Electric Hot Air Generator

Advantages of Electric Hot Air Generator;

• Chimney system, burner, fuel supply, storage are no longer needed, which saves money and reduces space requirements.
• Compared to a conventional boiler, they offer compact simple design, smaller footprint and weight.
• Simple installation and commissioning. There is no need for any ventilation.
• Flanged resistance heaters in accordance with DIN standards are used.
• With the SSR system, the energy power is driven proportionally.
• Precise temperature control
• Low maintenance and service costs
• Easy user interface with Tsb Energy control system.
• Non-pressurised energy production and transfer,
• High process reliability, remote control
• Conversion to thermal energy with an efficiency close to 100%.
• Low operating costs can be achieved by using cheap or renewable electrical energy,
• Its instantaneous response to peak traction with max power and its response to minimum usage with 1kW power if necessary is an excellent efficiency.
• Faster cold start is possible.
• There are zero emissions of COx, NOx and SOx at the user site.
• Quiet operation with virtually no noise emissions
• Customer-specific software revision with our expert staff specific to your company.
• The boiler can be optionally equipped with a PLC with different communication protocols such as Modbus, Profibus, etc. and thus boiler integration into any industrial process can be provided.

For higher hot air demand or fluctuating heat loads, several hot air generators can be connected in series (modular). Multiple systems like this are the right and economical solution.

The development of industrial electric boilers has become essential to cope with current environmental pollution. The Paris Agreement clearly states that global warming should not exceed 1.5 °C. For this reason, the energy sources used to generate electricity have evolved significantly in the last 10 years, with authorities in each country implementing policies aimed at promoting and supporting a rapid energy transition. Electrically heated industrial boilers have become an indispensable tool to deal with the dual challenges of energy optimisation and decarbonisation. At a time when wind power, hydropower and nuclear power can provide electricity without producing CO2, NOx and SOx, electric boilers have become a good environmental option.

TSB ENERGY offers future-orientated, electricity-based system solutions for industrial boilers. The focus is on resource conservation, reducing CO2 emissions and increasing the use of climate-friendly technologies.

Design: The Electric Hot Air Generator is designed and manufactured in accordance with TRD, DIN, EN, PED 2014/68/EC and ASME Section VIII Div 1 and all electrical components are UL labelled and wired in accordance with applicable National Electrical Code requirements.

The boiler is delivered ready for operation as a compact unit on a single chassis. The only action required is to connect the electric hot air generator to the electricity and to the devices that use hot air.

All our resistance electric boilers are designed to allow over-voltage conditions up to 10% without adversely affecting the integrity of the circuit components, and these resistances are controlled by SSR systems both to increase the service life and to supply energy in a proportional manner. 70-75 wpsi Incoloy sheathed elements are used in the system.

Hot air boilers are a completely special design. The most important point here is the turbulent contact of the heat-receiving fluid with all the surfaces contacted by the heat-giving fluid.

Since hot air boilers are designed based on the principle of economical and rapid movement of air, they provide economical heating for large volume processes.

Since the hot air outlet temperature can be kept within the desired range with the automated control of the fan and burner, it provides economical and high quality production in drying processes.

In hot air boilers, automation is provided either according to the ambient temperature or according to the outlet temperature and the desired temperature is maintained continuously in a proportional manner.

Ease of Use and Maintenance: The installation cost is much cheaper than other heating systems since the system consists of an air conveying ventilator of sufficient capacity, an air-to-air heat exchanger (hot air generator) and a burner.

It is easily maintained due to its simple structure and lack of control equipment. Failures such as freezing, bursting and flowing do not occur due to the air passing through it as a fluid.

The user-friendly PLC-HMI control unit provides easy access to components and simplifies operation and maintenance, minimising downtime and operating costs. One-button start-up, self-checking of the device to stop the system against possible errors, a panel with summary maintenance instructions with warnings according to the duration of use make it very reliable and understandable for the operator to use the electric hot air generator. Clean, smokeless, silent, reliable hot air is produced with a switch.

All security devices are monitored by PLC. Necessary safety measures are taken in case of alarm. Boiler control is carried out by the boiler operator via HMI. Active alarms and past alarms are monitored via the same HMI. Alarm and operation information is transmitted to other systems via digital contacts (dry contact). Remote data collection and boiler status information are available via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our boilers are equipped with advanced safety features such as high temperature protection, outer wall surface temperature protection, fan adequate pressure control, resistance surface temperature monitoring and emergency shutdown mechanisms. Since other heating systems are pressurised vessels, they require extreme safety systems, the malfunctions that may occur in these systems are dangerous and can cause major damage, such damage is not possible due to the non-pressurised nature of hot air boilers.

