Use of Immersion Heater in Chemical Process Applications

An immersion heater is a direct contact heating equipment that is positioned into the liquid that needs to be heated. The heating equipment runs on electricity. Apart from various residential uses, the immersion heater is also used in chemical industries. These are special industrial immersion heaters that are used for heating large amounts of liquids, chemicals, or oils.

How Does the Immersion Heater Work? 

The heating equipment is made up of a bundle of tubes to efficiently transfer the heat. The immersion heater is mounted on one side of the container, completely submerged in the liquid. The heating coils that are exposed to the liquid within the container, transfer the heat that it generates to the surrounding liquid. 

Immersion heaters are available in various kilowatt ratings, sizes, voltages, and terminations. When it comes to the usage of heaters for chemical processing, it needs to be done in the appropriate way for smooth operations. The heaters can be divided into two categories for chemical processing – pressurized closed systems and non-pressurized systems.

Pressurized System:

The square flange immersion heater (ideal for applications that require higher wattages) is used in industrial water boilers and storage tanks to hold degreasing solvents and fluid oils or to heat-transfer the fluids. The heater consists of a flat tubular heater brazed with four to six screw lugs or threaded stud terminals for wiring connections. The heater connects directly to the connecting valve. The flange can be unbolted anytime, thus replacing the heater. It is a great way of reducing the extensive downtime of the equipment.

The applications of this heater are high-purity water, oils, caustic cleansers, chemical baths, glycol solutions, water processing, and clean-water rinse tanks.

The ANSI flange heaters through the side heaters. They require high wattage in large tanks. They are used for high-pressure applications like superheated steam, compressed gases, or liquids. 

On the other hand, circulation heaters are designed for the efficient flow of heat through their thermally insulated heating chamber. The heater has an inlet as well as an outlet piping and liquid or gas flows through it. The design has a precise and quick heat distribution. So, if you are heating the applications that need lower wattage, you can choose this. Booster heaters are a form of circulation heater used for heating water and oils respectively. 

Non-Pressurized Systems:

Suitable for tanks where side installation is impossible, over-the-side- heaters hang on one side of the container or sit at the bottom. They are either L or O-shaped and provide even heat distribution. The best part is that they are portable and can be easily removed for cleaning heaters and tanks. They are available in a variety of optional sheath materials, kilowatt ratings, and terminals according to specific requirements. 

They are designed for heating water, solvents, oils, salts, and acids. This tool is mostly used to avoid freezing a product.  This tool can also be used as an oil immersion heater as they are apt for melting the highly- sensitive material. The pre-wired thermostat in the over-the-side-heater protects from overheating. 

Having said that, each of the heaters has its own set of features and benefits. The square flangs are more affordable and economical, whereas the ANSI flange heaters are usually more costly. 

Final Words…

The usage of immersion heaters in the chemical process enhances operational efficiency. The ability of the immersion heaters to regulate the temperature of a wide variety of materials and low maintenance is what makes them a versatile tool. You too can invest in high-quality immersion heaters from a reliable manufacturer like Patel Heaters & Control Pvt. Ltd for a smooth flow of operations. It will not just enhance the performance of the product but will also set your mind at ease.