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Immersion Heaters
Customizable
Product Catalog
Immersion Heaters
ELEKHEAT offers high-performance immersion heating solutions designed for precise and efficient heating in liquids, ensuring reliable performance across industrial and commercial applications.
Immersion heaters use resistive heating elements, made from durable materials like stainless steel or Incoloy, to heat liquids directly. They ensure rapid, uniform heat transfer and precise temperature control, with compatibility for thermostats and external controllers. Customizable in power, size, and materials, they are ideal for water heating, chemical processing, and industrial tanks.
Immersion Heater Applications
1.Industrial Processing
- Chemical reaction tanks
- Oil reservoirs
- Plating baths
2.Food and Beverage
- Pasteurization tanks
- Brewing kettles
- CIP systems
3.Energy and Power
- Boiler systems
- Solar water tanks
- Thermal storage units
4.Marine and Offshore
- Ballast water tanks
- Ship fuel tanks
- Offshore equipment
5.Automotive and Transportation
- Engine oil heaters
- Coolant reservoirs
- Fuel storage tanks
6.HVAC and Residential
- Domestic water heaters
- Central heating boilers
- Pool heaters
Product Lines
Flanged immersion heaters are composed of several key components engineered to meet specific operating conditions, ensuring efficient and reliable heating for industrial applications. Below is a detailed breakdown of their structure and features:
Heating Elements
- The heater consists of multiple electric heating elements, typically in a hairpin shape, either brazed or TIG welded for durability.
- The watt density (W/cm²) is carefully selected to match the application’s operating conditions and liquid medium.
- Materials for the heating tubes include stainless steel (AISI 321, AISI 316L, AISI 309) and high-performance alloys such as Incoloy 800/825 or Inconel 600, chosen based on environmental factors and temperature requirements.
Flange Design
- Flanges are manufactured to conform to various standards, including DIN, ASA, or custom specifications.
- The flange dimensions are calculated based on the required pressure and operating temperature, with sizes ranging from DN80 PN10 (3″ 150 lbs) to DN2500 PN250 (100″ 1500 lbs).
- The sealing system, whether single elastomeric (SEM) or double elastomeric (DEM), is chosen to ensure a reliable and leak-proof connection.
Electrical Connection Box
- Made from protected steel or stainless steel, the connection box houses the electrical terminals.
- Cable entries are sized to accommodate the number and power of the heating elements, with optional integration of a temperature control system for precise regulation.
- For operating temperatures above 110°C, an offset connection box is used to maintain junction box temperatures below 80°C for added safety.
Heating Bundle Dimensions
- The heating bundle consists of a specified immersion length and a diameter determined by the number of heating elements and the welding configuration.
- The total power output and maximum watt density (W/cm²) dictate the number and arrangement of heating elements.
Key Features
1.Construction:
Heating elements formed into two or three forks and cross-soldered onto a screw plug, available in brass or stainless steel.
Maximum working pressure of 15 bar.
Heated length must always remain submerged to ensure efficient heat transfer and prevent damage.
Optional thermostat cover for precise temperature control.
Electrical Circuits:
Compatible with 230V circuits (connection bridges included).
Designed to operate in conditions where fluid temperatures exceed 110°C.
Terminal boxes offset by 110 mm to protect connections from high temperatures.
2.Material Options:
Heating elements available in stainless steel (AISI 321, AISI 316), Incoloy (800, 825), or copper, depending on the application and liquid type.
Model Specifications
Material | Specific Load (W/cm²) | Applications | Thread Size |
|---|---|---|---|
Stainless Steel AISI 321 | 2 W/cm² | Air, oil, and heavy fuels | M45 x 200, M77 x 200 |
Stainless Steel AISI 316 | 4 W/cm² | Water and hot oils | Customizable |
Copper | 8 W/cm² | Water | M77 x 200 |
Incoloy 800 | 10 W/cm² | Water | Customizable |
Incoloy 825 | 12 W/cm² | Water | Customizable |
Bottom Tank Immersion Heaters
Bottom tank immersion heaters are designed for placement at the base of tanks to provide uniform heating for liquids. These heaters are built with 3 or 6 tubular heating elements arranged in a circular pattern, brazed or welded to a brass, steel, or stainless steel screw plug.
