Optimizing Tank Heating for Industrial Processes

Most processes in this world require some form of heat. Specifically, there is a need to heat something that resides in a tank. Water, fuel, etc... there seems to always be a need to maintain temperature or heat up product inside a tank. However, this requirement is not something to be taken lightly. It can be a a fairly complex challenge to address. There is a level of nuance associated with heating tanks in industrial settings that many operators only find out when they’re tasked with it. Ensuring that the operation is going about this process in the most efficient way possible is critical to the outcome. 

Whether we’re trying to heat a product that is already in a finished state or attempting to heat the materials used in the finished product, special considerations must be made.
We first need to calculate how much energy is needed for the process:

Qtot = Qm + Qloss + Safety factor

Where:

• Qtot is the total energy required.
• Qm is the energy absorbed by the process material including latent heat, the material in the tank and the tank itself.
• Qloss is the energy lost from the surfaces by the conduction, convection radiation, ventilation and evaporation.
• The safety factor typically ranges from 10% to 25%

This is just looking at the tip of the iceberg concerning this calculation.  In order to solve this equation, you have to go through a number of other steps to calculate Qm and Qloss.

Once we do go through that long process, however, and we know the total energy required, we must look at whether we should go with a direct or indirect heating method.  Is the material we’re trying to heat sensitive to contact?  If so, a direct heating method may be out of the question.  In these cases, an indirect approach may be optimal.  If there aren’t any restrictions, direct heating allows for there to be less of a loss of energy. 

You also need to consider the following: 

• Is the tank susceptible to corrosion? 
• How many gallons of liquid are involved? 
• How long is the process? 

Finally, there is the question of control. How tight does it need to be?  Do we need to strategize on utilizing a sensor? This is not so uncommon.

All of these elements need to be understood before making a recommendation on the best approach.

The main takeaway is that heating a tank for an industrial process can be a challenging task. I penned an article for Process Heating magazine in the spring of 2023 on this topic.  I encourage you to give it a read if you’d like to learn more.

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