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Efficient, application‑tuned heating for water, oils & process fluids
Flange, screw‑plug and side‑mount designs with engineered watt density, robust materials and hazardous‑location options.
Process‑driven sizing
Watt density matched to your fluid
Hazardous‑location options
ATEX/IECEx/NEC
Traceable materials
MTR & FAT reports
Product Categories
High‑power, pressure‑rated bundles for tanks and vessels.
30–1,500 kW · ASME B16.5 · Replaceable elements · EX options
Compact heaters for small/medium tanks with integral control options.
0.5–120 kW · 1″–3″ NPT/BSP · NEMA/IP enclosures
External‑access solutions for retrofits and easy maintenance.
5–300 kW · Removable bundles · Insulation kits
Hygienic, scale‑aware designs for water and aqueous media.
316L/copper · 10–20 W/cm² · Anodes optional
Compact heaters for small/medium tanks with integral control options.
0.5–120 kW · 1″–3″ NPT/BSP · NEMA/IP enclosures
Why choose Elekheat immersion heaters?
- Process‑driven sizing — heat‑up, hold and losses calculated; watt density tuned to fluid.
- Hazardous‑location designs — EX d/e terminal boxes, certified assemblies.
- Energy efficiency — high immersion efficiency, SCR/PID control, insulation options.
- Reliability — TIG‑welded elements, hydro‑tested heads, replaceable bundles.
- Lifecycle support — commissioning, spares, documentation, FAT.
Immersion Heater Manufacturing Process
Material Selection & Watt Density Guidelines
| Fluid Family | Typical Sheath | Suggested Watt Density | Notes |
|---|---|---|---|
| Potable/DI Water | 316L SS or Copper | 10–20 W/cm² | Consider low W/cm² for hard water; scale control. |
| Light Oils | Incoloy 800/825 | 2–8 W/cm² | Avoid hot spots; maintain flow across elements. |
| Heavy Oils | Incoloy 825 | 1–3 W/cm² | Preheat & recirculation recommended. |
| Caustic/CIP | 316L or Titanium | 4–12 W/cm² | Verify chloride stress corrosion risk. |
| Glycols/HTF | 316L or Incoloy | 3–12 W/cm² | Respect film temperature limits. |
How to Choose the Right Immersion Heater
Define the Duty
Heat‑up load: Q = m · Cp · ΔT. Required power: P = (Q / t) / η + losses with η ≈ 0.95–0.99 for immersion.
Set watt Density
Match to fluid film temperature limit; reduce W/cm² if viscosity or fouling is high.
Pick the Mounting
Flanged — high power, pressure‑rated vessels, easy element replacement. Screw‑plug — compact tanks, lower kW. Side‑mount — retrofit, external access, minimal downtime.
Materials & E. Controls
Materials: 316L, Incoloy 800/825, Titanium per corrosion & chlorides. Controls: PID/SCR primary, high‑limit cutout, level interlocks, E‑stop.
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What is an immersion heater?
An immersion heater is an electric heating element installed directly into a liquid or process tank so heat is transferred at the source. Powered by single- or three-phase supply, sheathed elements convert electrical energy to heat, controlled by thermostats or sensors. Common mountings are flange and screw-plug. Engineers select sheath alloys and watt density to match the fluid, avoid hot spots, and meet safety or hazardous-area requirements.
Immersion Heater Applications
Water & Aqueous Solutions (tanks, rinse baths, DI/RO storage)
Type: flange or screw-plug · Sheath: 316L/copper · Notes: manage scaling; add anodes.Light Oils & Fuels (diesel, hydraulic, lube)
Type: screw-plug or flange · Sheath: Incoloy 800/825 · Notes: low–medium W/cm²; SCR for ramping.Heavy/Viscous Oils (gear, crude, asphalt, bitumen)
Type: high-kW flange bundles · Sheath: Incoloy 825 · Notes: very low W/cm²; recirculation recommended.Chemical Processing (alkalis, caustics, CIP/NaOH, phosphates)
Type: flange/screw-plug · Sheath: 316L or titanium · Notes: verify chloride/SCC; use thermowells.Heat-Transfer Fluids & Glycols (HTF, MEG/TEG)
Type: flange with controls panel · Notes: protect film temperature; add high-limit cutout.Water Treatment (sludge, digesters, sand filters backwash)
Type: side-mount/flange · Notes: corrosion-resistant enclosures; NEMA 4/4X.Food & Beverage (syrups, oils, jacketed tanks, CIP tanks)
Type: sanitary designs · Sheath: 316L · Notes: hygienic seals; tight PID control.Oil & Gas / Hazardous Areas (separators, amine, produced water)
Type: EX d/e assemblies · Notes: ATEX/IECEx/NEC, T-class compliance, instrumentation interlocks.Plating & Surface Finishing (acid/alkaline baths, anodizing)
Type: immersion or side-mount · Sheath: titanium/316L · Notes: chemical compatibility first.Freeze Protection & Maintenance Heat (storage tanks, sumps)
Type: screw-plug/side-mount · Notes: thermostatic control with level/flow interlocks.Power & Utilities (deaerators, condensate, make-up water)
Type: flange · Notes: ASME flanges; redundancy for uptime.
FAQs for Immersion Heaters
Watt density (W/cm²) is power per element surface area; lower values reduce film temperature and protect sensitive fluids.
Yes. ATEX/IECEx/NEC compliant assemblies with EX d/e terminal boxes and T‑class ratings are available.
Match watt density to the fluid, maintain velocity across elements, use PID/SCR control to avoid overshoot, and apply filtration/softening where required.
Yes—UL‑listed panels with PID or SCR, high‑limit safety, level interlocks, alarms, and remote I/O for DCS/PLC.
Typical 2–6 weeks depending on configuration. Deliverables include GA drawings, wiring, IOM manual, and test reports.
