What is Immersion Heater, Its Types and Uses in Chemical Process Applications?

Immersion heaters are types immersed in oil, water, solvents, process solutions, molten substances, and gases, where they discharge all their heat in the liquid, which makes them 100% power-efficient. These heaters are provided in a wide range of sizes, voltages, kilowatt ratings, terminations, sheath substances, and accessories. They are generally custom engineered for a particular application.  

The necessary immersion heater configurations are the screw plug heater, flange heaters, pipe insert or bayonet, circulation, or in-line, booster, and of an over-the-side pattern. They are normally accessible in a spherical or a flat tubular design. The flat range can run at an increased watt density without heating the sheath much.   

Uses and Types  

These heaters have many applications in chemical processes. Understanding which heaters to point out and how to set up them can make a manufacturing procedure more cost-effective. Heaters also are classified into two types such as pressurized and non-pressurized systems.  

Pressurized systems  

The square flange immersion heater is employed in storage tanks holding degreasing solvents, industrial water boilers, fuel oils, heat-transfer liquids, and corrosive solutions. The assembly includes a circular or flat tubular heater welded to 4 or 6-bolt flanges with screw lug or attached stud terminals for wiring links. These heaters bolt instantly to an associate flange that is welded to a tank nozzle or wall. Assembly modification is as simple as unbolting the flange and changing the heater, so reducing extended equipment time out.  

The screw plug heater fixes an interlaced opening or half or full pipe merging in a tank wall. Applications involve highly pure water, caustic cleaner, oil, glycol solutions, chemical baths, liquid paraffin, clean water, and process water rinse tanks.  

ANSI flange heaters are through-the-side heaters for liquid immersion use that need high wattage in big tanks. The uses are the same to those of screw plug heaters, but ANSI flange heaters are employed in high-pressure use such as compressed gases or liquids, and superheated steam.

Pipe insert heaters are employed for heating liquids in very big storage tanks. The heater is fixed inside a pressure-tight bayonet pipe that couples to a flange link on the side of the tank, thus offering the pressure boundary that lets remove the heater without removing the tank.  

Circulation heaters are all-in-one components with the heater fixed inside its individually reclusive tank. The heater has an inlet, and outlet pipe and the liquid or gas flows through the tank. By the time the material comes out, it is heated to an appropriate temperature. This design has a quick response and even heat allocation.   

An innovative circulation heater is accessible for usage that need accurate temperature control for gases and different liquids. Quick-response heat exchangers offer a quicker thermal response and increased power in a smaller footprint when evaluated to most other traditional circulation heaters. These generally have low wattage needs and are one phase.  

Non-pressurized systems  

Over-the-side heaters are made into L and O shapes and are set up at a tank’s top, with the heated part dipped together on the side or at the base. These heaters give even heat allocation. They are portable, simply taken out for heater and tank cleaning, and give huge working area within the tank. A range of optional sheath substances, kilowatt ratings, terminal areas, and mounting processes are accessible. Often, these heaters are used for freeze safety.

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Two different over-the-side heaters are the vertical thin-profile loop heater is a tubular heater style that hangs on the side of an open drum, and the tank heater, that simply fits into the closure hole of a 55-gallon drum and is employed for melting heat-sensitive substances, for example, paraffin (wax), grease, lard, different oils, and viscous liquids.  

Cost comparisons  

Particular application features or requirements restrict most heater selections. Square flanges and screw plug heaters are usually the most cost-effective solutions. In contrast, ANSI flange heaters and circulation heaters are normally more expensive as their power and size needs are much higher. 


So, immersion heaters are an economically and ecologically sound process for heating substances and give a clean energy source without leaving remaining discharge or contaminants. Also, if you are looking for more details on these heaters, please follow Marathon Heater.