Industrial Applications of Immersion Electrical Heaters

Industrial immersion electrical heaters have a number of industrial applications. These heaters are a convenient way to heat water and other liquids such as oil, solvents, etc. as it allows the user to heat as much or as little liquid as is required. The heaters apply direct heat to the liquid with nearly 100 percent efficiency. There is a range of such immersion electrical heaters available with varying industrial uses.

Circulation heater

circulation heaters

Also known as in-line heaters, a circulation heater constitutes of a flanged immersion heater that is mounted in a pressure vessel that is thermally insulated and consists of an inlet as well as an outlet nozzle. In the case of larger units, mounting lugs can provide support. The temperature control is provided by a pre-wired thermostat or a digital control panel. Depending on your need and requirement, various mounting options are made available.


Due to the versatility of this kind of heater, they are used for a number of processes and are able to withstand any weather. They are used to heat, pre-heat, or maintain the process temperature of a number of liquids and gases in an industrial and commercial setting.

Petrochemical industries rely heavily on heating systems; they are widely used in locations such as Calgary and Alberta for heating oils, chemicals, and other heating fluids and mediums. The thermostat used in the heater allows temperature variation during petrochemical processes. Right from gasoline refining to chemical processing, circulation heaters are extremely useful. Depending on the design and capacity of the heater, it can help boost heating processes from 300Kw to 2000Kw.

Circulation heaters are also used to heat clean water for industrial washing. Immersion heaters are mounted over thermally-insulated chambers that allow for efficient heating of the flowing medium. The inlet and outlet nozzle let the fluid flow in and out of the circulation heater. For water application usually stainless steel or copper sheath material is used. The drain valve that can be installed anywhere throughout the heater allows for the removal of water thus helping in easy maintenance. The selection of a circulation heater is dependent on the flow rate of water, watt, and specifications of the sheathing material.

Other applications include curing and drying, heat shrinking, thermal forming/sealing, and chemical processing.

Flanged heaters

Flanged immersion heaters are designed especially to heat gasses and liquids within a tank or pressure vessels. This kind of heater is ideal for applications that require higher kilowatts. This heater uses direct heat application on the liquid medium. Flanged heater usually consists of ANSI-rated flanges which could be carbon or stainless steel, along with several hairpin elements and bugle tubular elements. The sheathing material used can be copper, Teflon, steel, or stainless steel. The direct immersion method helps in easy monitoring and is also energy efficient.

Flange heater applications


Flanged heaters are extensively used in the chemical industry wherein they are used to heat flat-walled metal parts, food warming, dies and molds, and even in furnaces. These heaters require less maintenance and provide high temperatures in less time.

The food industry also makes heavy use of flanged heaters as they’re easy to install and are virtually maintenance-free. Fast-food restaurants use flanged heaters to keep their equipment working properly and also to keep the food fresh. Oil pre-heating equipment and food processing equipment rely heavily on these kinds of heaters.

Power plants, which make use of boilers for the production of heat, use flanged heaters for oil application in boiler equipment that in turn help with power production for the plant. Flanged heaters are also used extensively in energy companies for equipment and ships. They are used for desalting seawater which is then used in equipment as well as irrigation. The desalted water can be used freely in machines without the fear of the equipment getting corroded. This type of heater is also used for heating crude oil, thus allowing free flow through the pipelines which are usually situated in extremely cold climates. These heaters are also fitted in gas turbines for optimum heat and temperature control for the smooth working of the turbines.

Thus, due to their cost-effectiveness and higher productivity, flanged heaters are widely used in a number of industrial applications.