Advantages of Electric Immersion Heaters in Chemical Manufacturing

The chemical manufacturing industry has unique challenges in the production, storage, and transportation of materials. Corrosion, costs, and controls effect quality and efficiency. Electric immersion heaters are the best heating solution for the chemical industry.

Here are some of the top advantages of using electric immersion heaters for chemical manufacturing:

Costs

The cost of manufacturing chemicals is on the rise. To stay competitive, companies need to tighten up their processes and reduce wasted spending. One of the big shifts here is moving away from fossil fuels.

With the continued rise in the cost of fossil fuel, more companies are looking for alternatives. As a result, major industries are turning to electric power to reduce operational costs. Electricity not only comes in at a lower cost but also has much less wasted power.

Fossil fuel has a significant amount of energy lost when used, whereas electricity loses virtually none. That means all the power a company pays for goes directly into the operation. This results in less wasted spending and more profitable production.

Efficiency

Electric immersion heaters are not only efficient with their energy use, they also offer a more efficient operation. Electricity is capable of achieving temperatures quickly and predictably, allowing for faster, more consistent heat transfer.

Accessories like thermocouples can provide more accurate temperature readings and safety shutoffs. These ensure better efficiency, as well as improving safety. Custom flanges also allow electric immersion heaters to provide uniform heat distribution, further improving accuracy and efficiency.

Heating Controls

Electric immersion heaters provide better heating control. Better control results in more efficient energy use, which reduces costs. But that is only part of their benefits.

In chemical manufacturing, imprecise heat controls lead to significant issues. Improper heating can cause the final product to degrade and/or yield undesirable properties. Often, these damages are not recoverable.

With the more precise heat control and monitoring of electric immersion heaters, they can increase production yield, with reliable quality. The operations are safer and more cost-effective.

Customization

Wattco industrial immersion heaters are custom-manufactured, using designs and materials intended for your specific process. Depending on the chemical make-up of the medium and the process itself, different sheath material protects the heater from damage:

  • Copper: A copper sheath can heat water with a PH between 6 & 8.
  • Steel: Steel sheaths are common for degreasing solutions, solvents oils, and medium weight oils.
  • Stainless Steel: Stainless steel heaters provide further protection over steel. For example, in heating electrified alkaline cleaners, wash tanks, and caustic fluids.
  • Teflon-Coated: Teflon is a popular choice for more caustic solutions. For example, hydrochloric acid, sulfuric acid, and ammonium bi-fluoride.
  • Titanium: Titanium sheaths are a good solution for heating corrosive materials in chemical manufacturing. They are corrosion-resistant, and the rights coatings can make them resistant to most chemical mediums.

In addition to materials, the settings and design of the heater are also customizable. A team of engineers can help determine the right voltages, wattages, and flange layouts for maximum efficiency and safety.

Maintenance & Lifespan

Simplicity is central to electric immersion heater design. A simple design results in less opportunity for failure, breakdown or wear. As well, it makes the heating equipment easy to maintain. These two factors, result in a long lifespan requiring minimal repairs.

Proper immersion heater maintenance is easy on electric equipment. Maintenance can often be performed with simply a powerwasher. Regular maintenance not only prevents damage and downtime, it also helps to keep your heater running at peak performance.

If a flange is damaged over time, they are simple to replace. This prevents users from having to purchase a whole new unit and also limits downtime. The installation of a replacement flange is fast and easy.

Purchase An Electric Immersion Heater for Chemical Manufacturing

To get the best electric immersion heater for your chemical manufacturing process, contact Wattco. Our team helps you pick the optimal configuration for your process and heated medium. Contact us today for quotes or information.

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