Mighty-Blade Process Heaters – Introduction & Design


The flat shape of the Mighty-Blade provides greater surface area inch for inch of length than round elements. With the Mighty-Blade, equipment can he designed with more wattage in less linear space than with conventional elements. Or, by replacing an existing tubular heater with a Mighty-Blade of the same length, the watt density is significantly reduced. In immersion applications the narrow profile increases natural convective flow of materials being processed, resulting in lower sheath temperatures and improved heat transfer to the process. Materials being processed are less susceptible to degradation. In processes where these considerations are not as critical, watt densities can be reasonably increased. The .275″ x 1″ dimension creates anti-corrosion, self-cleaning effects that significantly extend the Mighty-Blade’s useful life by not allowing the collection of foreign materials on the sheath. The multiple coil design permits an individual element the flexibility to be wired at the installation in single phase, three phase, three heat or dual voltage. The Mighty-Blade can be used in virtually any immersion, clamp-on, forced air or radiant heating application.
Download-PDFMighty-Blade Process Heaters Standard Products
A Mighty-Blade has over 50% more surface area per inch of length than a .475″ dia. tubular element. 2.3 square inches per linear inch on the Mighty-Blade versus 1.49 square inches per linear length on the tubular allows more wattage or lower watt densities. The narrow width and greater surface area of the Mighty-Blade increases the velocity of many materials as they flow past the sheath. Heat transfer is improved and the Mighty-Blade’s operating sheath temperature is lower than a tubular element. A typical application using a 3 tubular element immersion heater at 22 watts per square inch and a rating of 9kw has an immersed length of 47-1/2″ (A). By utilizing the same spatial limits and installing a Mighty-Blade Immersion Heater, the rating, at the same 22 watts per square inch, can be increased to 13.8kw (B). In the same manner, the original 9kw item at 22 watts per square inch needs only a 31-1/2″ immersion length (C). A Mighty-Blade immersion heater with the same dimensions as the tubular element heater would have a watt density of 13.9 at 9kw. Note the vertical position of the Mighty-Blade elements. As illustrated, much more wattage can be packed in the same area, the same wattage can be provided in less area, or, in the same area at the same rating, processes can be heated at significantly lower watt densities with the Mighty-Blade.