Key Features:
Watt density and heating tube material are tailored to the liquid being heated.
Supplied with terminal links, seals, and nuts.
Available for 230V and 400V circuits, with options for 1-phase or 3-phase configurations.
Optional pocket (Ø 6.5 mm internal) for additional functionality.
Material | Thread Size | Specific Load (W/cm²) | Applications |
|---|---|---|---|
Stainless Steel AISI 321 | M45 x 200 | 2 W/cm² | Oil, heavy fuels |
Copper | M77 x 200 | 8 W/cm² | Water |
Accessories
Threaded immersion heaters are compatible with a variety of mounting hardware and optional components to enhance functionality and ease of installation:
Mounting Hardware: Suitable for all threaded models, available in brass or stainless steel.
Accessories:
Joints
Nuts
Flanges for soldering
Terminal covers
Terminal boxes
Usage Recommendations
Ensure the heated length is always submerged to maintain efficiency and prevent damage.
Select materials based on the type of liquid and desired watt density.
Use optional thermostat covers for temperature control in demanding applications.
ELEKHEAT’s threaded immersion heaters deliver reliable, efficient heating solutions tailored to diverse industrial needs, ensuring long-lasting performance and customizable configurations.
Tank Heaters
RBA Series – Immersion Heaters for Tanks
The RBA Series immersion heaters are specifically designed for water heating applications, offering efficient and reliable performance. These heaters are constructed from high-quality stainless steel and feature advanced designs to ensure durability and optimal heat transfer.
Key Specifications:
Materials: Heating elements made of stainless steel tubes (AISI 321 or AISI 316L) or Incoloy (Ø 8.5 mm, 10 mm, or 16 mm).
Construction: Single or double pin heating elements mounted on a sheet, securely welded to a waterproof case for maximum reliability.
Riser Tube: Stainless steel riser tube in AISI 321 or AISI 316L for added durability.
Specific Charge: 2 W/cm², ideal for water heating applications.
Voltage Options: Compatible with 230V–400V power supply, available in 1-phase or 3-phase configurations.
RBI Series – Immersion Heaters for Tanks
The RBI Series immersion heaters are designed for heating fuels, ensuring efficient and safe operation in demanding industrial applications. These heaters feature robust construction to withstand harsh conditions.
Key Specifications:
Materials: Heating elements made from stainless steel AISI 316 Ti for corrosion resistance and high-temperature durability.
Specific Charge: 4 W/cm², optimized for heating various fuels.
Applications: Designed specifically for fuel tanks and related heating requirements.
Voltage Options: Supports 230V–400V in both 1-phase and 3-phase configurations.
The RC Series Base Pump Heaters are designed for efficient heating of heavy fuel oil in industrial applications, ensuring smooth operation of upstream suction devices. These heaters are introduced into tanks through the manhole and are built to withstand demanding conditions.
Key Specifications:
Materials: Heating elements are constructed from stainless steel AISI 321 or AISI 316L, providing excellent durability and resistance to harsh environments.
Specific Load: Low surface charge density of 2 W/cm², ideal for heavy fuel oil heating.
Design: Features 3 or 6 tubular elements, designed for uniform heat distribution and efficient energy use.
Riser Tube: Equipped with a Ø 42.4 mm riser tube and an adjustable height fastening system for flexible installation.
Optional Sensor: Temperature sensors can be integrated for precise temperature monitoring and control.
Voltage: Compatible with 230V–400V power supply in 1-phase or 3-phase configurations.
Contact Elekheat today by dialing 008618914757574 or use our contact form ,We are happy to answer any questions. Elekheat is your best partner for heating element solutions!
