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Industrial Immersion Heaters

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Electric Immersion heaters are tubular heating elements used to directly heat liquids found in a variety of industries from process heating, power, chemical, oil and gas, pharmaceuticals, metals processing to the food & beverage industry.

Durex Industries has over 40 years of experience in the application, design, and manufacture of robust immersion tank heaters and process assemblies for immersion heating applications.

Electric Immersion Heaters

Our screw plug, flange, and over-the-side immersion heaters are designed to provide a quick and efficient way to reach and maintain required temperatures to prevent liquids from freezing in colder conditions, maintain production flow at a constant temperature, provide precise heat distribution, and allow fluids to transfer effectively.

Durex immersion heaters are constructed from hairpin bent tubular heating elements brazed or welded into threaded screw plugs or flanges and typically inserted horizontally through the side of a tank or vessel directly into the fluid.

Using direct heating allows for the fluid to quickly reach the desired temperature and ensure optimized high performance results.

Durex Industries Immersion Heater Capabilities

Quick ship on standard immersion heater designs
Standard and custom designed immersion heaters
C-UL heating element component recognition available
ASME Section VIII Div 1 manufacturer with “U-partial” code stamp capability
CSA hazloc certified terminal enclosures available
Fast responsive engineering assistance

Contact Durex Industries for Standard and Custom Immersion Heaters

We have thousands of standard designed immersions heaters for quick field replacements and convenient ordering. Durex also has extensive experience with custom designed electric immersion heaters for storage tanks, reservoirs, and circulation flow applications.

Immersion Heaters Factors to Consider

Choosing the right type of immersion heater for your application is important. The goal is to optimize the heater configuration to ensure the longest life possible while minimizing overall product and life cycle costs.

Durex Industries’ team of engineers will assist you in providing the best and most efficient heating solution required for you application.

Consider the below factors when requesting a quote or ordering your immersion heater:

Hazardous location installation
Voltage rating, phase and kW power rating
Available Amps at site of installation
Time required to reach desirable temperature setting
Temperature control and sensing: thermostats, sensors, temperature control panels
Quantity of liquid being heated and if flowing or mixing
Viscosity and thermal conductivity of the fluid
Corrosive nature of the fluid
Tank or heating vessel insulation thickness and type
Space limitations for installation or heater removal
Outdoor or indoor installation
Ambient environment operating conditions

Immersion Heaters Application Guidelines

Industrial tubular immersion heating elements are used for direct liquid heating applications. They are constructed of one or more heater elements brazed or welded into various types of mounting fittings. Standard and custom engineered electric heater designs are available for tailored solutions to your thermal application requirements.

The goal is to optimize the heater configuration to ensure the longest life possible while minimizing overall product and life cycle costs. The general temperature, sheath material and watt density guidelines below can aid in proper heater selection for some common liquids. Contact Durex for further assistance.

Liquid	Max. Operating Temps °F (°C)	pH Level and/or Concentration	Recommended Sheath Material	Typical Plug/Flange Material	Max. Watt Density W/in²(W/cm²)
Clean, Potable Water	212 (100)	Neutral (pH 6 to 8)	Copper	Brass	60-90 (9.5-14)
Process Water & Weak Solution	212 (100)	pH 5 to 9; 2-3%	Incoloy®, 304SS	Steel or 304SS	48 (7.5)
Demineralized, Deionized Water	212 (100)	Neutral	304SS or 316SS (passivated)	304SS or 316SS	60 (9.5)
Weak (Acidic) Solutions*	210 (100)	Up to 5-6%	Incoloy®, 316SS	Steel	48 (7.5)
Mildly Corrosive (Acidic) Solutions*	180 (80)	5-15%	Incoloy®, 316SS	304SS or 316SS	20-30 (3.5)
Severely Corrosive (Acidic) Solutions*	180 (80)	>15%	Incoloy®, titanium, Teflon®	304SS or other	15-16 (2.5)
Caustic Soda 10%	200 (100)	pH 14; 10%	Incoloy®	Steel	20-23 (3.5)
Caustic Soda 50%	250 (120)	pH 14; 50%	Incoloy®	Steel	16 (2.5)
Fuel Oil 1 & 2; Kerosene Lube Oil SAE 10 to 30	200-250 (95-120)	-	Steel	Steel	20-23 (3.5)
Fuel Oil 4 & 5; Lube Oil SAE 40 to 50	200-250 (95-120)	-	Steel	Steel	15-16 (2.5)
Fuel Oil 6 & Bunker C	160 (70)	-	Steel	Steel	6-8 (1.2)
Hydraulic Oil	100 (40)	-	Steel	Steel	15-16 (2.5)
Ethylene Glycol	300 (150)	-	Steel	Steel	23-30 (3.5-4.5)
Glycerine	500 (260)	-	Incoloy®	Steel	8-10 (1.5)
Molten Salt Bath	800 (425)	-	Steel, 321SS, Monel®	Steel	23-30 (3.5-4.5)
Paraffin Wax	150 (65)	-	Steel or 304SS	Steel	15-16 (2.5)
Molasses	100 (40)	-	304SS or 316SS	304SS	4-5 (0.7)

* Sheath material and watt density dependent on type of acid, concentration, temperature, aeration, movement, etc.

Please note that the user accepts full responsibility for validating that a heater is suitable for a given liquid or gas heating application.
Ensure that heater elements are completely covered in liquid AT ALL TIMES. Failure to do so may cause the heater elements to operate in open air and fail prematurely, or worse, lead to ignition of flammable vapor mixtures, causing serious personal injury and equipment damage. Liquid level sensors are highly recommended.
Durex recommends the use of a thermostat or process controller as well as a high limit sensor and FM approved safety controller to prevent unexpected over temperature conditions.