--- title: "High-Power DC Electric Duct Heater" url: "https://xgthermal.com/products/high-power-dc-electric-duct-heater/" language: "en" --- # High-Power DC Electric Duct Heater Project-engineered process-air heating powered by solar PV and suitable industrial DC systems. Equipment Overview ## DC electrical power. Industrial process heat. XGTHERMAL's High-Power DC Electric Duct Heater is engineered for industrial process-air heating from solar PV and other suitable DC power systems, with project-specific electrical, thermal and control integration. A completed 500 kW / DC1000V photovoltaic-powered project demonstrates the application of high-power DC resistance heating in an industrial refinery environment. [Discuss Your Requirements](https://xgthermal.com/contact.html) ![Concept illustration of a high-power DC electric duct heater](https://xgthermal.com/images/products/product-details/high-power-dc-electric-duct-heater-concept.webp) Concept illustration. Final construction follows the approved project design. ### DC1000V reference 500 kW photovoltaic-powered project configuration. ### Modular heating groups Five 100 kW groups in the completed reference project. ### Plant control integration PLC-based local / remote operation and communication. Applications ## DC-powered process-air heating for industrial applications. The heater is configured around the available DC electrical architecture and air-heating duty. Daqing Refining is the completed reference; other applications remain subject to engineering review. ### Solar PV Process-Air Heating Uses photovoltaic electricity as the energy source for industrial process-air heating. ### Industrial DC-Bus Heating Duct-air heating integrated with a suitable industrial DC power architecture. ### Refinery & Petrochemical Air Heating Process or utility air heating where a suitable DC supply is available. ### Industrial Electrification Projects Electric process-air heating for facilities increasing the use of electrical energy. Engineering & Operation ## From solar electricity to heated process air. Photovoltaic-electric heating (PV-EH) converts solar-generated electricity into useful industrial heat. In a direct-DC architecture, the duct heater is the thermal load within the project’s electrical system—a form of industrial Power-to-Heat, also described as PV-to-Heat. Selection combines the air-heating duty with DC voltage and current, switching and protection, heating-group arrangement, temperature control and plant integration. - Solar PV → project DC power system → approved DC interface → duct heater → heated process air. - Heating elements and airflow design matched to thermal duty and pressure-drop limits. - Heating groups, connection equipment and controls engineered together. - XGTHERMAL’s heater-side scope is defined separately from PV generation and DC power management unless expressly included. [Explore Solar PV & Direct-DC Heating](https://xgthermal.com/solutions/direct-dc-solar-pv-process-heating/) 01 ### PLC-Based Control The reference project uses a Siemens SIMATIC S7-200 SMART PLC for heater-system control. 02 ### Modular Heating Groups The 500 kW reference configuration is divided into five 100 kW heating groups. 03 ### Overtemperature Protection Heating-group temperature monitoring and overtemperature protection are provided. 04 ### Local / Remote Operation The reference system supports both local and remote operating modes. 05 ### Plant Integration DCS signals and Modbus RTU / RS485 communication are supported in the reference project. Technical Data & Delivery Scope ## Review the details that matter. The 500 kW / DC1000V values describe the completed reference configuration, not a fixed rating for every heater. Final ratings, protection and certification follow the approved project design. [Request a Datasheet](https://xgthermal.com/contact.html) ### Specifications | Specification Parameters | Specification Details | | --- | --- | | Rated Heating Power | 500 kW | | Power Supply | DC1000V | | Heating Groups | 5 × 100 kW | | Heated Medium | Air | | Installation | Duct / inline air heating | | Control System | PLC-based | | Reference PLC | Siemens SIMATIC S7-200 SMART | | Operation | Local / remote | | Plant Interface | DCS | | Communication | Modbus RTU / RS485 | | Temperature Protection | Heating-group overtemperature protection | | Power Application | Photovoltaic-powered industrial heating | ### Standards & Certification | Area | Engineering Position | | --- | --- | | Hazardous-area engineering | Reference-project procurement identifies the 500 kW unit as an Ex electric heater. Final construction and marking must be confirmed for each project. | | Explosion-proof design basis | GB/T 3836 / IEC 60079 may be reviewed according to the required