Immersion Heaters
Industrial immersion heaters are a fast and efficient way of heating up various liquid solutions in processing equipment, as well as in large tanks through the use of tank immersion heaters.
Heating up liquids using direct heat transfer allows for the liquid medium to quickly reach the desired temperature using electric heating elements such as flanged heaters, screw plug heaters, over the side heaters or immersion water heaters.
This application is commonly used in chemical processes, large petrochemical containers as well as large water containers that require fast heat up time. With minimal maintenance requirements, immersion heaters are an excellent solution to rapid heating in almost any industrial environment.
The use of electric immersion heaters has been more popular in the past several decades as rising costs of fuels (and the necessary infrastructure that comes with it) force individuals to select a more cost efficient way of heating their applications.
Ecologically conscientious groups have long advocated for cleaner energies to help save the environment. Electric immersion heaters have been known to use the cleanest form of energy, leaving no residual discharge and provide immediate heat transfer to any medium.
Types of Immersion Heaters
WATTCO manufactures a variety of immersion heaters including flanged immersion heaters, circulation heaters, inline heaters, and over-the-side heaters.
Flanged Immersion Heaters
Flanged immersion heaters have the ability to hold multiple hairpin elements that can be mounted onto the side of a container (commonly referred to as a tank immersion heater). Its versatility allows it to offer up to 750 KW of power on a single unit. Among its various uses include utility companies, defence contractors, petrochemical researchers and boiler manufacturers.
Learn more about our Flanged Immersion Heaters 
Circulation Heaters (or In Line Heaters)
Circulation heaters (or In Line Heaters) use flanged immersion heaters or screw plug heaters within a vessel chamber to heat up liquids from an inlet and expels the heated liquid through an outlet using the force of a pump to allow easy circulation.
The circuit of running liquid is then reheated to reach a target temperature. It is often referred to as the most efficient use of electric heating as heat is initially applied to liquid at ambient temperature, but then recirculated at an elevated temperature that does not require as much energy to reach your target temperature.
The use of insulation around piping and the tank itself allows the heat to be contained. The circulation vessel is often reinforced with high quality insulation that helps prevent heat loss.
Coupled with the use of a high quality alloy that prevents heat loss (high grade stainless steel) the unit is a complete system that allows users to use thermocouples, RTD temperature sensors or standard mechanical thermostats to maintain liquids at optimum temperatures.
Safety sensors are also available such as high temperature sensors to help prevent excessive heat or over temperatures. This protects both the liquid you are heating as well as protection to your industrial heater.
Use of Immersion heaters:
- Chemical Processing: It heats chemicals, acids, and other liquids in storage tanks and reactors and maintains their temperature.
- Oil and Gas Industry: Heats the crude oil and hydrocarbons, maintains the viscosity of oils, lubricants, and fuels, and prevents freezing.
- Water Treatment Plants: Allows heating water for coagulation and flocculation.
- Food and Beverage Industry: It heats water, oils, or other liquids for cooking, sterilization, and cleaning.
- Metal and Machinery Industry: Heats degreasers to remove contaminants from machinery.
- Power Generation: Heats fluids in boilers for steam production.
- Renewable Energy Systems: Act as a backup heater in solar thermal systems.
Learn more about our circulation heaters
Learn more about our in-line heaters
Over-The-Side Heaters
Over-the-side heaters are used to heat up larger containers of liquid that have openings. Immersion heaters and tank immersion heaters are often available with several different ranges of temperatures that can be fine tuned for extreme accuracy.
As such, very tight and efficient control can be maintained which has a positive effect on the performance of the industrial plant. Along with this, several mounting options can be also be availed which further facilitate processes. Examples include screw plug connections, over the side designs, 3 phase immersion heaters, immersion water heaters and flanges. There are several options for piping as well such as flanged, welded or threaded.
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WATTCO also manufactures other industrial heating solutions such as infrared heaters, screw plug heaters, pipe heaters and more. Click here to view all of our products.
Each type of immersion heater in Wattco’s product catalog comes with their own unique specifications. Please refer to their indivudual pages: Over the side heaters Circulation heaters Screw plug heaters Flange heaters
