Immersion heaters provide significant benefits in colder climates, where they are popular because of their high power density, small size, and ability to be put in existing infrastructure. As a result, they’re used in various applications wherein arctic and subarctic temperatures are typical.
Electric immersion heaters are a popular choice for industrial heating since they are quick, cost-effective, and efficient. In addition, heating liquids in tanks, pressure vessels, and drums is common.
If the process fluid is too acidic for close interaction with the immersion heaters, it can also be employed as part of a heating loop. The high energy density of these heaters, also known as bayonet heaters, allows liquid to achieve the necessary temperature quickly.
That said, we’ll look at the most typical applications for immersion heaters in colder climates.
Tank Insulation Application
Tank insulation, which is necessary for heat retention in the tank, is another application of immersion heaters. Inline heaters are used in tank heating to pull fluid from the tank, heat it in a separate chamber with one or more immersion heaters, and then return it to the tank. Inline heaters of this type can be put on a skid for added flexibility in installation and removal.
When choosing an immersion heater for a tank heating application, the sheath material, watt density (W/cm2), and maximum working temperatures must be carefully considered. A good choice ensures optimal longevity and total cost of ownership minimization.
Tank heating Application
The cooler temperature exacerbates the issue of adequately heating the process fluid. If left unchecked, this can lead to costly equipment breakdowns and shutdowns.
Flanged immersion heaters are the most common immersion heater used for tank farm heating. The flanged immersion heater is used in most greenfield expansion tank farms. However, screw-type immersion heaters are also used in some non-pressured applications.
Immersion heaters installed over the side are more prevalent in brownfield sites when existing infrastructure prevents the use of flanged or screw plug immersion heaters. The existing infrastructure permits liquid to reach temperatures beyond freezing in colder climates.
On the other hand, the process temperature should not be decided entirely by the liquid’s freezing point.
Above the freezing point, crystallization and viscosity changes begin. As a result, specific considerations must be made while determining the operating temperature.
Chemical Industry Application
Immersion heaters are essential in the chemical industry, especially in colder climates, because they retain chemicals at a consistent temperature and prevent freezing. Heaters mounted over the side, flanged, screwed in, ducted, or circulated help keep chemicals warm.
In the chemical industry, cooling towers are often used to refrigerate water. Heating the cooling water above the freezing point is necessary for sub-zero conditions.
Because anti-freeze cannot be used in an open circulating tower, electric immersion heaters are more commonly used to raise the temperature of the cooling water circuit above freezing point. Since they are always fully immersed and used in direct heating applications, they are 100 percent efficient in transferring heat to the cooling water.
The cooling tower basin’s electric immersion heaters are designed to keep the water in the basin from freezing, but they do not protect the piping or the fill. Heat trace is frequently necessary to heat the piping.
The temperature should be kept above the freezing point using the digital control panel. It should also feature a low-level cut-off if the basin’s water level dips below the immersion heater.
The cooling tower design usually decides the installation positions, which typically has 2 or 2-1/2″ NPT ports built into the basin for horizontal immersion heater insertion above the sump sludge level.
The water level should be 2″ above the immersion heater, and the immersion heater should be 2″ above the basin bottom, which is a rule of thumb.
Immersion Heaters for Diesel Engines
For diesel engines working in cooler temperatures, gelling and freezing are common concerns. An electric immersion heater is one of the most efficient ways to heat a diesel engine, especially in colder climates. The AC drives the heater in the diesel engine block to heat the fluid.
Electric immersion heaters are used in diesel engines to heat the coolant so that the machine can start in more excellent conditions. There are four basic types of electric immersion heaters:
- Threaded immersion heaters
- Cartridge immersion heaters
- Freeze plug immersion heaters
- Bolt-on design immersion Heaters
Most immersion heaters for diesel automobiles feature copper heat transfer components. The installation of a cartridge immersion heater does not necessitate the emptying of the coolant, whereas the structure of other types does.
Purification of Water
Carbon tanks filter water to eliminate contaminants, including chlorine, bacteria, pollution, and other chemical substances that might affect the water’s flavor and taste.
An immersion heater boils water to sterilize it in a way that sustains the tanks free of foreign substances. Therefore, immersion heaters play a huge role in water purification, especially in colder climates.