Immersion Heaters: General Specifications
| Specification | Details |
|---|---|
| Voltage | Standard: 120V, 230V, 400V, 480V. Custom options available upon request. |
| Wattage | Range: 500W to 500kW depending on model and requirements. |
| Watt Density | 1 W/cm² to 12 W/cm², adjustable based on heating requirements. |
| Materials | – Stainless Steel: AISI 321, AISI 316L – Incoloy: 800, 825 – Copper – Titanium. |
| Operating Temperature | Standard Range: -200°C to 650°C (material-dependent). |
| Heating Element Types | Tubular, Hairpin-shaped, or customized elements for specific requirements. |
| Installation Options | – Flanged Immersion Heaters – Threaded Immersion Heaters – Over-the-Side Heaters – Bottom-Mounted Tank Heaters. |
| Power Supply | Single-phase and three-phase power supply options available. |
| Certifications | Certified to ISO, CE, UL, and CSA standards (region-specific). |
How do I extend the lifespan of an immersion heater in industrial applications?
1.Choose the Right Material: Match the material (e.g., stainless steel, Incoloy) to the liquid type.
2.Ensure Proper Submersion: Always keep the heating element fully submerged.
3.Use Temperature Controls: Install thermostats to prevent overheating.
4.Regular Maintenance: Clean scaling or sediment and inspect for corrosion.
5.Monitor Watt Density: Select an appropriate watt density for your application.
Why Partner with ELEKHEAT?
- Global Reach: Trusted by clients in over 40 countries, we bring international expertise to every project.
- Proven Expertise: Established in 1997, we have nearly three decades of experience in delivering high-performance heating solutions.
- Custom Solutions: Tailored designs to meet the specific needs of high-temperature and corrosive environments.
- Reliable Quality: ISO-certified manufacturing ensures durability and consistent performance in demanding conditions.
- Technical Support: A dedicated team of engineers providing end-to-end assistance, from concept to deployment.
Have a Question?
At ELEKHEAT, we’re here to provide the answers you need. Whether you’re looking for product information, technical specifications, or need assistance with maintenance, our team of experts is ready to help. Don’t hesitate to reach out—we’re committed to ensuring you get the support you need for the best heating solutions.
- Selection Guide
- Installation Guide
- Resource Center
When selecting an immersion heater, it is crucial to evaluate the specific requirements of your application. The type of liquid being heated, such as water, oil, or corrosive chemicals, determines the choice of materials. Stainless steel, Incoloy, or copper are commonly used to ensure durability and compatibility with the fluid and operating environment.
Voltage, wattage, and watt density are critical to achieving optimal heating performance. Low watt densities are suitable for delicate applications, while high densities enable rapid heating. Proper submersion length and positioning of the heater are equally important for uniform heat distribution and system efficiency.
Design configurations should align with the application’s size and complexity. Flanged heaters are ideal for large tanks and industrial setups, while threaded heaters are better suited for pipelines and compact tanks. For high-pressure or hazardous environments, heaters with explosion-proof enclosures or high-pressure ratings offer added safety.
Temperature control options, such as integrated thermostats or external controllers, enhance precision and operational efficiency. Additionally, selecting heaters that comply with standards like UL, CSA, or ISO ensures safety and reliable performance. ELEKHEAT offers customized solutions and expert guidance to optimize your heating systems for any application.
Selection Guide for Integrated Thermostats and External Controllers
When choosing between integrated thermostats or external controllers for immersion heaters, it is essential to consider application requirements, technical specifications, and compatibility. Below is a detailed selection guide:
| Criteria | Integrated Thermostats | External Controllers |
|---|---|---|
| Applications | - Water heating systems - Light-duty oil heating - Low-pressure or small-scale industrial use | - Multi-zone industrial heating - Chemical processes - High-pressure or complex systems |
| Temperature Range | Up to 150°C (moderate temperature) | Over 150°C (high temperature and precise control) |
| Control Features | Basic on/off or adjustable setpoints | Programmable, real-time monitoring, multi-sensor compatibility |
| Customization | Limited to pre-set temperature ranges | Fully customizable: supports RTDs, thermocouples, programmable PID |
| Installation | Pre-installed, simple setup, minimal wiring | Requires external mounting, wiring, and programming |
| Durability | Suitable for low-to-moderate environmental stress | Designed for harsh environments and demanding conditions |
| Cost | Cost-effective for standard applications | Higher initial cost but superior precision and control |
| Power Ratings | Up to 3 kW | 3 kW and above for high-power industrial systems |
| Additional Features | Compact, factory-assembled unit | Advanced safety features (overheat protection, alarms) |
Key Considerations for Selection
1.Application Complexity
For simple, standalone heating tasks, integrated thermostats provide a user-friendly and budget-friendly option.
