Immersion heaters heat various fluids in industrial applications and come in three types: side mounted, flanged, and screw cap. Over-the-side immersion heaters are easy to clean and use different heating elements. Flanged immersion heaters are easy to control and support high tank pressure. Screw cap immersion heaters are compact and ideal for frost protection and process water heating.
An immersion heater is a mechanism that heats a variety of fluid types, including water, oil, solvents, salts, galvanic baths and acids, used in industrial applications. Immersion heaters come in three varieties: side mounted, flanged and screw cap and are installed in a tank or other vessel. With the heating element immersed in the fluid it is heating, all of the heat is generated within the liquid and the immersion heater becomes nearly 100% energy efficient.
An over-the-side immersion heater is commonly used when installing a side immersion heater, such as a flanged or screw cap unit, is inconvenient. Over-the-side units are installed across the top of the tank. Its heat source is therefore along the side or bottom of the tank. This makes the unit easy to remove for cleaning and provides a generous amount of working space within the tank itself.
Over-the-side immersion heaters are constructed using a variety of heating elements, including steel, copper, cast iron, titanium and the Incoloy® alloy. The natural flow of liquid within the tank or vessel allows for even heat distribution. Over-the-side units are available with different kilowatt power ratings. They are constructed in different shapes and use different mounting methods, depending on the type of industrial application.
A flanged immersion heater consists of a tubular element bent into a hairpin shape and welded into a flange. A flange is a disc-shaped protruding edge that allows one object to be strengthened and/or attached to another object. A flanged immersion heater is installed by connecting it to the corresponding flange welded to the side of the tank. Flanged immersion heaters use a standard pipe flange ranging from 3 inches (7.6 cm) to 14 inches (about 35.6 cm) in diameter to support the high tank pressure of certain fluids.
Flanged units are available in many sizes and kilowatt ratings. They are among the most commonly used methods of heating fluids and are designed for use in all tanks, irregularly shaped pressurized vessels, and vats. Flanged immersion heaters are easy to control and energy efficient.
A screw cap immersion heater, also referred to as a bushing heater, is often used in industrial tanks and process pipelines. Like the flanged unit, a screw cap immersion heater consists of a tubular element bent into the shape of a hairpin. These units, however, are screwed directly into the tank wall through a threaded opening. They can also be screwed into a pipe fitting or weld flange. Screw cap units are available in a selection of sizes from 1/2 inch (1.27 cm) to 2.5 inch (6.35 cm).
Screw cap immersion heaters are also available in a variety of kilowatt ratings and in a variety of jacket materials. These compact heaters can be made using different types of thermostats. They are ideal for frost protection and process water heating.
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