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Industrial Flange Heaters: High-Efficiency Immersion Solutions
Direct from Manufacturer. Custom engineered for Oil Tanks, Water Processing, and Corrosive Chemical environments.
- ANSI Flanges 2"-24"
- Incoloy & SS316L Sheath
- 480V/600V 3-Phase
How to distinguish different flange heaters
As an expert in industrial heating, I have categorized the types of flange heaters based on application scenarios, structural design, control methods, and explosion-proof ratings.
For B2B procurement managers and engineers, selecting the correct type is not just about efficiency—it is a matter of operational safety.
Classification by Heating Medium
This is the most critical classification, as the medium determines the watt density ($W/cm^2$) and the sheath material of the heating elements.
Water Heating Flange Heaters
- Characteristics: High watt density (typically $6-10 W/cm^2$).
- Materials: Usually Stainless Steel 304 or 316L.
- Applications: Industrial boilers, cleaning systems, water storage tanks.
Oil Heating Flange Heaters
- Characteristics: Extremely low watt density (usually $1-2.5 W/cm^2$) to prevent oil carbonization caused by localized overheating.
- Materials: Carbon Steel or Stainless Steel.
- Applications: Thermal oil furnaces, hydraulic oil heating, lubricant preheating.
Corrosive Chemical Heating
- Characteristics: High resistance to chemical attack.
- Materials: Incoloy 800/840, Titanium, or PTFE (Teflon) coatings.
- Applications: Electroplating baths, phosphating tanks, strong acid/alkali heating.
Classification by Protection Rating
This relates directly to the design of the Terminal Box, a key focus for engineers during technical reviews.
General Purpose
NEMA 1 rated, suitable for standard indoor industrial environments.
Moisture/Weather Resistant
NEMA 4/4X rated, featuring gaskets to prevent rain or spray from entering the housing.
Explosion-Proof
NEMA 7 rated. These feature heavy-duty, flame-proof enclosures designed to contain internal sparks and prevent the ignition of external flammable gases.
Applications
Oil storage tanks
Pipelines
Chemical reactors
Thermal oil systems
Water tanks
Technical Specifications
Comprehensive data for Mechanical Engineers and Procurement Managers.
| Project | Parameter Example |
| Power | 3 kW – 300 kW |
| Voltage | 220V / 380V / 415V / 480V |
| Heating Medium | Water / Oil / Gas |
| Flange Standard | ANSI / DIN / JIS / Customized |
| Heating Element | SS304 / SS316 / Incoloy |
| Temperature Range | Up to 450°C |
| Protection Class | IP65 / IP66 |
| Certification | CE / ATEX / IECEx |
| Temperature Control | Integrated Thermowell with Thermostat or Type J/K Thermocouple |
Explosion-Proof Option
Explosion-proof flange heaters are designed for hazardous areas with flammable gases or dust.
Explosion-proof enclosure: Ex d / Ex e
Hazardous area: Zone 1 / Zone 2
Temperature class: T3 / T4 / T5
Compliant with ATEX / IECEx standards
Support non-standard customization
It can be customized according to customer requirements and drawings, and we can also provide customers with thoughtful solutions
Why Engineers Choose Elekheat
Built for Performance. Verified for Safety.
Corrosion Resistance
We use premium Incoloy 800/840 and SS316L seamless tubing to withstand harsh chemical environments and high-temperature oxidation.
Precision TIG Welding
Every element is TIG-welded to the flange face, ensuring a leak-proof seal capable of withstanding pressures up to 3000 PSI.
Safety Compliance
Available with NEMA 4 (Moisture) and NEMA 7 (Explosion Proof) terminal housings for hazardous locations (Class I, Div 1).
Quality & Manufacturing Capability
Certified manufacturing, strict quality control, and proven export experience for explosion-proof flange heaters used in hazardous industrial environments.
Factory & Workshop
Our flange heaters are manufactured in a dedicated industrial facility with specialized workshops for heating element fabrication, welding, assembly, and explosion-proof enclosure installation.
Production Process
Quality Control & Testing
100% routine testing before shipment
Incoming Material Control
All incoming materials are inspected and verified to ensure compliance with technical specifications and certification requirements.
In-Process Quality Control
- Welding inspection
- Dimensional and assembly checks
- Electrical wiring verification
Final Testing
| Test Item | Description |
|---|---|
| Insulation Resistance Test | Ensure electrical safety |
| Dielectric Strength Test | High-voltage withstand test |
| Power & Performance Test | Rated power verification |
| Temperature Control Test | Safety temperature limitation |
| Explosion-Proof Inspection | For ATEX / IECEx models |
Compliance & Certification
Stop Production Downtime Caused by Heater Failure
In heavy-duty industrial applications, generic off-the-shelf heaters often fail due to improper watt density or material incompatibility. This leads to carbonization in oil tanks or rapid scaling in water systems.
Elekheat’s Flanged Immersion Heaters are built differently. We calculate specific watt density (W/cm²) based on your exact medium viscosity. Whether you need a replacement for a boiler or a custom solution for a petrochemical tank, our heaters are engineered to last.
Installation Example
Size confirmation
Before purchasing, confirm whether the flange size, the center distance of themounting holes and the pipe length from the flange to the bottom are appropriate.
For the first installation, you need to purchase the matching flange
For top-mounted installation, pay attention to the length of the cold zone to avoid local hightemperature that may burn the heating tube
At ELEKHEAT, we’re here to provide the answers you need. Whether you’re looking for product information, technical specifications, or need assistance with maintenance, our team of experts is ready to help. Don’t hesitate to reach out—we’re committed to ensuring you get the support you need for the best heating solutions.