct heater control based on operating conditions.
Piping Distribution
Self-regulating and constant-wattage heat trace cables are used for pipe temperature maintenance and freeze protection.
Refueling / Make-Up Water
Circulation heaters provide temperature control for refueling water, make-up water, and plant water usage.
Condensate Storage
Immersion heaters provide the extra heat needed to maintain condensate return temperature.
Service and Maintenance
Yearly service visits ensure optimal operating conditions and help predict needed maintenance.
Solar Energy
Process temperature maintenance and freeze-protection keep solar energy production facilities on-line.
Chromalox manufactures precision engineered heat and control systems for each solar application, from raw material processing to module manufacturing and system integration.
Circulation Heaters
Chromalox circulation heaters afford high-energy efficiency, fast heating, and uniform heat distribution for numerous plant heating applications. They provide high turn-down capability, tight outlet temperature control, and variable flow rates. A variety of electrical terminal enclosures is available to meet the requirements of your application.
Immersion Heaters
The stainless steel sheath elements and thermowells in our flanged and screw plug immersion heaters are ideal for process water applications. A wide variety of ANSI and customized flanges and element lengths is available with ratings up to 500 kW. A patented 360° rotatable housing is available on most models of our screw p lug models to facilitate easy conduit connections.
Vaporizers
Designed for use with organic fluids to transfer heat at high temperatures and low pressures, Chromalox pre-engineered, prewired, and pre-piped packages are designed for flexible, dependable, and efficient operation. All units are ASME-certified to 150 psi at 750°F (400°C) with 300 lb construction throughout. Seal-welded element design eliminates leaks and improves serviceability. Available with over-pressure, process, remote, or skid-mounted controls.
Heat Transfer Systems
Our hot oil and water systems are safe, versatile, user-friendly self-contained heating and cooling packages that provide direct or indirect process heating. Pre-engineered and constructed with carefully matched components, these systems eliminate component selection and assembly, and provide easy installation and trouble-free operation.
Heat Trace and Controls
Heat trace is used to counteract the heat loss from process equipment and piping through its insulation, to prevent solution precipitation and the increase of viscosity or solidification of product, and to provide freeze protection. Chromalox offers a variety of heat trace cable; temperature control, monitoring, and management in one, modular package; and all of the necessary components needed to complete the installation, including splices, power connection boxes, and water-resistant end-seal terminations.
Component Heaters
Component heaters can be used by themselves and they can be integrated into more complex heating systems providing a complete thermal solution for your heating requirements. Shape and size most often are the determining factor in most heater applications. Chromalox carries the widest selection of standard component heaters in many shapes, sizes, and wattages.
Control Systems
From basic, low-cost temperature and process controllers, to monitors and overtemperature controls, to more sophisticated control systems like the Chromalox® intelliPANEL™ 3-phase SCR power control panel featuring unique color touchscreen technology, Chromalox can design the right system for your plant’s needs. We are the only heating element supplier offering a complete line of controls, control panels, and accessories.
Tank Heaters
Specially designed to fit high-temperature and corrosive applications. Chromalox offers multiple products for large stationary, small portable, and underground tanks for just about any material and location.