Process Industry

The process industry is a large field of expertise which covers the chemical and mechanical steps to process certain types of liquid applications that are carried out globally in a large scale. Control panels requiring accurate temperature controls as well as industrial heating methods that need to provide immediate thermal conductivity through a large containment field. Electric flanged heaters are often selected for their low maintenance and ease of installation as well its efficient properties that enable process engineers to provide a reliable heat source that would meet their project objectives of effectively heating liquid mediums efficiently to certain temperatures within a fixed period of time.
 
Process Industry
Industrial circulation heaters use flanged heater assemblies along with precise digital controllers that heat up circuits of liquid within a short period of time. Chemical processes that are located outdoors use these types of heating applications that are moisture resistant or even explosion proof to ensure safety precautions are adhered to. NEMA 4 (moisture resistant) and NEMA 7 (Explosion proof) housings are used to help prevent unsafe scenarios. The petrochemical industry uses Wattco heating elements specifically in areas using hazardous materials where exposure to highly volatile gas is present and safe heating equipment is necessary. Process immersion heaters have specific and valuable uses and each task depends on the exact temperature of the heater. This makes it critical for precision controls in the heaters. An immersion heater is a heating element that is immersed in a tank so a liquid or gas can be heated.
 
Types of Immersion Heaters Flanged
Flanged immersion is a type of immersion heater that consists of a hairpin bent tubular elements that are welded into the flange. It is provided with wiring boxes for electrical connections. Flanged immersion heaters are installed by bolting the heater to a matching flange welded to the tank. There are plenty of selection for flange sizes, voltages, kilowatt rating, sheath, and terminal housings. A flange heater is applicable for all types of heating and applications. Flanged heaters are mostly used for heating oil, or transferring fluid and corrosive solutions. It is made for pressurized tanks and vessels. It is usually mated with a companion flange that is either welded  to a tank or into a pipe body. A properly designed flanged heater can provide a high degree of efficiency because the energy generated is quickly dissipated into the medium being heated.
 
Advantages
·         Easy to install.
·         Easy to maintain.
·         Easy to control.
·         Has an appropriate heating size for the right application.
·        Made for higher kilowatt output.
 
Uses and Applications
·         Hot water storage tanks
·         Cleaning and rinsing tanks
·         Heat transfer systems
·         Process air equipment
·         Boiler equipment
·         Food Processing Equipment
·         Freeze protection
·         Warming equipment
·         For preheating all grades of oil
·         heat transfer system
 
Over-the-side heater
Over-the-side immersion heaters are designed for tanks and vessels where side immersion heaters cannot be installed. Over the side immersion heaters are made of mounted tubular elements that are perfectly designed for freeze protection, heating water, oils, salts, acids, and viscous solutions. These heaters are recommended for solutions requiring easy removal for cleaning and inspection. Over the side immersion heaters are versatile enough to be designed for easy installation in the top of the tank directly immersing along the side and the bottom. It takes up little space which eliminates the need for tank penetrations (there are some applications that require the perforation of holes in the tank. Here it is not necessary) and provides ample working space inside the tank. Elements are custom configured for evenly distributing heat by direct contact.
 
Advantage
·         Portable and can easily be removed
·         Easy to maintain
·         Comes in variety of shapes
·         Can be immersed along the side or bottom of the tank.
·         Lightweight
·         NEMA 4/4x enclosures available for moisture protection
·         Sheath materials available for corrosive liquids, acids, etc.
·         Allow 1 to 3 phase operations
·         Moisture resistant
·         Provide uniform temperature
·         No drilling holes needed
·         Designed for safety
 
Uses and Applications
·         Caustic Solution
·         Freeze protection
·         Storage tanks
·         Viscous oils
·         Salts
·         Paraffin
·         Solvents
·         Degreasing tanks
 
Circulation Heaters
Circulation heaters are packaged units consisting of screw plug or flanged immersion heater mounted in a thermally-insulated heating chamber. These heaters have an inlet and outlet piping to where the liquid or gas goes through the tank to reach the desired temperature. Circulation heaters, also known as “in-line heaters”, use stainless steel, titanium, or steel flanged heater in most applications. Compact and efficient, circulation heaters are used to force or provide natural circulation systems to heat flowing liquids or gasses. It is a perfect solution for generating heat and enhancing the performance of normal immersion heaters.
 
Advantage
·         Compact
·         Durable
·         Easy to install
·         Provides greater wattage over smaller heater bundles
·         Easy mounting support.
·         Maximum dielectric strength
·         Reduce heat loss from the vessel
·         Quick response time and even heat distribution
 
Circulation Heater Applications
·         Demineralized Water
·         Deionized Water
·         Potable Water
·         Clean
·         Industrial water rinse tanks
·         Lubricating oils
·         Paraffin
·         Caustic cleaners
·         Super-heating steam
·         Nitrogen, hydrogen, and other gas systems
·         Electric heating systems for pre-heating and exhaust gas post-heating.
 
There are three ways to install a circulation heater:
 
Vertical Mounting for Liquids
Terminal housing is at the top and the inlet pipe is at the bottom. Heating elements are immersed at all times to prevent premature failure. Recommended for liquid heating or low temperature gas heating.
 
Horizontal Mounting Mounting the heater with the inlet-outlet pipes facing up will ensure that the elements are immersed at all times. If to be used for liquid heating, the outlet may be possible at either end but for heating gasses, the inlet should be closest to the terminal enclosure to reduce terminal box wiring temperature.
 
Vertical Mounting for Gasses Mounting circulation heaters with the terminal enclosure and inlet pipe at the bottom will minimize terminal box wiring temperatures. Recommended for high temperature gas heating.
 

Mentioned Products

 
 

Since they can be transferred from tank to tank when necessary. Over the Side Heaters are perfect for process.

Best used when heat needs to be transferred to a solution quickly and efficiently. Flanged heaters use a durable alloys such as steel, stainless, titanium and hastelloy for a wide of temperature ranges. Temperature controls and digital controllers make this product an optimum choice for the oil and gas industries.
Especially effective when there is limited time available for maintenance. These heaters do not come into direct contact with your liquid solution (usually corrosive or viscous) so replacement is simple without the need to empty your tank.
Circulation heaters can provide prices heating at various stages of processing. Wattco circulation heaters can be customized for a wide variety of uses and can act at various points in the processing process.

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