new century heaters

VERTICAL IMMERSION HEATERS

Our vertical immersion heaters for molten metal are built with heavy-gauge ICA wire wound on cast ceramic cores, ensuring consistent wire spacing for even heat distribution. The elements are designed to operate with high-density, high-conductivity, non-wetting protection tubes for reliable thermal performance in demanding applications.

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  • 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 our immersion heaters specifically for molten metal systems. When paired with our specially designed protection tubes, these heaters provide one of the most robust and efficient molten metal heat sources in the industry.

Power requirements are typically 25 to 30 percent lower than glow bar furnaces. Users benefit from a significant reduction in melt loss and improved metal quality compared to both glow bar and gas-fired reverb furnaces. These advantages, combined with extended refractory life, result in long-term cost savings.

Immersion heaters virtually eliminate melt loss in melters. Since the refractory is never superheated, refractory life is typically at least doubled over that of glow bar and gas-fired reverb holding and melting furnaces. Corundum formation is eliminated in properly designed immersion-heated systems. In contrast, superheating molten aluminum increases hydrogen absorption and promotes the formation of aluminum oxides, which may remain suspended in the melt or settle and later become reintroduced into circulation.

We use the heaviest gauge ICA wire in the industry to manufacture durable, long-life immersion heaters that can operate at temperatures up to 2,000°F. The wire is recessed in precision-cast ceramic cores with separating grooves that maintain proper coil spacing, preventing contact and shorting. Each core is engineered to match its mating protection tube, ensuring consistent performance. Extra-heavy leads are brought out and insulated away from the heater core for reliable, trouble-free connections.

In holding furnace applications, immersion heaters offer more efficient heat transfer by delivering energy directly into dip wells and degassers. This design avoids the insulating oxide layer that forms on the surface of molten metal. The heat source is located beneath any separating refractory arch and placed in close proximity to the dip well or degassing head for faster thermal response.

AVAILABLE HEATERS

Our ceramic components are engineered to withstand the demands of immersion heating and must pass a rigorous in-house quality control process. All vertical immersion heaters include a thermocouple, protection tube, and cast copper connectors for reliable, ready-to-install performance.

Part Numbers

NV9KW90V: Vertical 9KW 90V Immersion Heater with 8×30 Protection Tube, Thermocouple, Connectors, & Gasket

NV12KW120V: Vertical 12KW 120V Immersion Heater with 8×30, or 9×40 Protection Tube (NV12KW120-9×40), Thermocouple, Connectors, & Gasket

N3Phase: 3 Phase Vertical Heater, Thermocouple, Connectors, & Gasket

NV20KW120V: Vertical 20 KW 120V Immersion Heater Includes 12×42 Protection Tube, Thermocouple, Connectors, & Gasket

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

Start-Up in a Cold, Dry Furnace

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

Introducing Metal to the Furnace

  1. Reduce the heater power by 10%.
  2. After 15 minutes, add metal quickly until it reaches 3 inches above the top of the heaters .
  3. Increase power to 90% and continue filling the furnace.
  4. Raise the thermocouple high limit to 1850°F.
  5. If the heater approaches the high limit at 90% power, you may increase it to 1900°F.

Note: The metal temperature will drop significantly before beginning to rise.

Normal Operation

After determining the power required to maintain bath temperature (usually no more than 70%), set the maximum allowable power to 20% above that level to allow for recovery.

Protection Tube Maintenance

  • Buildup on protection tubes causes elevated heater temperatures and potential failure.
  • Spot buildup can lead to unexpected failure with no warning.
  • Periodic cleaning of protection tubes is essential for extending heater life.
  • Cleaning frequency depends on oxide buildup, often caused by alloy modifications or breakdown furnace contamination.

Modes of Immersion Heater Failure

Most common cause:
Sludge from the bull ladle sticking to the upper surface of the protection tube.
This sludge forms during melting and is
not removed by degassing.

Remedy:
Dispose of remaining sludge in a designated waste receptacle.
Scrape tubes regularly to remove buildup.
Watch for sludge accumulation on the
furnace floor, which can reach the bottom of the tube and cause failure.

Other Potential Failures and Remedies

  • Improper PID loop settings
  • Set to increase or decrease power at approximately 2% per minute.
  • Incorrect SCR fuse
  • Most SCR units use fast-acting fuses. Substitutes may lead to catastrophic failures, including molten metal contact with the protection tube.
  • Metal remaining in the tube may cause a replacement heater to fail as well.
  • Improper power transformer
  • Some furnace builders use 220V or 240V transformers in place of the recommended 200V, often due to delivery time constraints.
  • If your controller allows, limit the maximum output to 90%. Many SCR units include current limiting features.
  • High wire temperature
  • Lowering the maximum wire temperature by 100°F can double heater lifespan , according to manufacturers.
  • Current spikes may also contribute to premature failure.
  • Transformer configuration
  • If using two heaters, your system may have a Scot T-type transformer.
  • Using phase-angle firing instead of zero-crossover SCR firing may offer performance benefits. Some SCR units can be switched between modes.


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