project configuration. | | Destination-market certification | ATEX / IECEx / EAC certification routes can be evaluated where required by the destination market and final equipment configuration. | | EU electrical conformity | European-market requirements must be assessed against the final electrical design and supply scope. | Certification availability depends on the final equipment configuration, destination market, hazardous-area classification and third-party assessment. Listed standards describe engineering and documentation support, not blanket certification for every configuration. ### Supply Scope | Typical Heater-Side Scope | Scope Boundary | | --- | --- | | DC electric duct heater assembly | Configured to the approved thermal and mechanical duty | | Heating elements / heating groups | Grouping and ratings confirmed during project engineering | | Electrical junction / connection equipment | Heater-side interface matched to the agreed battery limit | | Temperature instrumentation | Monitoring and protection points defined during engineering | | PLC-based heater control | Local / remote control and approved operating logic | | Plant interface | DCS and communication interface as specified | | Project documentation | Final document list agreed with the purchaser | Selection Support ## From operating conditions to a practical equipment review. Share the process-air duty and DC supply envelope so we can review the thermal load, electrical interfaces and control requirements. ### What to share with our team. Air heating requires airflow, air properties, temperature rise and operating pressure, together with the DC supply and protection architecture. The flowing-liquid calculator does not apply to this equipment. - Airflow and operating range - Air composition if not ordinary clean air - Inlet and target outlet temperature - Normal / minimum / maximum airflow - Design pressure and allowable pressure drop - DC supply voltage and available DC power - Minimum / normal / maximum DC operating conditions - Upstream DC power-system architecture - Ambient conditions and hazardous-area classification - Required destination-market certification - PLC / DCS and local / remote requirements - Communication, alarm and shutdown requirements [Send Your Specification](https://xgthermal.com/contact.html) ### Common engineering questions. What is a high-power DC electric duct heater? It is a project-engineered resistance heater that uses a DC electrical supply to heat industrial air flowing through a duct or inline heating section. Can the heater operate with photovoltaic power? Yes, when the heater interface and upstream power architecture are engineered together. XGTHERMAL’s completed reference used photovoltaic electricity with a DC1000V heater interface. What is photovoltaic-electric heating (PV-EH)? Photovoltaic-electric heating (PV-EH) uses electricity generated by photovoltaic systems as an energy source for useful heat. In industrial applications, the electrical and thermal architecture depends on the project's PV/DC power system and process-heating requirements. Does XGTHERMAL supply the photovoltaic power system? Not automatically. The heater-side scope is defined separately from photovoltaic panels, power conversion, storage and plant-wide energy management unless those items are expressly included. How is heater power divided and controlled? Heating groups are arranged to the approved electrical architecture and control philosophy. The 500 kW reference project uses five 100 kW groups with PLC-based control. Can the heater be engineered for hazardous areas? The reference procurement identifies the unit as an Ex electric heater. Final hazardous-area design, marking and certification route must be confirmed for each project. What information is required for heater sizing? Provide the air duty, operating temperatures, flow range, pressure limits, DC supply envelope, upstream system architecture, installation conditions, area classification and plant-control requirements. Manufacturing & Project Experience ## 500 kW of heating. A completed DC reference. XGTHERMAL engineered a photovoltaic-powered electric heating system for industrial air heating, with a DC1000V interface and five 100 kW heating groups. [Review Our Capabilities](https://xgthermal.com/about.html) ### PV-Powered Industrial Air Heating Project The reference configuration combines duct-air heating with PLC-based local / remote operation and plant-control integration. - 500 kW heating capacity · DC1000V electrical interface. - Five independently arranged 100 kW heating groups. - Siemens SIMATIC S7-200 SMART PLC. - DCS signals · Modbus RTU / RS485 communication. [View Project Details](https://xgthermal.com/projects/pv-powered-dc-industrial-air-heating/)