Causes of Infrared Heating Element Bursting and Precautions

During the use of infrared heating elements, improper usage or substandard product quality often leads to tube bursting. In mild cases, you only need to replace a component, but in severe cases, it may cause a fire, resulting in significant economic losses. To help prevent and avoid such issues, we will share some insights on this topic.

Analyzing the Causes of Tube Bursting: Product Quality Issues and Improper Usage

Product Quality Issues

1. Substandard Raw Material Quality: High-quality infrared heating elements are produced using premium dehydroxylated quartz tubes. However, many manufacturers (in fact, most of them) use non-dehydroxylated quartz tubes to save costs. More conscientious manufacturers may use high-grade, non-dehydroxylated quartz tubes, but a small portion of them only care about selling their products without considering their performance in actual use.
2. Inadequate Production Process: If the sealing process of the quartz tube is not handled properly, slow air leakage can occur. This can cause the tube to burst within seconds of use.
3. Incorrect Model Selection: If you select a heating element designed for 220V when your system requires 380V, and you use improper wiring, it will cause the heating element to overheat and eventually burst.
4. Inadequate Manufacturer Design: If the power per meter is designed too high, the internal temperature of the tube can rise excessively, causing expansion and increasing the likelihood of a tube burst.
5. Insufficient Protective Gas: If the protective gas does not meet the required process standards, it can lead to heat buildup, resulting in a tube burst.
6. Thin Wall Thickness of the Quartz Tube: Some unscrupulous manufacturers reduce material usage to cut costs, producing quartz tubes with walls that are too thin, increasing the risk of bursting.

Improper Usage

1. Mixed Use of Infrared Heating Elements: Some customers use heating elements intended for mold heating in open air, or use elements designed for liquid heating in air. Both scenarios can lead to tube bursting.
2. External Impact: If the infrared heating element is subjected to an external force or accidental impact during use, it may get damaged.
3. Impurities in the Heating Medium: When heating water or thermal oil, if the medium contains too many impurities, scale or carbon buildup can form quickly. If the user does not clean the tube surface regularly, the buildup thickens, preventing the heat from dissipating properly. This leads to internal overheating, causing cracking and bursting.
4. No Temperature Control: Failing to regulate the temperature of the infrared heating element can cause it to operate at the maximum permissible temperature for extended periods, which increases the risk of tube bursting.
5. Incorrect Wiring Method: Using the wrong wiring method, such as connecting in a delta formation when a star connection is required, can also cause overheating and bursting.

When selecting infrared heating elements, do not risk tens of thousands of dollars in losses just to save a few dollars on a substandard product. It’s important to have the system installed and used by professionals.

Precautions for Using Infrared Heating Elements

1. Operating Temperature: If the heating element operates at 200°C or more, specific precautions are required. Wiring must differ if the temperature exceeds 500°C.
2. Installation Angle: The heating element should be installed either vertically or horizontally.
3. Installation Spacing: There should be a spacing of 20mm between two heating elements.
4. Distance Between Heating Element and Product: The distance between the heating element and the object being heated should range from 20mm to 300mm.
5. Operating Environment: The environment should be clean, and the heating element should avoid contact with oil, water, or dust. If the equipment experiences significant vibration, appropriate shock absorption measures should be in place.
6. Installation Method: Quartz heating elements are fragile and should be installed using special mounting clips provided by the manufacturer. Handle with care during installation to minimize the risk of damage caused by human error.

By adhering to these precautions and using quality products, you can significantly reduce the risk of tube bursting and ensure the safe and efficient use of infrared heating elements.

At GlobalQT, we specialize in high-quality infrared heating elements. For more information, visit our website or contact us at contact@globalquartztube.com.