Material: Thermoblock, Hot Air Boiler All sheets of our generators are made of stainless steel in accordance with EN 10028-8. AISI304, AISI309 or AISI310S quality sheet metal is used according to the requested hot air temperature. Resistance sheath thickness up to 1mm provides high resistance to corrosion and mechanical loads. TSB ENERGY electric boilers are heated with seamless drawn tube AISI304, AISI316, AISI310S quality stainless steel resistances with a large heating surface.

Efficiency: It produces hot air within 3-5 seconds as soon as it is switched on, and stops heating when the system stops, so there are no storage and preheating as in boilers, so there are no standby losses, no unnecessary heat losses. For industrial applications, boilers must provide high operational reliability and availability. Tsb Energy's efficient energy systems offer exactly these qualities. TSB ENERGY electric hot air boilers are heated by stainless steel heating elements with a large heating surface. The output of the heating elements is regulated proportionally via solid state rollers. The most important energy efficiency advantage is the instantaneous modulating adjustment of the electrical output according to the actual heat demand during the operating cycle and the consumption of electricity according to the instantaneous demand.

Since all of the incoming electrical energy is converted into heat energy (only small heat losses caused by surfaces are deducted), an efficiency close to 100% is achieved.

HAB-E boilers consist of a stainless steel body, which offers numerous advantages in terms of performance, application and periodic maintenance.

Precise temperature control with multiple power cascading allows the boiler to react quickly to load changes. This enables it to perform fast cold starts when required, utilising the available grid power to its full capacity.

100mm thick high density front and rear door insulation provides low heat loss from radiation. The thermal insulation is covered with galvanised and painted DKP sheet with low lambda value. All insulation has low conductivity and high density materials.

Environmentally Friendly Design: Our zero emission electric steam boilers offer a cleaner alternative to traditional fossil fuel systems, helping you reduce your carbon footprint and achieve your carbon neutral goals.

To achieve these goals with industrial boilers, there is the option of power-to-heat: excess electricity from production peaks is used to run electric boilers in an economically and ecologically viable way in industrial and commercial applications.

Customisation: We know that every production and process has its own individual differences, and based on the analysis of your process, we optimise and customise our proven devices for you.

With our expert staff, our company designs and manufactures the most efficient, least maintenance-intensive electric industrial heat devices suitable for all processes and supports them up to the maintenance services during operation. Electric boilers put you on a more climate-friendly path and provide a system solution for the future.

Our experts will be happy to help and support you with your projects. If you have further questions, please do not hesitate to request an individual expert consultation. Our experts will review your project requirements together with you in order to reach the most ideal one.

What is Hot Air Boiler - Thermoblock?

Electric hot air boilers are closed non-pressurised containers with air as a heat-receiving fluid on one side of their surfaces and heat-giving electrical resistance elements (resistance) on the other side, with air flow walls specially designed according to the heat load , where electrical energy is used as a power source instead of fossil fuel.

When to Use Hot Air Boiler - Thermoblock?

Electric boilers are safe, versatile and easy-to-use heat sources for hot air production.
Electric boilers are used in areas where there is sufficient electrical energy or where it is not possible to remove exhaust gas from gas or diesel burners, where open ignition is prohibited or where fuels such as diesel or gas are not available. With the widespread use of solar panels and wind turbines, they are 0 emission heat generation devices that are preferred by businesses. Since it does not produce flue gas emissions, the company will not pay emission fees.

Ideal Hot Air Boiler Selection;

Hot Air Boiler - Generator - Thermoblock Where it is used;

•  Drying of bricks, briquettes, tiles and similar building elements
•  Drying of ceramic products
•  Drying of mine ore, fire soil and similar granular materials
•  In the manufacture of insulation materials
•  In artificial fertiliser production
•  Drying of timber, paper and similar products
•  Drying of soft products such as wool, cotton
•  Drying of powder detergent and similar powder or granular chemical products
•  Drying of dyed products
•  Drying of grain, wood dust, coal dust
• Drying of table salt, milk powder and similar foodstuffs

Hot Air Boiler-Thermoblock Advantages;

• The initial installation cost is much less than other industrial heating systems,
• It provides 25-35% financial savings due to low chimney outlet temperature and heat conduction rate compared to hot water and steam heating systems,
• Heating is provided upon switching on and there is no waiting time,
• There is no danger of freezing and leakage,
• The device operates automatically and safely.

Hot Air Boiler - Advantages of Thermoblock compared to other heat systems;
Accurate and Efficient Transmission of Produced Hot Air;

Hot air boiler - In industrial heating with thermoblock, duct diameters and cross-sections should be selected correctly, air velocities should not exceed the ideal range, all carrier ducts should be insulated with the required insulation material.