Designing heating solutions are rarely as simple as matching power requirements to a standard product, especially when the application brings physical constraints that don’t fit neatly into an off-the-shelf design. That was the case when a Tempco distributor reached out for help with a custom process heater request involving a particularly challenging reservoir.
Defining the Challenge
The distributor’s customer was working with a large fuel oil reservoir measuring 8 feet by 23 feet, but with an unusually shallow depth of just 16 inches. The fuel oil needed to be kept warm to support the customer’s process, and the system required a total of 30 kW of heating power. To add another layer of complexity, the immersion heaters had to be installed through the top of the reservoir rather than from the side or bottom.
At first glance, the size and shape of the tank posed a clear challenge. With such a large surface area and minimal depth, relying on a single heater could lead to uneven heating. Heat would have to travel a long distance across the reservoir, increasing the risk of temperature inconsistencies and reduced efficiency. Recognizing this, Tempco took a closer look at the application details and engaged in several technical discussions with the customer to fully understand the requirements and limitations.
Strength In Numbers
Rather than forcing a standard solution into a non-standard space, Tempco proposed a custom-designed approach using multiple immersion heaters. The idea was to distribute the heat throughout the reservoir instead of depending on conduction alone to spread warmth across the large area. By placing heaters in four different locations within the tank, the fuel oil could be heated more evenly and reliably.
The proposed solution centered around four custom immersion heaters, each providing 7.5 kW of power to collectively meet the 30 kW requirement. This modular approach allowed for better heat distribution while also accommodating the top-entry installation constraint. To make installation possible, Tempco included a specific mounting method in the design. Each heater would be installed through the top of the reservoir using a mating plate that securely attached the heaters to the tank.
Every heater was carefully designed to meet the application’s physical and performance requirements. Each unit featured three coiled tubular heating elements, a design choice that reduced watt density to below the maximum of 16 watts per square inch. This helped ensure safe and efficient heating of the fuel oil. The heaters were wired for three-phase power and built with an immersed length of 15 inches, ideal for the shallow depth of the reservoir.
Mounting and mechanical stability were also critical considerations. Each heater was mounted on a 6-inch, 150-pound steel flange to provide a robust connection to the tank. Additionally, a bracket was installed on the heater end to stabilize the elements during operation. This prevented the heaters from drooping when powered, helping maintain proper positioning and long-term reliability.
By combining detailed application review, customer collaboration, and custom engineering, Tempco was able to deliver a solution tailored specifically to the challenges of this reservoir. The final design addressed the tank’s shallow depth, large footprint, and top-entry installation requirement while providing consistent heating across the entire system.
Need a custom heating solution? Tempco’s team has decades of experience designing parts that last. Contact Tempco to find the right fit for your application.
