Electrostatic Precipitator (ESP) Heaters

Keeping industrial air clean relies on systems that perform without fail. Our Electrostatic Precipitator (ESP) Heaters are crafted to address the toughest issues in ESP systems, delivering steady, targeted heat that prevents moisture buildup and ensures smooth operation. 

Heating Element Material

Nickel-Chromium (NiCr) alloy or Kanthal for stable heat output in industrial environments

Sheath/Outer Material

Stainless Steel (SS 304/316) or Incoloy for resistance to corrosion and high temperatures

Voltage Rating

110 V – 240 V (single-phase); up to 480 V (three-phase) for industrial ESP systems

Power Rating

100 W to 10 kW, scalable based on hopper/duct size and heating requirements

Temperature Range

50°C to 200°C for moisture prevention; up to 300°C for specialized high-heat ESP zones

Product Description

Condensation, ash buildup, and corrosion can clog ESP hoppers, driving up maintenance costs and risking system shutdowns. Our ESP heaters combat these problems with rugged construction and precise heating, maintaining temperatures from 50°C to 200°C with power ratings of 100 W to 10 kW. 

Heat-Up Time

5 to 10 minutes to reach target temperature, depending on power and ambient conditions

Watt Density

2 W/in² to 15 W/in², optimized for safe and efficient heat distribution

Insulation Material

Magnesium Oxide (MgO) or Mica for high-temperature insulation and electrical safety

Corrosion Resistance

High resistance to moisture, ash, and acidic flue gas residues; suited for ESP conditions

Dimensions

Length – 150 mm to 1000 mm; Diameter – 8 mm to 20 mm (customizable per hopper/duct design)

Shape/Configuration

Tubular (straight or bent), flat, or strip; designed for hopper walls or duct surfaces

Current-Carrying Capacity

1 A to 50 A, depending on power rating and conductor sizing

Heat Transfer Method

Conduction and convection; direct heating of surfaces to prevent condensation

Mounting/Fitting Type

Flange, threaded (NPT/BSP), or surface-mounted clips; adaptable to ESP hopper/duct layouts

Safety Features

Overheat protection (thermal fuse), grounded sheath, and optional temperature sensors

Standards Compliance

Meets or exceeds UL 1030, IEC 60335-1, and ASME B31.1 standards for industrial heating

Technical Advantages

ESP systems operate in punishing environments such as moist, dusty, and acidic that test heater endurance. Our ESP heaters are made with tough alloys and corrosion-resistant sheathing like Incoloy, standing firm against these challenges. 
 
Inefficient heating can lead to costly blockages and energy waste. With a watt density of 2-15 W/in² and a heat transfer method combining conduction and convection, our heaters deliver targeted warmth to hopper walls or ducts, preventing condensation with minimal power draw. 

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Industry Applications

Power Plant Emissions Control

Powers heaters in coal-fired plant ESPs, preventing hopper condensation for efficient ash collection. 

Cement Manufacturing

Integrates into ESP systems for dust control, ensuring reliable heat in high-particulate environments. 

Steel Production Facilities

Supports ESP hoppers in smelting operations, maintaining performance amid heat and corrosive gases. 

Chemical Processing Plants

Enhances precipitators for fume extraction, delivering steady heat to manage moisture in harsh conditions. 

Pulp and Paper Mills

Equips ESP units for emissions reduction, preventing buildup in humid, dusty pulp processing lines. 

Incineration Systems

Drives heaters in waste-to-energy ESPs, ensuring consistent operation under high-ash and moisture loads. 

Reliable Heat for Uninterrupted Operation

Our ESP heaters come in versatile shapes such as tubular, flat, or strip and mounting options like surface clips or flanges, ensuring an easy fit into hoppers or ducts. This adaptability speeds up assembly and reduces costs, giving purchasing managers a practical component that integrates seamlessly into your manufacturing process. 

Moisture-related failures or inconsistent heat can disrupt ash collection and air quality compliance. Our heaters feature safety measures like thermal fuses and provide steady, reliable heat, keeping ESP systems clog-free even in high-moisture conditions. 

Electrostatic Precipitator (ESP) Heaters

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How do your ESP heaters prevent hopper clogging in high-moisture conditions? 

Our heaters deliver targeted heat to keep hopper surfaces above the dew point, stopping moisture and ash from sticking and clogging the system. This reliability reduces downtime and cleanup costs, giving sourcing teams a component that keeps ESPs running smoothly even in wet, challenging environments. 

What’s the advantage of choosing your heaters over cheaper alternatives? 

Unlike lower-cost options that wear out fast in corrosive ESP settings, our heaters use durable materials like Incoloy, offering longer life and fewer replacements. For procurement heads, this means better value over time, with reduced maintenance expenses and improved system uptime that justifies the investment. 

Can your heaters be installed in older ESP systems without major retrofitting? 

Yes, with flexible configurations like strip or bent tubular designs and mounting options such as clips or flanges, our heaters adapt to existing hopper or duct layouts. This ease of retrofitting saves purchasing managers from costly redesigns, making upgrades quick and cost-effective for legacy equipment. 

How do your ESP heaters support high-throughput industrial operations? 

Built to handle continuous use with power ratings up to 10 kW, our heaters maintain steady performance in high-ash, high-volume ESP systems like those in power plants. This capacity ensures uninterrupted dust collection, offering sourcing professionals a solution that meets the demands of large-scale production without faltering. 

What testing backs up the reliability of these heaters in harsh ESP environments?

Our heaters undergo extensive stress testing for heat, corrosion, and moisture resistance, simulating real-world ESP conditions like acidic flue gases. This proven durability gives procurement teams confidence in a component that won’t fail prematurely, reducing risks and supporting long-term system reliability. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Electrostatic Precipitator (ESP) Heaters

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