Electric Heating Elements for Process Pump Temperature Control
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Solution Overview
Problem
Existing heating systems for pumps, such as cartridge, platen, and blanket heaters, face limitations including long heat-up times, radiation heat loss, high cost, and space constraints, making them inefficient and impractical for various applications.
Innovation Solution
Integration of electric heating elements, including flexible membrane heaters, band heaters, and thermocouples linked to a controller, which can be applied to existing pump designs to provide efficient and controlled heat tracing in both stationary and mobile settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cartridge heaters are used to heat pump components, then temperature control is achieved, but heat-up time increases due to long heat transfer path and large thermal mass
Solution Approach 1:
The patent extracts the heating function from traditional cartridge heaters and relocates it to the mechanical seal assembly, which is in direct contact with the pumped material. This eliminates the long heat transfer path through pump casing and piping, enabling rapid heating of the material without heating the entire pump structure.
Solution Approach 2:
The mechanical seal assembly serves as an intermediary heating element that directly contacts the pumped material. Instead of heating the pump casing and relying on thermal conduction to the material, the seal assembly acts as a localized heat source that transfers thermal energy directly to the material at the point of contact.
2Loss of energy
If cartridge heaters are positioned close to the material for efficient heating, then heat transfer improves, but space constraints and geometry limitations restrict placement options
Solution Approach 1:
The patent makes the mechanical seal assembly multi-functional by combining its sealing function with a heating function. The seal assembly, which is already present in the pump system for sealing purposes, is equipped with heating elements to provide localized heating, eliminating the need for separate heaters and accommodating space constraints.
Solution Approach 2:
The heating elements are nested within the mechanical seal assembly structure. The seal assembly contains the heating elements, which are integrated into its components, allowing the heating function to be embedded within the existing pump architecture without requiring additional external space.
3Temperature
If traditional heating systems are used, then heating function is provided, but system bulk increases and mobility is reduced
Solution Approach 1:
The patent extracts the heating function from bulky external heating systems and relocates it to the compact mechanical seal assembly. This eliminates the need for external heating equipment, insulation layers, and associated support structures, significantly reducing overall system bulk while maintaining effective heating capability.
Solution Approach 2:
The heating elements are implemented as thin-film or flexible heating components integrated into the seal assembly, replacing traditional bulky cartridge heaters or external heating jackets. This enables effective heating with minimal additional volume and weight.
4Temperature
If cartridge heaters are used, then temperature regulation is achieved, but radiation heat loss increases due to distance from material
Solution Approach 1:
The patent extracts the heating function from distant cartridge heaters and places it directly at the material contact point through the mechanical seal assembly. This eliminates the radiation heat loss associated with distance by ensuring the heat source is in direct contact with or extremely close to the pumped material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables faster heat transfer, reduced costs, and improved control over heating zones, addressing the inefficiencies of traditional heating systems while being adaptable to different pump types and applications.
Implementation Method 1
electric heating elements, including flexible membrane heaters, band heaters
Implementation Method 2
thermocouples linked to a controller
Data Source
AI summary
Electrically heated pumps are disclosed that include electric heating elements that are linked to a process controller. In a magnetic drive pump, the external jacketing on the pump head, pressure relief valve and casing can be replaced with electric heating elements attached to the pump through the use of adhesive or mechanical fastening devices. For the bracket portion of the magnetic drive pump, the external jacketing can be removed and the heating element is attached to the canister that contains the liquid and that is located between the inner and outer magnetic drive assemblies. Through the use of appropriately placed thermocouples in the head, pressure relief valve, casing, bracket, canister, etc., and a single or multi-channel on/off, proportional or PID controller, the heating zones may be linked together, monitored and controlled to the application requirements. The disclosed pump designs may also be applied to auxiliary equipment such as strainers.