CUSTOM HEATING ELEMENT ASSEMBLY
Flanged Immersion Heater
Custom Flanged Immersion Heaters for Tanks, Vessels and Industrial Liquid Heating
Xiangyuan Machinery manufactures custom flanged immersion heaters for direct liquid heating in tanks, vessels, circulation heaters, process equipment and industrial fluid systems.
Each heater consists of multiple electric heating elements welded or fixed onto a flange, with a terminal box for electrical connection. Flange size, immersion length, sheath material, watt density, temperature sensor, control cabinet and safety protection can be customized according to liquid type, tank structure and working conditions.
Product Overview
A flanged immersion heater is an electric heating element assembly designed for direct immersion heating of liquids in tanks, vessels, circulation heaters and process systems. The heating elements are mounted onto a flange and inserted into the liquid through a tank or vessel opening.
The heater can be designed for water, oil, thermal oil, hydraulic oil, chemical liquid, wastewater and other industrial fluids. It is commonly used for liquid heating, temperature holding, freeze protection, viscosity reduction and process temperature control.
Compared with simple screw-plug heaters, flanged immersion heaters are more suitable for higher power, larger tanks, pressure vessels, circulation systems and applications requiring multiple heating elements in one assembly.
The heater can be supplied with a standard terminal box, high-temperature terminal box, explosion-proof terminal box or complete control cabinet according to site requirements.
Key Features
Key design features of the Flanged Immersion Heater can be customized according to liquid type, tank size, flange standard, immersion length, working temperature, pressure, watt density, material compatibility and safety requirements.
Direct immersion heating
Heating elements are immersed directly into the liquid to provide efficient heat transfer for tanks, vessels and circulation systems.
Custom flange size and standard
Flange size, flange rating and connection standard can be customized according to tank opening, vessel design or pipeline connection.
Multiple heating element arrangements
Heating tube quantity, layout, diameter, length and support structure can be designed according to heating power and installation space.
Suitable for tanks and vessels
Used for storage tanks, process vessels, oil tanks, water tanks, chemical tanks, pressure vessels and industrial containers.
Removable flange assembly
The complete heating element bundle can be removed from the flange opening for inspection, replacement or maintenance when site conditions allow.
Material selected by liquid type
SS304, SS316L, SS310S, Incoloy and selected corrosion-resistant materials can be used according to liquid properties and temperature.
Watt density design
Heating element surface load can be selected according to liquid viscosity, heat sensitivity, fouling tendency and allowable sheath temperature.
Sensor and protection options
Temperature sensor, thermostat, low-level protection, dry-heating protection and over-temperature alarm can be configured when required.
Explosion-proof terminal box optional
Explosion-proof terminal boxes and control systems can be provided for hazardous-area liquid heating applications when required.
Typical Technical Parameters
The following parameters are for reference only. Final flanged immersion heater design can be customized according to process conditions and project requirements.
| Parameter | Customizable Range / Options |
|---|---|
| Product Name | Flanged Immersion Heater |
| Heating Medium | Water, oil, thermal oil, hydraulic oil, chemical liquid, wastewater and other process fluids |
| Heating Power | Customized according to tank volume, flow condition, liquid properties, temperature rise and heating time requirement |
| Temperature Range | Customized according to liquid type, working temperature and material selection |
| Installation | Tank, vessel, pressure vessel, circulation heater, pipeline heater or customized equipment |
| Flange Standard | GB, ANSI, ASME, DIN, JIS or customized flange standard |
| Flange Material | Carbon steel, SS304, SS316L or selected alloy material |
| Heating Element Material | SS304, SS316L, SS310S, Incoloy 800, Incoloy 840 or customized material |
| Immersion Length | Customized according to tank size, liquid level range, installation direction and maintenance space |
| Watt Density | Designed according to liquid viscosity, heat sensitivity, fouling tendency and allowable sheath temperature |
| Element Arrangement | Multiple straight, U-shaped or customized heating elements welded or fixed onto the flange |
| Terminal Box | Standard terminal box, high-temperature terminal box or explosion-proof terminal box optional |
| Temperature Sensor | Thermocouple, PT100, thermostat or customized temperature sensor |
| Control Method | Thermostat, PID control, SCR power control, staged control, PLC control or complete control cabinet |
| Protection Options | Over-temperature, low-liquid-level, dry-heating, leakage, grounding, short-circuit and emergency stop protection |
| Optional Design | Explosion-proof terminal box, protective sleeve, support structure, baffle, control cabinet and skid integration |
Structure, Materials, Control and Safety
Structure of the Heater
The flanged immersion heater is installed through a tank, vessel or circulation heater flange opening. The heating element bundle is immersed directly in the liquid and transfers heat to the surrounding medium for liquid heating, temperature holding or process heating.
