Electric Hot Water Generator
What is Electric Hot Water Generator – HWG-e Series
Hi-Therm Electric Hot Water Generator is an Industrial grade hot water generating system for versatile applications
Hi-Therm electric hot water generator is a closed-loop or direct use water heating system that employs electrical heating elements. The system comprises a closed-loop circulation of hot water through the user equipment for process heating and the return water is reheated in the hot water generator. In case of direct use, hot water generated is stored in a tank for further use. Unlike conventional fuel-fired heaters which burn coal, diesel or gas to heat up water, the HWG-e delivers a cleaner, safer and high efficiency alternative for high temperature applications.
It comes as a packaged skid-mounted unit consisting of the hot water generator along with the accessories such as the hot water circulating pump and the control panel. In case of pressurised hot water, a pressurisation tank is also supplied which ensures continuous pressurisation for high temperature applications up to 140°C. All Hi-Therm Electric Hot Water Generators are custom designed and built to meet application specifications.
Why Choose Electric Hot Water Generator HWG-e
Zero Combustion, Zero On-site Emissions
Suited for specific industrial decarbonization targets or to avoid pollution norms.
Lower Maintenance & Less Downtime
HWG-e removes combustion related maintenance & hazards
Packaged compact design & silent operation
Simply keep it next to the point of use with no dedicated room requirement
Pressurized hot water systems available
Delivers up to 140°C of hot water effectively without hassles of steam
Flexible Capacity (12 kW – 1.2 MW+)
Select from standard capacities or request custom built systems
Flameproof design and various other customisations available
Makes it a versatile option for specific industrial field requirements
| Parameter | Values |
|---|---|
| Heating Capacity | 12 kW to 1320 kW (10,000 Kcal/hr to 11 Lac Kcal/hr) |
| Max. Working Temperature | 90°C (Standard) & Up to 140°C (Optional) |
| Power Supply Range | 380-440 V / 3 ph / 50 Hz / 60 Hz (To be specified) |
| Thermal Efficiency | 98% |
| Working Pressure | Less than 5 Bar (Higher head available on request) |
| Heater Control Circuit | Thyristor (SCR) based - Automatic |
| Heat Flux | Less than 12 watts/in² |
| Temperature Controller | PID based (1°C precision) |
| Turndown Ratio | Step-less |
| Pump Type | Air-cooled Centrifugal with Mechanical Seal |
| Temperature & Pressure Cut-off | Yes |
| Low Level Controller | Yes (Expansion Tank) |
| Motor Overload Protection | Yes (O/L Relay Provided) |
| Heater Fault Protection | Yes (MCBs Provided) |
| Multifunction Meter (MFM) | Yes |
| Over Pressure Protection | Yes (Safety Relief Valve) |
| HMI-PLC / DCS Operation | Yes (Optional) |
| Design Standard | Standard Engineering Practices / ASME (Optional) |
State-Of-The-Art Design Features That Sets e-TFH Apart
Indirect Design
The heater is of a shell & tube type design. It has an insulated pressure vessel with indirect heating tubes. The tubes hold long-life, removable cartridge Ni-Cr heating elements. The hot water does not remain in direct contact with the heating elements. Contrary to immersion heaters where the heating elements are always in contact with the water. This simplifies heater replacement without draining the system or halting the operation. It makes it ideal for continuous industrial use.
Thyristor (SCR) Operated
It ensures soft starting & efficient operation, by avoiding sudden surge of power through the heaters. This extends heating elements life by preventing sudden thermal shocks to the resistance elements. In comparison to contactors, thyristors have no mechanical contacts hence improving reliability and reducing maintenance. In case of large capacity heaters above 480 kW, the heaters are divided into multiple batches with individual thyristors which are sequentially turned on. This reduces current peaks and improves plant power factor and grid stability.
Controls With Local/Remote Working & Added Safeties
All temperature, pressure & low-level safeties protect the system along with an audio-visual alarm and incidence indicator on the control panel. The same can be remotely monitored & operated from the client's DCS. A mechanical safety relief valve at the heater outlet protects the pressure vessel in case of overpressure due to blocked discharge.
Shell Sizing & Internal Baffles
High water volume ensures adequate thermal storage. Internal baffles designed to ensure good flow and uniform heating, preventing hotspots and also minimizing pressure drop across the heater, thereby reducing the load imposed on the circulating pump.
High Heat Transfer Area and Low Heat Flux
The heating surface area of the tubes are designed for adequately low heat flux. This significantly lowers thermal stress on the heater tube's surface.
Stepless Modulation & Precise Temperature Control
Outlet water temperature is precisely maintained through the PID temperature controller set point. The PID controller provides a proportional signal to the thyristor, this system provides step-less modulation of electrical input over the full range of the heater capacity. It also enables close temperature control for accurate response and sizable power savings on part load operations.
Industry Applications of HWG-e
| Chemicals | Pharmaceutical | Food and Beverages |
| Research Labs | Edible Oil Processing | Jacket Heating |
| Effluent Treatment | Educational Institutions | Testing Chambers |
| Metal Pretreatment | Preheating | Process Heating |
| Cosmetics | Pilot Plants | Rotary Dryers |