Abstract: Under the "dual carbon" initiative, replacing traditional fossil fuels with high-power green energy heating has become an inevitable trend. Ensuring stable operation of high-temperature, high-voltage, and high-power electric heating systems hinges on optimizing their internal structural design. This study conducts comparative analysis of heat sources, insulation materials, and outer wall materials for electric heating tubes in high-power systems. Through systematic research, we establish design principles applicable to various petrochemical heating scenarios across different temperature ranges. The findings provide theoretical guidance and practical references for implementing large-scale green energy heating solutions in petrochemical industries.