How to optimally use heaters for chemical processing

Immersion heaters are the most common choice of a chemical processing plant. Immersion heaters come in a huge variety of shapes and sizes which is best to function as chemical heating elements. All that a company needs to focus upon is what type of chemical heating elements they should select as this determines the final strategy to implement immersion heaters into their system.

Since immersion heaters are used for many different industrial applications, one needs to be familiar with the best choice of chemical heating elements available in the market. Immersion heaters as the name says are put in the solvent that they heat up. The solvent could be molten metals or non-metals, gases, water, oil or any other chemical.

Immersion heaters are highly energy efficient as they heat the liquid while releasing their energy but one needs to familiarise themselves on the different shapes and sizes, accessories, kilowatt ratings, voltages, terminations, sheath materials and the options to customise them as per your final need. The basic design of immersion heaters consists of a flange, a booster, a screw plug, an inline circulation and a pipe as per design. Most of them have a tubular design that handles higher watt densities easily.

The industrial immersion heaters are generally categorised into two groups:

1. Pressurised system: Such immersion heaters operate in storage tanks or water boilers where they are welded or brazed with a bolt flange that has an external interface terminals to connect the wiring. They are directly connected with the companion flange that is welded inside the tank wall or inside a nozzle. The assembly is very easy and it is easy to clean, maintain and replace by most companies when needed. They are generally used for caustic cleaners, clean water rinse tanks, processed water tanks, chemical baths, glycol solutions and liquid paraffin that need precise temperature control of the fluids. The high power they provide and the fast thermal reaction in small footprints makes them particularly useful when you also have to deal with low wattage consumption and single phases.
2. Non-pressurised system: These immersion heaters come in L and O shapes that are installed on top of the tank. They provide an even distribution of heat to the heated elements that are either at the bottom of the tank or on the sides. They are also easy to install, maintain and remove when the tank needs cleaning or the heater needs to be replaced or maintained. They are easily customised and manufacturers provide a huge range of options in terms of terminal enclosures, sheath materials, kilowatt ratings and their mounting methods. They are used to heat solvents, water, salts, acids, oils, etc. and are many times used to protect the solvent from freezing. The heat sensitive materials like grease, wax, various oils, lard and other viscous liquids that are heat sensitive find an application for these immersion heaters that have a tubular design and are hung over the side of the drum in an open tank system.