Main structure can include:
- Mounting flange
- Electric heating element bundle
- Heating element fixing structure
- Cold section and heated section
- Terminal box or explosion-proof junction box
- Cable gland
- Temperature sensor
- Support structure for long elements
- Optional baffle or protective sleeve
- Optional control cabinet
Flange size, immersion length, element quantity, watt density, terminal box direction and support structure should be designed according to liquid type, liquid level, tank size, installation direction and maintenance requirements.
Materials and Customization
Material selection depends on liquid type, working temperature, corrosion level, viscosity, fouling tendency and installation environment.
For water and normal oil heating, SS304 or carbon steel flange structures can be used for common applications. For corrosive liquids or chemical process fluids, SS316L or selected corrosion-resistant materials can be considered. For higher-temperature oil, thermal oil or special process media, SS310S, Incoloy 800, Incoloy 840 or other high-temperature alloy materials may be selected.
Heating element watt density should be reviewed carefully for viscous liquids, heat-sensitive liquids and liquids with scaling or fouling risk.
Common material options include:
- Stainless steel 304 for water and normal fluids
- Stainless steel 316L for corrosive liquids
- Stainless steel 310S for higher temperature conditions
- Incoloy 800 / 840 for high-temperature or special applications
- Customized alloy material for special chemical media
Customization options include:
- Heating power
- Voltage
- Flange size and standard
- Immersion length
- Element diameter
- Element quantity and arrangement
- Power density
- Tube sheath material
- Terminal box direction
- Temperature sensor
- Low-level protection
- Explosion-proof design
- Control cabinet
Control System
Flanged immersion heaters can be used with a thermostat, temperature controller or complete control cabinet depending on heating power, tank size and process requirements.
Control options can include:
- Temperature controller
- Thermostat
- PID closed-loop control
- SCR / thyristor power regulation
- Staged power control
- Multi-zone control
- Liquid temperature monitoring
- Low-liquid-level interlock
- Over-temperature alarm and shutdown
- PLC control cabinet
- Remote signal interface
Safety Protection
Liquid immersion heating applications require reliable protection against element overheating, low liquid level, dry heating, leakage and electrical failure.
Available safety protection options include:
- High-limit temperature protection
- Liquid temperature monitoring
- Low-liquid-level interlock
- Dry-heating protection
- Overload, short-circuit, leakage and grounding protection
- Emergency stop through control cabinet
- High-temperature terminal box design
- Explosion-proof terminal box or explosion-proof control system for hazardous-area applications
Typical Applications
Flanged immersion heaters are used where liquids need to be heated directly inside tanks, vessels, circulation heaters or industrial process equipment.
Water tank heating
Used for industrial water tanks, process water systems and temperature-controlled water storage applications.
Oil tank heating
Provides direct immersion heating for oil tanks to maintain temperature, reduce viscosity and support fluid transfer.
Thermal oil heating
Can be used for thermal oil tanks or circulation systems where stable liquid temperature is required.
Chemical tank heating
Custom materials can be selected for chemical liquids according to corrosion level, concentration and process temperature.
Wastewater heating
Supports wastewater temperature maintenance, treatment process stability and low-temperature operation.
Pressure vessel heating
Designed for process vessels and pressure containers where flange connection and direct liquid heating are required.
Circulation heater element assembly
Used as the removable heating element bundle inside circulation heaters and inline liquid heating equipment.
Industrial cleaning tank heating
Provides heated liquid for cleaning, washing, degreasing and surface treatment tanks.
Marine tank heating
Can be customized for shipboard water, oil or auxiliary fluid tanks according to marine installation requirements.
