PHI Immersion Heaters
PHI Immersion Heater Solutions
Immersion heating places the heat source directly inside the molten-metal bath, allowing heat to be transferred closer to where it is required.
For aluminum processing, this can support fast temperature recovery, stable bath temperature, reduced furnace heat loss and improved process control compared with heating the bath only from the furnace atmosphere or surface.
PHI provides several immersion-heating technologies depending on the application.
Direct Heating for Aluminum Melting, Holding & Die Casting
PHI provides immersion heater solutions for molten aluminum, designed to transfer heat directly into the metal bath.
Compared with conventional indirect furnace heating, immersion heating places the heat source closer to the aluminum, supporting:
Faster Temperature Recovery
Stable Molten-Metal Temperature
Efficient Direct Heat Transfer
Reduced Furnace Heat Loss
Improved Process Control
Immersion heating applies to HPDC, gravity die casting, LPDC, degassing, filtration and transfer-ladle applications. PHI can provide different immersion-heating technologies depending on the furnace design, aluminum capacity, required heating power and operating condition.
Immersion Heater Technologies
Ultra-Compact Immersion Heater
High power from a compact heating area.
PHI Customized Resistance-Wire Immersion Heater
Engineered around your furnace.
PHI SiC Immersion Heater
High-temperature heating for aluminum melting & holding.
01
High Power from a Compact Heating Area
Ultra-compact immersion heaters are designed to provide high heating output while occupying relatively little space inside the molten-aluminum bath.
This makes them particularly suitable for applications where furnace space is limited but rapid heat recovery is required.
Key Benefits
Compact Design
Suitable for restricted installation areas.
Direct Heating
Heat is transferred directly toward the molten metal.
Fast Recovery
Supports quick temperature recovery after metal charging or transfer.
Stable Temperature Control
Suitable for aluminum holding and die-casting applications.
Applications
- Holding Furnace
- HPDC
- LPDC
- Gravity Die Casting
- Degassing Unit
- Filtration Unit
- Transfer Ladle
- Launder Heating
02
Engineered Around Your Furnace
PHI can design and manufacture customized immersion heaters using industrial heat-resistant resistance wire or heating coils.
Depending on the application, PHI can use suitable FeCrAl or NiCr resistance-heating alloys.
The heating wire is installed inside an electrically insulated and protected heater structure rather than being directly exposed to molten aluminum.
Fully Customizable
PHI can customize:
- Voltage
- Power / kW
- Electrical Resistance
- Heater Diameter
- Overall Length
- Heating Length
- Immersion Depth
- Protection Tube
- Mounting Flange
- Terminal Arrangement
- Thermocouple
- Electrical Connection
This solution is particularly suitable for
Replacement Heater
When an existing heater needs to be reproduced or redesigned.
Special Furnace Design
For furnaces requiring unusual dimensions or installation positions.
OEM Furnace Production
For furnace manufacturers requiring customized heating elements.
Retrofit Projects
For upgrading an existing furnace heating system.
03
High-Temperature Heating for Aluminum Melting & Holding
For demanding aluminum melting and holding applications, PHI can provide immersion heater assemblies using Silicon Carbide (SiC) heating elements.
SiC heating elements offer high-temperature capability and high heat-generation potential, making them suitable for industrial aluminum furnace applications.
Important Design Principle
The SiC heating element itself should not be placed directly in molten aluminum.
Instead, the heating element is integrated into an appropriately engineered protection-tube assembly.
Applications
- Aluminum Melting Furnace
- Aluminum Holding Furnace
- Central Melting System
- Die-Casting Holding Furnace
- Furnace Retrofit
- Customized Non-Ferrous Furnace
Which Immersion Heater Is Suitable?
| Technology | Main Strength | Typical Application |
|---|---|---|
| Ultra-Compact Immersion Heater | High output from compact space | Holding, HPDC, LPDC |
| PHI Resistance-Wire Heater | Maximum customization | Replacement, OEM, retrofit |
| PHI SiC Immersion Heater | High-temperature capability | Melting & holding |
Heater Selection Depends on Your Process
- Aluminum Capacity
- Operating Temperature
- Required Heating Power
- Heat Loss
- Required Recovery Time
- Furnace Dimensions
- Available Installation Space
- Voltage & Power Supply
Aluminum Melting
Electric heating solutions for molten-aluminum production.
Holding Furnace
Maintain stable aluminum temperature before casting.
HPDC
Immersion heating for high-pressure die-casting holding furnaces.
LPDC
Controlled heating for low-pressure die-casting systems.
Gravity Die Casting
Stable bath temperature and rapid temperature recovery.
Transfer & Launder Heating
Reduce temperature loss during molten-metal transfer.
Related Products
PHI Non-Ferrous Furnaces
PHI Non-Ferrous Flux
PHI Crucible
PHI Coating
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