For processes requiring advanced control or compliance with industry standards, external controllers are preferred.
2.Environmental Conditions
Integrated thermostats perform well in controlled or standard environments.
External controllers are recommended for challenging conditions, such as high humidity, high temperatures, or corrosive environments.
3.Power and Voltage Requirements
Check the wattage and voltage compatibility of the thermostat or controller with your immersion heater to ensure reliable operation.
4.Maintenance and Scalability
Integrated thermostats are easier to replace and maintain for single-unit applications.
External controllers allow for scalability and easy integration with other monitoring systems.
5.Standards and Certifications
Ensure the product meets relevant certifications such as CE, UL, or CSA for safety and compliance.
1. Pre-Installation Checklist
Inspect the Heater: Ensure no visible damage to the heater or its connections before installation. Avoid using damaged equipment.
Prepare the Surface: Clean the tank or pipe where the immersion heater will be installed. Use isopropyl alcohol or a similar solvent to remove oil, debris, and moisture.
Verify Specifications: Confirm the voltage, wattage, and compatibility of the immersion heater with your application requirements.
2. Tools and Materials Required
Adjustable wrench or spanner
Thread seal tape (for threaded heaters)
Torque wrench (if specified)
Electrical connectors and insulating tape
Temperature controller (optional, for precise heating control)
3. Installation Procedure
A. For Flanged Immersion Heaters:
1.Align the Heater: Position the flange on the matching tank flange. Ensure the heater elements are immersed in the liquid.
2.Secure the Flange: Tighten bolts or clamps evenly in a star pattern to create a uniform seal.
3.Check Gasket: Ensure the gasket is correctly placed to avoid leaks.
4.Connect Wiring: Follow the wiring diagram provided with the heater. Use appropriate electrical connectors and verify grounding.
B. For Threaded Immersion Heaters:
1.Apply Thread Seal Tape: Wrap the heater's threads with seal tape to prevent leakage.
2.Screw in the Heater: Insert the heater into the tank fitting and tighten securely with a wrench.
3.Ensure Proper Orientation: Verify that the heater is fully immersed when in operation.
C. For Over-the-Side or Bottom-Mounted Heaters:
1.Position the Heater: Place the heater into the tank with the elements fully submerged.
2.Secure the Mounting: Attach brackets or supports to hold the heater in place.
4. Electrical Connection
1.Verify Power Supply: Ensure the supply voltage matches the heater's rating.
2.Connect Wires: Secure the lead wires to the power source using proper connectors.
3.Temperature Control: Attach a thermostat or controller if required.
5. Operational Guidelines
Initial Testing: Run the heater at low power to confirm proper operation.
Avoid Dry Heating: Ensure the heater is fully submerged during operation to prevent element damage.
Periodic Inspection: Regularly check for corrosion, scaling, or wear on the elements.
6. Safety Precautions
Do not energize the heater before it is fully immersed.
Use proper grounding to prevent electrical hazards.
Monitor temperature to prevent overheating and damage to the tank or liquid.
7. Maintenance and Troubleshooting
Scaling Removal: Regularly clean the heater to remove scale buildup.
Replace Damaged Parts: Inspect connections, elements, and gaskets; replace as necessary.
Monitor Performance: Check for uneven heating or power fluctuations.
For further guidance or customized installation support, contact ELEKHEAT today.
Welcome to Elekheat Resource Center, your one-stop destination for comprehensive technical documentation and industry insights. Designed to support professionals across various sectors, our resource hub provides access to valuable information.
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