Crude oil and heavy oil heating
Used for viscosity reduction, storage tank heating and oil transfer support in oilfield and petrochemical systems.
Process vessel temperature holding
Maintains stable temperature inside process vessels for batch heating and industrial liquid processing.
Hazardous-area liquid heating
Explosion-proof terminal boxes and control systems can be configured for hazardous-area liquid heating applications.
How to Select the Right Flanged Immersion Heater
To design a suitable flanged immersion heater, please provide the following liquid, tank, flange and control information when available.
1. Liquid type
Provide the liquid name, composition, viscosity, corrosion level and whether the liquid is heat-sensitive, dirty or easy to foul.
2. Tank or vessel size
Provide tank diameter, length, volume, vessel structure and available installation opening if known.
3. Liquid level
Provide normal liquid level and minimum liquid level. This is important for immersion length and dry-heating protection design.
4. Required temperature
Provide initial temperature, target temperature, temperature holding range and allowable temperature tolerance.
5. Heating time
Confirm how quickly the liquid needs to reach the target temperature so heating power can be calculated correctly.
6. Working pressure
Provide normal working pressure, maximum design pressure and whether the heater will be installed in a pressure vessel.
7. Flange standard
Provide flange standard, flange rating, flange diameter, bolt hole layout and sealing surface requirement.
8. Immersion length
Confirm available insertion depth, required heated length, cold section length and maintenance pull-out space.
9. Material requirement
Select SS304, SS316L, SS310S, Incoloy or corrosion-resistant material according to liquid temperature and chemical compatibility.
10. Voltage and power
Confirm supply voltage, phase, frequency and required heating power if already calculated.
11. Terminal box requirement
Confirm terminal box direction, wiring access, waterproof requirement, high-temperature requirement or explosion-proof requirement.
12. Safety protection requirement
Confirm requirements for over-temperature protection, low-liquid-level protection, dry-heating protection and emergency stop.
13. Control method
Confirm whether thermostat control, PID control, SCR power regulation, staged control, PLC control or remote signal is required.
14. Power density requirement
For viscous, heat-sensitive or scaling liquids, lower watt density may be needed to reduce local overheating and fouling risk.
15. Drawing or sample photo
If there is an existing flange, tank opening or old heater sample, provide drawings or photos to support accurate customization.
Frequently Asked Questions
Common questions about flanged immersion heaters for tanks, vessels and industrial liquid heating applications.
What is a flanged immersion heater?
A flanged immersion heater is an electric heating element assembly mounted on a flange and inserted directly into liquid inside a tank, vessel or circulation heater.
What liquids can it heat?
It can be designed for water, oil, thermal oil, hydraulic oil, chemical liquid, wastewater and other industrial process fluids according to material compatibility.
What information is needed to customize it?
Liquid type, tank or vessel size, flange standard, immersion length, power, voltage, working temperature, pressure, material and terminal box requirement are typically needed.
Can an explosion-proof terminal box be supplied?
An explosion-proof terminal box can be considered where applicable for hazardous-area liquid heating projects. The final configuration should be reviewed according to the site classification and project requirements.
Why is watt density important?
Watt density affects heater surface temperature. Viscous, heat-sensitive or scaling liquids may require lower watt density to reduce local overheating and fouling risk.
Why Choose Xiangyuan Machinery
Xiangyuan Machinery provides custom industrial electric heaters, heating elements and complete electric heating systems for demanding process applications. Each flanged immersion heater can be engineered according to liquid properties, tank size, flange standard, immersion length, heating power, material compatibility, control logic and safety requirements.
Thermal & Material Engineering
Custom design according to tank, vessel or circulation heater requirements Material selection for water, oil, chemical liquid and wastewater heating
Flexible Mechanical Arrangement
Flange size, immersion length and watt density customized by project
Control & Safety Integration
Standard, high-temperature or explosion-proof terminal box options Integrated heater and control cabinet supply
Complete Project Supply
Low-level and dry-heating protection options Factory inspection before delivery
Need a custom flanged immersion heater?
Tell us your liquid type, tank size, liquid level, flange standard, immersion length, required temperature, voltage, power and control requirements. Xiangyuan Machinery can customize flanged immersion heaters for tanks, vessels, circulation heaters and industrial liquid heating applications.