Flanged Immersion Heater

Flanged Immersion Heaters represent advanced tank and vessel heating technology specifically engineered for direct heating of industrial fluids, chemicals, oils, and process liquids in large-capacity storage tanks and pressure vessels. These sophisticated heating assemblies feature precision-manufactured MgO-packed hairpin or bulge tubular heating elements that are expertly welded or brazed into ANSI or DIN standard flanges, providing secure, leak-proof mounting solutions for demanding industrial applications. The robust flange-mounted design ensures reliable operation under high-pressure conditions while enabling easy installation and maintenance without vessel drainage.

High watt density up to 65 W/in²
Operates to 650 °C
Replaceable elements without vessel drainage

Technical Specifications

Heating Element Material	NiCr, FeCrAl alloys with high-purity MgO insulation
Sheath Material Options	SS304/310/316/321, Incoloy, Inconel, Titanium
Operating Temperature Range	Up to 650°C (1202°F) - customizable
Maximum Watt Density	Up to 65 W/in² (10 W/cm²)
Power Rating Range	1 kW to 300 kW+ (custom ratings available)
Voltage Options	110V, 230V, 415V, 480V AC (custom available)
Flange Standards	ANSI 150–600#, DIN PN16/40 (DN50–DN200)
Flange Size Range	2" to 24" diameter (custom sizes available)
Immersion Length Range	50 mm–3000 mm (custom lengths available)
Pressure Rating	Up to 40 bar (600 PSI) - custom ratings available
Terminal Box Rating	IP23 standard, IP66/ATEX/IECEx optional
Control Integration	Built-in thermostat, RTD, PLC interface options
Service Life	10,000 to 20,000+ hours typical operation
Mounting Orientations	Horizontal, vertical, angular configurations

Construction

Precision Hairpin/Bulge Elements: High-quality NiCr or FeCrAl tubular coils with MgO insulation providing efficient heat transfer, uniform temperature distribution, and extended operational life in demanding fluid heating applications.
Engineered Welded Flange: ANSI 150/300/600# or DIN PN16/40 flanges manufactured from carbon steel, SS304/316, or Incoloy providing leak-tight mounting, pressure resistance, and chemical compatibility.
Weather-Resistant Terminal Enclosure: IP23 standard or IP66/ATEX optional terminal boxes with ceramic terminal blocks and cable glands ensuring safe electrical connections and environmental protection.
Chemical-Compatible Gasket System: High-temperature PTFE, graphite, or Viton flange gaskets providing chemical compatibility, zero-leakage operation, and long-term sealing integrity under demanding conditions.
Integrated Thermowell Assembly: Optional stainless steel thermowell with PT100 RTD or thermocouple sensors providing accurate temperature monitoring, process control feedback, and safety system integration.
Advanced Control Interface: Optional control modules featuring PID controllers, safety interlocks, communication interfaces, and automated systems for sophisticated thermal management and plant integration.

Key Features

Leak-proof flange design ensuring zero-maintenance operation
Wide alloy selection for corrosion and chemical resistance
Explosion-proof and hazardous area certifications available
Custom flange sizes and element configurations for any application
Field-replaceable elements eliminating vessel downtime
Uniform heat distribution throughout large vessel volumes
High watt density capability enabling compact heating solutions
Precise temperature control with integrated sensor systems
Energy-efficient direct heating minimizing thermal losses
Robust construction engineered for continuous industrial operation

Applications

Chemical process baths and reaction vessels
Heat transfer oil circulation and heating systems
Water treatment and wastewater processing tanks
CIP/SIP vessels in food and pharmaceutical industries
Industrial storage and blending tank heating
Steam generation and boiler feed water systems
Petroleum refining and petrochemical processing
Textile dyeing and chemical processing baths
Power plant water heating and conditioning
Pharmaceutical manufacturing process vessels