Immersion Heaters for Process Fluids

Electric Immersion Heater


Process fluids are found in every major industry, and process fluid heating is an essential task for each of these. Electric immersion heaters are the ideal solution for heating industrial process fluids.

This article offers a review of common industrial process fluids, as well as their heating challenges and solutions.

Industrial Process Fluids

Some of the most common industrial process fluids include:

  • Deionized Water
  • Detergents
  • Compressed Gases
  • Machining fluids

Deionized Water

Deionized water is water with no charge. Ions can be removed by using electrically charged resins to attract and remove salts, creating deionized water. Deionized water is used for a variety of industrial applications including steam turbines, water treatment, and pharmaceutical systems.


Detergents play an essential role in a variety of industries. From sanitation to commercial laundries, to the textile industry detergents are essential. In addition to cleaning, they also play a part in manufacturing products such as insecticides and printing inks.

Compressed Gases

High-pressure applications, like compressed gases, take advantage of the safety and control of immersion heaters. Compressed gases are used in a variety of industrial applications such as welding.

Machining Fluids

Machining fluids are essential in manufacturing industries. They see frequent use for cooling, lubrication, and their corrosion-resistant properties.

Challenges for Process Fluid Heaters


Industrial processing and manufacturing frequently uses corrosive mediums. Corrosion can cause damage to critical equipment, resulting in inefficiencies and shortening heater lifespans. The best way to address corrosion is with custom-manufactured immersion heaters.

Custom manufacturers can select corrosion-resistant sheath materials to protect immersion heaters from specific mediums. As well, manufacturers can select from different materials to protect against high heats and varying wattages.


Process fluids containing highly conductive material, such as potassium, can cause problems for heaters. They present a challenge for uniform heating as well as creating a risk of heater burnout. Setting the immersion heater for low-voltage heating helps to avoid these complications.

Contact Wattco to help determine the right wattage and voltage for your specific application.

Flow Rates

Maintaining a consistent flow rate is important. It keeps materials at the ideal temperature and viscosity. As well, it prevents adding extra strain on your process heater. Electric immersion heaters offer precision heating to help maintain flow rate. As well, regular maintenance such as oil flushing prevents sediment buildup and blockages that can affect flow rates.

Fluid-Borne Particles

Fluid-borne particles are another good reason to perform regular maintenance. Many industrial process fluids contain particulate that builds up as sediment inside of the system. As sediment builds up it reduces the efficiency and lifespan of your heater.

The position of the heater during installation can prevent sediment build-up from fluid-borne particles. As well, regular flushing will extend the lifespan of your system.

Even Distribution

Even heat distribution is important for process heating. Uneven heat distribution can be problematic with process fluids, especially if they are combustible. Flange heaters are a popular style of immersion heater because the flanges allow for fast, even heat distribution.

Immersion Heater Types for Process Fluids

Tank Immersion HeaterTank Heating

Tank heaters are often necessary for industrial process fluids. In colder climate or outdoor environments, tank heating is important to prevent liquids from freezing. In addition to freeze protection, immersion heaters for tanks are also useful for preheating or maintaining optimal temperatures for process fluids.

The most popular types of tan heaters for process fluids are:

  • Screw Plug Heaters
  • Flange Heaters
  • Over-The-Side Heaters

Screw plug heaters screw directly into the tank, usually in the lower portion. It offers fast, efficient heating in closed tanks. They are the ideal option for smaller tanks.

In larger tanks, flange heaters are the most efficient heating solution. They are one of the best immersion heaters for oil because of their efficiency and even heat distributions. As well, like screw plug heaters, they can be outfitted with explosion-proof enclosures.

Over-The-Side immersion heaters offer easy installation in open tanks. Skid-mounting makes them easy to use in multiple tanks. This is useful in preheating process fluids in open containers.

Circulation Heaters

Circulation, or in-line, heaters are ideal immersion heaters for closed systems. They reheat fluid as it flows through the circulation heater. This maintains target temperature and keeps the fluid viscous so it is easy to pump through the pipes.

Process Fluid Immersion Heater Quotes

For the most efficient processes and long-lasting equipment, look for custom immersion heaters. Wattco custom-manufactures immersion heaters for your specific application, for optimal settings and materials. Contact us today for curing tank immersion heater quotes and information.