When you need to heat large quantities of fluid in an efficient and cost-effective manner for your plant or facility, industrial immersion heaters are the only type of equipment up to the task. Electric immersion heaters are versatile and incredibly effective components used for regulating the temperature of process solutions, oils, heat transfer fluids, corrosive chemicals and more. The range of design styles and their high level of customization make immersion heaters perfect for industrial applications of all types for a wide variety of industries. However, it’s essential to choose the right type of immersion heater for your specific application to receive the maximum benefits it offers. By selecting an industrial immersion heater optimized for your particular application, you’ll reduce costs, improve your efficiency and output, increase the safety of your facility and give your immersion heater lasting longevity. Throughout this article, we’ll cover everything you need to know about immersion heaters and outline how to select the best type to suit your specific needs.
BY HEATMAX HEATERS
Before we dive deeper into specifics, let’s cover the fundamental question, “What is an immersion heater?” Electric immersion heaters (sometimes called bayonet heaters) are an industrial solution for heating liquids stored inside processing equipment such as tanks, process pipes, pressurized vessels, vats and more. Every immersion heater is outfitted with heating elements used for direct heating of various industrial mediums. An immersion heater can operate in different environments while delivering consistent performance – whether it’s used for a pure water tank or a corrosive solution. Electric immersion heaters are a cost-effective and ecological method for heating mediums while providing a clean energy source without leaving pollutants or residual discharge.
Industrial immersion heaters are used in a variety of industrial mediums for specific purposes. These mediums commonly include water, oil, highly viscous liquids, processing gas, hazardous chemicals and more. For example, electric immersion heaters are often used in water tanks for enhanced freeze protection in cold months and in oil tanks to regulate and maintain the proper viscosity of the oil. Because the elements are fully immersed in the medium, an immersion heater has a near 100% efficiency rating – proving their advantage over other heating methods like steam or boiler systems.
All industrial immersion heaters feature an electric-resistant heating element encased within an enclosed jacket and sheath. Once the element is directly inserted at the top of the tank or through a side fitting, electricity will run through the heating element generating heat which spreads through the liquid medium. The amount of time it takes to heat a medium depends on the quantity of liquid, the immersion heater’s power level, insulation, and the conductivity of the heating element materials.
Electric immersion heaters can be divided into several distinct designs based on how they are inserted into the medium being heated. Several common varieties are used more often than others, but as technology has developed to allow for more innovation, the varieties of industrial immersion heaters have grown. When choosing an industrial immersion heater, note the tank size and design to find the best-suited type for your application. At Heatmax, we carry the following immersion heaters:
Now that you know what an electric immersion heater is, what they do, how they work and the different varieties you have to choose from, it’s time to get into the specifics that will help your heater work at total efficiency and have a long lifespan. These are some of the most important elements to consider before ordering your industrial immersion heater.
One of the first considerations when looking for your electric immersion heater is sheath material. It’s essential to find the proper sheath material for your application, as unique sheath materials react differently to certain liquids. If you, by chance, use your industrial immersion heater in a medium with the incorrect sheath material, it can lead to a critical failure of the equipment. Nickel-based, corrosion-resistant alloys are the most common due to their superior strength at high temperatures. At Heatmax, we offer sheath materials made from copper, stainless steel, titanium and incoloy. Specialty alloys such as hastelloy, incoloy 600, monel and alloy 20 are also available.
The watt density (watts per square inch) of your industrial immersion heater is determined by the thermal properties of the medium and process temperature. In application, watt density accounts for the electric immersion heater’s operating temperature for a given set of fluid conditions. In general, the more viscous the medium is, the lower the watt density of the electric immersion heater will be. The lower the watt density is, the larger the physical size of the immersion heater will be. To calculate your required watt density, consult a Heatmax sales engineer.
The next factor to consider for your industrial immersion heater is wattage, which will determine its capability to deliver the necessary temperature. Three elements factor into determining the required level of wattage:
At the core of a heating element is a resistance wire, or heater coil, that creates heat as electricity flows through it. The resistance wire is made from a combination of nickel and chrome with refractory metals such as tungsten, molybdenum or tantalum encased in stainless steel or titanium. A majority are then insulated with magnesium to act as a filler between the heating element and sheath. The composition of these heating elements can vary depending on the medium being heated. At Heatmax, we make our elements in-house, allowing for more precise engineering to your specific medium and a faster turnaround time.
