Immersion heaters are widely used in many industries to aid in the manufacturing, processing and heating of many products like food, oil, water and chemicals. They consist of tubular or huge heating elements, which are immersed in the liquid before the heating starts. Engineers and industrialists consider these contraptions very effective and efficient because the entire heat energy that is generated is dispersed directly into the source without dissipating it.

The sheath material, which is the actual heating element, is chosen carefully and accordingly to the product that needs to be heated. If care and caution are not used while selecting the right casing, you may end up damaging both the product and the heater itself.

Importance in Oil Industry

In oil industries, immersion heaters are used to provide the right amount of heat to oil, which allows it to easily flow through pipes. Once installed to the oil tank or the container, immersion heaters are not detachable. However, you can remove different parts from the device for repair and maintenance. These are especially designed with a body with technological modifications that make them sturdy enough to withstand extreme weather and environment along with being longer lasting than many other similar contraptions. Another benefit of oil heaters is their smaller size, which makes it easier to install them in smaller spaces. The pocket tube, which is the actual controlling device, is attached to the heater in a way that when these are immersed in the tank, the control box will be located on the exterior wall away from the product for safety. This has proven to be beneficial as a precautionary measure. For example, if something went wrong with the heater or the controller, it would not be necessary to empty the entire tank.

Another common feature of these oil immersion heaters is the surface load, which is always kept at a constant temperature without any alteration in order to keep the oil from rotting up. If you are not careful of this, a carbon layer will develop on the interior walls and surface of the device that may disrupt the heat transfer procedure.

How to Select the Right Circulation Heater

One of the proper ways to select the circulation heater is to check the sheath material, watt density and temperature control mechanism. Given below are a few guidelines to help guide you through the selection process when choosing a heater.

  • Always ask the manufacturer and supplier about the heating element, which has to be chosen according to the heating medium. For example, in the case of oil for pipeline industries, a strong heating material is required to withstand high temperatures without corroding the product and heater itself.
  • If possible have a test run before buying but remember not to exceed the actual temperature or watt density.
  • The most up-to-date technology includes a temperature control mechanism built outside the actual heater so you can easily monitor and manage the process away from the device. This has proven beneficial for health and safety.
  • The terminal enclosure must be well adjusted and of the right size to cover the wiring and protect the control mechanism from damage.
  • For large storage tanks, it is recommended that large size or multiple heaters are used to provide the exact temperature, keeping the oil viscous enough to flow easily through pipes.

Where Should You Use a Fuel Oil Heater?

Engineers prefer to use light- or medium-weighted oil circulation heaters as these are perfect for maintaining the temperature exactly as desired, which also helps to improve the oil flow and transfer through pipes. Most fuel oil heaters are used to reduce the viscous drag of the oil, which encourages easy flowing. The technique of preheating fuel oil is considered best for better performance of the burners, allowing the use of even low-grade fuel for a superior final product.
 
Benefits of a fuel oil heater include:
  • You can easily find a screw plug or flange design for these types of heaters.
  • These are resistant to moisture, corrosion free and are completely safe from explosion and other hazardous outcomes.
  • They come with or without a built-in thermostat so you may buy the one that best suits your needs and preferences.
  • They are tested, approved and certified by different evaluation agencies.

Sheath Material Used in the Process

Among many different aspects, sheath or the actual casing of the heater and heating tool is important to get the process done in an efficient and effective way. Given below are some common materials used in the manufacture of the device.

  • Incoloy, which is the combination of nickel, iron alloy and chromium, is the most common type used in circulation heaters. The quantity of nickel is always kept high to prevent the gadget from corrosion and provide resistance against carbon layer scaling. It is used widely to heat air, gas, water and oil along with elements that are less corrosive. In case of strong chemicals, sturdier Incoloy is used.
  • Low carbon steel is applied during different fluid heat transfer process. This is commonly used in high and low viscosity petroleum oils, wax, liquefied salts and other similar elements that are not harmful for the steel sheath.
  • Stainless steel is also used where there are chances of chlorides developing over the actual product that is to be heated. It is made with the combination of nickel, chromium, iron alloy and molybdenum, which are all strong corrosion-resisting elements. For stronger sheaths of the same material, instead of molybdenum, titanium may be used to prevent carbon precipitation from developing.
  • Copper is also used as a sheath medium — but mostly in water-related products. It prevents tanks from freezing in extreme temperatures.

Safety Precautions

While installing and using circulation heaters, there are some safety precautions that must be followed in order to keep the device operating at full capacity.

  • It is advised not to use the thermostat as a power switch to disconnect or turn off the heater. Instead, always use an alternative switch or a power source.
  • Do not kick, bend or handle the heating tube as it can deteriorate the operating performance.
  • When functional, do not expose any body part to the heater or the elements within the tank.
  • Do not make physical contact between the thermostat and the heating/capillary tube as it will create an electric shock that may destroy the heater and deteriorate the oil that is being heated.

How to Keep Your Oil Circulation Heater Maintained for the Long Term

Once you purchase the heater, it is your responsibility to keep it maintained for long-term use. Given below are some maintenance tips.

