processheating

Process heating is the application of thermal energy to raise or maintain the temperature of a material, product, or intermediate as part of a manufacturing, fabrication, or processing operation. It encompasses methods that transfer heat by conduction, convection, or radiation, and is used to achieve target temperatures, heat-up rates, or residence times required by a process.

Common heat sources include combustion-based systems (gas or oil burners), electric resistance elements, induction coils, infrared heaters, microwave heating, and hot-fluid loops. Heating can be direct, where the material is exposed to the heat source, or indirect, where heat is transferred through a furnace wall or heat exchanger.

Typical applications span metal processing (annealing, hardening, tempering, braze and soldering), welding, coating and curing of polymers and composites, drying and dehydration, baking in food processing, and various chemical processes that require elevated temperatures.

Design and operation focus on efficient heat transfer, energy management, and process control. Engineers optimize heat transfer rates, temperature uniformity, and dwell times while minimizing energy losses. Heat integration and recovery, such as exhaust gas or hot-fluid recovery, can improve overall plant energy performance. Control strategies employ sensors, instrumentation, and automation to maintain setpoint temperatures and respond to disturbances.

Safety and regulatory considerations cover high-temperature equipment, combustible atmospheres, heat flux hazards, and proper energy isolation. Process heating remains a major component of industrial energy use, influencing product quality, throughput, and operating costs.