new century heaters

HORIZONTAL IMMERSION HEATERS

Our horizontal immersion heaters for molten metal use heavy-gauge ICA wire wound on cast ceramic cores, ensuring precise wire spacing for even heat distribution. The elements are housed in high-density, high-conductivity, non-wetting protection tubes for reliable performance in demanding environments.

  • Drop Shipping to Installation Facilities is Available
  • Dedicated Customer Service Representatives
  • Industry-Leading Manufacturing Timelines, Expedites Also Available


heaters are single phase

Immersion heaters improve heat transfer in holding furnaces by delivering energy directly into dip wells and degassers. This avoids the oxide layer that forms on the surface of molten metal.

save up to 30% on energy

Immersion heaters typically require 25 to 30 percent less power than glow bar furnaces. They also significantly reduce melt loss and improve metal quality compared to both glow bar and gas-fired reverb furnaces.

controls available

We also supply immersion heater accessories including seal cones, ceramic inserts, thermocouples, mounting hardware, protection tubes, and more.

made in the usa

New Century immerison heaters are designed & manufactured in Eau Claire, Wisconsin, U.S.A.

WE WILL WORK WITH YOUR FURNACE BUILDER 

New Century Heaters has engineered immersion heaters specifically for molten metal systems. Paired with specially designed protection tubes, these heaters deliver one of the most robust and efficient molten metal heat sources available.

Power requirements are typically 25 to 30 percent lower than glow bar furnaces. Compared to glow bar and gas-fired reverb furnaces, immersion heaters significantly reduce melt loss and improve metal quality. These benefits, combined with extended refractory life, result in substantial cost savings for the user.

Immersion heaters virtually eliminate melt loss in melters. Since the refractory is never superheated , its service life is typically at least doubled compared to traditional heating methods. Properly designed immersion-heated furnaces also eliminate corundum formation. Superheating the surface of molten aluminum increases hydrogen absorption and leads to the formation of aluminum oxides , which can remain suspended or settle in the melt.

We use the heaviest gauge wire in the industry to build long-lasting immersion heaters capable of operating up to 2,000°F. The resistance wire is recessed in precision-cast ceramic cores with separated grooves to prevent coil contact and shorting. Each ceramic insert is engineered to match its mating protection tube, optimizing heat transfer. Extra-heavy leads are extended and insulated away from the heater core to ensure trouble-free electrical connections .

In holding furnaces, immersion heaters deliver heat directly into dip wells and degassers. The energy bypasses the insulating oxide layer on the melt surface, resulting in more efficient thermal transfer. Because the heat source is placed beneath any separating refractory arch and close to the dip well or degassing head, response times and performance are improved.

AVAILABLE HEATERS 

Our ceramic components are specifically engineered to withstand the demands of immersion heating and must pass a rigorous in-house quality control process. All horizontal immersion heaters include a thermocouple and cast copper connectors . Protection tubes are not included and must be ordered separately.

Part Numbers

NH10.5KW120V: Horizontal 10.5KW 120V Immersion Heater with thermocouple & connectors.

NH12KW200V: Horizontal 12KW 200V Immersion Heater with thermocouple & connectors.

NH15KW120V: Horizontal 15KW 120V Immersion Heater with thermocouple & connectors.

NH15KW200V: Horizontal 15KW 200V Immersion Heater with thermocouple & connectors.

NH17.5KW200V: Horizontal 17.5KW 200V Immersion Heater with thermocouple & connectors.

NH19.5KW95V: Horizontal 19KW 95V Immersion Heater with thermocouple & connectors.

Immersion Heaters Are Ideal Solutions For: 
  • Holding Furnaces (inline & free-standing)
  • Degassing Stations (inline & free-standing)
  • Low-Pressure Furnaces
  • Molten Metal Filter Boxes
  • High Purity Melters
  • Automatic Pouring Systems
  • Ladle Melting Furnaces (crucible & refractory-lined)
  • Temperature Boosters in Dip-Wells


Start-Up in a Cold, Dry Furnace

  1. Close the furnace.
  2. Before turning the power on:
  • Set the heater thermocouple high limit to 1700°F.
  • Set the initial power to the heater at 15%.
  • Turn the power on.
  1. Increase the power by 5% every 5 minutes until the heater temperature approaches 600°F.
  2. As the furnace warms up, reduce power to avoid tripping the 1700°F high limit. Excessive cycling can damage the ceramic tube and heater wire.
  3. Allow the heater to run at or just below 1700°F until the interior of the furnace reaches 1400°F.
  4. Hold the furnace at 1400°F (± 50°F) for four hours before adding metal. Some furnaces may require up to 48 hours of preheating.

Introducing Metal to the Furnace

  1. Reduce power to the heaters by 10%.
  2. After 15 minutes, add metal quickly until the level is 3 inches above the top of the heaters.
  3. Turn power up to 90% and continue filling.
  4. Raise the thermocouple high limit to 1850°F.
  5. If necessary, increase the high limit to 1900°F to maintain heating.

Note: The metal temperature will drop before it begins to rise.

Normal Operation

After identifying the power required to maintain the bath temperature (typically not more than 70%), set the maximum power to about 20% higher to allow for recovery.

Protection Tube Maintenance

Build-up on the protection tube can raise heater temperature and cause failure. Spot build-up may lead to sudden failure without warning.

Scraping the protection tubes periodically helps ensure longer heater life. Oxide buildup is often caused by alloy modifications and carryover from the breakdown furnace.

Common Causes of Heater Failure

Sludge from the bull ladle is the most common cause, forming during melting and sticking to the top of the protection tube. Degassing does not remove this sludge.

Remedy:
Sludge should be emptied into a waste receptacle. Scrape protection tubes regularly. Watch for sludge on the furnace floor that could rise near the bottom of the tube.

Other Possible Failures and Fixes

  • Improper PID loop settings: Adjust to change power at approximately 2% per minute.
  • Incorrect SCR fuse: Using slow-acting fuses can cause catastrophic heater failure and molten metal damage inside the tube.
  • Wrong power transformer: Using 220V or 240V transformers instead of 200V can lead to failures. If possible, limit maximum output to 90% via your controller.
  • High wire temperature: Lowering max temperature by 100°F may double heater life.
  • Dual-heater setups (Scot T-type transformers): Consider using phase-angle firing instead of zero crossover. Some SCR units support this option.


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