  • During maintenance and cleanup of the heater, disconnect all electric power supplies and safely remove the wiring console if it is detachable.
  • Use the drain plug or outlet to remove sludge and carbon deposits that develop on the walls of the device.
  • Keep the bolts and terminal connections tightened.
  • Before actually starting up the heating process, check the thermostat at every temperature in order to evaluate the performance and durability of the heating rod and thermostat itself.
  • While maintaining a particular part, remove it from the heat before working on it.

With a little care and attention to detail while selecting an immersion heater for your process, you can find a design that will deliver long life and effective heating. *

Immersion heaters are widely used in many industries to aid in the manufacturing, processing and heating of many products like food, oil, water and chemicals. They consist of tubular or huge heating elements, which are immersed in the liquid before the heating starts. Engineers and industrialists consider these contraptions very effective and efficient because the entire heat energy that is generated is dispersed directly into the source without dissipating it.

The sheath material, which is the actual heating element, is chosen carefully and accordingly to the product that needs to be heated. If care and caution are not used while selecting the right casing, you may end up damaging both the product and the heater itself.

Importance in Oil Industry

In oil industries, immersion heaters are used to provide the right amount of heat to oil, which allows it to easily flow through pipes. Once installed to the oil tank or the container, immersion heaters are not detachable. However, you can remove different parts from the device for repair and maintenance. These are especially designed with a body with technological modifications that make them sturdy enough to withstand extreme weather and environment along with being longer lasting than many other similar contraptions. Another benefit of oil heaters is their smaller size, which makes it easier to install them in smaller spaces. The pocket tube, which is the actual controlling device, is attached to the heater in a way that when these are immersed in the tank, the control box will be located on the exterior wall away from the product for safety. This has proven to be beneficial as a precautionary measure. For example, if something went wrong with the heater or the controller, it would not be necessary to empty the entire tank.

Another common feature of these oil immersion heaters is the surface load, which is always kept at a constant temperature without any alteration in order to keep the oil from rotting up. If you are not careful of this, a carbon layer will develop on the interior walls and surface of the device that may disrupt the heat transfer procedure.

How to Select the Right Circulation Heater

One of the proper ways to select the circulation heater is to check the sheath material, watt density and temperature control mechanism. Given below are a few guidelines to help guide you through the selection process when choosing a heater.

  • Always ask the manufacturer and supplier about the heating element, which has to be chosen according to the heating medium. For example, in the case of oil for pipeline industries, a strong heating material is required to withstand high temperatures without corroding the product and heater itself.

  • If possible have a test run before buying but remember not to exceed the actual temperature or watt density.

  • The most up-to-date technology includes a temperature control mechanism built outside the actual heater so you can easily monitor and manage the process away from the device. This has proven beneficial for health and safety.

  • The terminal enclosure must be well adjusted and of the right size to cover the wiring and protect the control mechanism from damage.

  • For large storage tanks, it is recommended that large size or multiple heaters are used to provide the exact temperature, keeping the oil viscous enough to flow easily through pipes.

Sheath Material Used in the Process

Among many different aspects, sheath or the actual casing of the heater and heating tool is important to get the process done in an efficient and effective way. Given below are some common materials used in the manufacture of the device.

  • Incoloy, which is the combination of nickel, iron alloy and chromium, is the most common type used in circulation heaters. The quantity of nickel is always kept high to prevent the gadget from corrosion and provide resistance against carbon layer scaling. It is used widely to heat air, gas, water and oil along with elements that are less corrosive. In case of strong chemicals, sturdier Incoloy is used.

  • Low carbon steel is applied during different fluid heat transfer process. This is commonly used in high and low viscosity petroleum oils, wax, liquefied salts and other similar elements that are not harmful for the steel sheath.

  • Stainless steel is also used where there are chances of chlorides developing over the actual product that is to be heated. It is made with the combination of nickel, chromium, iron alloy and molybdenum, which are all strong corrosion-resisting elements. For stronger sheaths of the same material, instead of molybdenum, titanium may be used to prevent carbon precipitation from developing.

  • Copper is also used as a sheath medium — but mostly in water-related products. It prevents tanks from freezing in extreme temperatures.

Safety Precautions

While installing and using circulation heaters, there are some safety precautions that must be followed in order to keep the device operating at full capacity.

  • It is advised not to use the thermostat as a power switch to disconnect or turn off the heater. Instead, always use an alternative switch or a power source.

  • Do not kick, bend or handle the heating tube as it can deteriorate the operating performance.

  • When functional, do not expose any body part to the heater or the elements within the tank.

  • Do not make physical contact between the thermostat and the heating/capillary tube as it will create an electric shock that may destroy the heater and deteriorate the oil that is being heated.

How to Keep Your Oil Circulation Heater Maintained for the Long Term

Once you purchase the heater, it is your responsibility to keep it maintained for long-term use. Given below are some maintenance tips.

  • During maintenance and cleanup of the heater, disconnect all electric power supplies and safely remove the wiring console if it is detachable.

  • Use the drain plug or outlet to remove sludge and carbon deposits that develop on the walls of the device.

  • Keep the bolts and terminal connections tightened.

  • Before actually starting up the heating process, check the thermostat at every temperature in order to evaluate the performance and durability of the heating rod and thermostat itself.

  • While maintaining a particular part, remove it from the heat before working on it.

With a little care and attention to detail while selecting an immersion heater for your process, you can find a design that will deliver long life and effective heating.