Chemical processing facilities rely on electric process heaters to maintain precise temperatures for tanks, pipelines, reactors, and air systems. Choosing the right Chromalox heater improves process efficiency, product quality, and equipment reliability.
Flanged Immersion Heaters
Flanged immersion heaters are one of the most common heater styles used throughout chemical processing plants. They install directly into tanks or vessels through a bolted flange and are designed to heat:
These heaters provide high heating capacity while remaining easy to service when maintenance is required.
- Water
- Process chemicals
- Caustic solutions
- Heat transfer oils
- Cleaning solutions
These heaters provide high heating capacity while remaining easy to service when maintenance is required.
Circulation Heaters
Circulation heaters heat liquids or gases while they flow through piping systems. A circulation heater combines electric heating elements with a pressure vessel, allowing process fluids to be heated before reaching downstream equipment.
Typical applications include:
They provide accurate temperature control and are commonly paired with PID controllers and temperature sensors.
Typical applications include:
- Chemical transfer lines
- Water systems
- Heat transfer oil loops
- Fuel gas heating
- Process skids
They provide accurate temperature control and are commonly paired with PID controllers and temperature sensors.
Screw Plug Heaters
Screw plug heaters are compact immersion heaters that thread directly into smaller tanks, reservoirs, and piping. They are commonly used for:
Because they require only a threaded connection, installation is straightforward.
- Pump reservoirs
- Lubrication systems
- Freeze protection
- Small chemical tanks
Because they require only a threaded connection, installation is straightforward.
Process Air Heaters
Process air heaters are designed to heat moving air and other gases. In chemical plants they are often used for:
Chromalox manufactures several styles depending on airflow, operating temperature, and hazardous-area requirements.
- Drying systems
- Air preheating
- Gas heating
- Ventilation systems
- Instrument air
Chromalox manufactures several styles depending on airflow, operating temperature, and hazardous-area requirements.
Heat Transfer Systems
Rather than heating a process directly, heat transfer systems circulate thermal fluid through equipment. These systems provide consistent temperatures for:
They are often selected when precise process control and uniform heating are critical.
- Reactors
- Mix tanks
- Jacketed vessels
- Heat exchangers
- Batch processing equipment
They are often selected when precise process control and uniform heating are critical.
How to Select the Right Heater
Selecting the proper heater begins with understanding the process. Consider:
Proper sizing improves heater life while helping maintain stable process temperatures.
- Fluid or gas being heated
- Operating temperature
- Required heat output
- Flow rate
- Pressure
- Tank or pipe connection
- Hazardous-area classification
- Available voltage
Proper sizing improves heater life while helping maintain stable process temperatures.
Frequently Asked Questions
Which Chromalox heater is best for chemical tanks?
Flanged immersion heaters are the most common choice for heating process tanks and vessels.
When should circulation heaters be used?
Whenever liquids or gases need to be heated while flowing through piping.
Can Chromalox heaters be installed in hazardous locations?
Yes. Many models are available with hazardous-location approvals when properly specified.
What information is needed to replace a heater?
Temperature, fluid type, voltage, wattage, pressure, process connection, flow rate, and hazardous-area requirements.
Flanged immersion heaters are the most common choice for heating process tanks and vessels.
When should circulation heaters be used?
Whenever liquids or gases need to be heated while flowing through piping.
Can Chromalox heaters be installed in hazardous locations?
Yes. Many models are available with hazardous-location approvals when properly specified.
What information is needed to replace a heater?
Temperature, fluid type, voltage, wattage, pressure, process connection, flow rate, and hazardous-area requirements.
Finding Replacement Chromalox Heaters
Big Chief supplies genuine Chromalox process heaters for chemical processing applications, including immersion heaters, circulation heaters, process air heaters, screw plug heaters, and complete thermal systems. Our engineering team can help identify the correct replacement heater based on your process conditions and equipment specifications.
