An industrial electric heater converts electrical energy into heat to warm liquids, gases, or steam with precision and efficiency. Used across chemical, energy, food, and pharmaceutical industries, electric heat exchangers ensure thermal stability, process reliability, and environmental compliance in demanding industrial applications.
Industrial electric heater: definition and operating principles
An industrial electric heater is specifically designed for heating fluids, including hazardous liquids, whenever intermediate heating is required without interrupting the flow. Unlike a traditional heat exchanger, which draws heat from an external source, the electric process heater transfers the heat generated from electrical energy directly into the fluid through one or several resistive elements, ensuring immediate and highly efficient thermal input.
These elements are typically made from durable alloys such as stainless steel or Incoloy, chosen for their ability to withstand corrosion, high pressure, and elevated temperatures over extended periods. Shaped into a tubular configuration, these elements provide both mechanical strength and excellent heat transfer performance, guaranteeing stable thermal conditions in demanding industrial environments.
Depending on process requirements, the electric heat exchanger may be installed directly in tanks, mounted on flanges for integration into pipelines, or housed in pressurized vessels. Each unit incorporates advanced control systems with sensors and thermostats to maintain precise temperature levels, even under fluctuating operating parameters. This combination of robust construction and intelligent regulation allows the electric tubular heater to deliver stable, reliable, and energy-efficient heat wherever it is needed in the industrial process chain.
Applications of the electric heater in industrial processes
Because of their versatility, industrial electric heaters are used across multiple industrial sectors.
In the chemical and petrochemical industries, electric process heaters play a central role in keeping process fluids within precise temperature limits at every stage of production. Many heating systems are installed directly on transfer lines or at intermediate points in the process to prevent the fluid from cooling or thickening before it reaches the next reactor, separator, or storage tank. For example, when handling heavy oils, bitumen, or other viscous materials, industrial process heaters are used to maintain the required temperature to ensure proper flow conditions, protect pumps and metering equipment, and avoid process interruptions. This continuous thermal control is essential in facilities operating 24/7, where temperature deviations can compromise product quality and overall efficiency.
In power generation, electric heat exchangers are used to preheat auxiliary fluids like feedwater or lubrication oils to ensure optimal operating conditions for turbines and auxiliary equipment. Their ability to function within pressurized circuits makes them suitable for critical thermal applications, including steam generation systems where temperature stability is essential.
The food and beverage sector benefits from industrial tubular heaters in processes such as pasteurization, sterilization, or CIP (Clean-In-Place) cleaning, where both efficiency and hygienic design are key requirements. Similarly, in pharmaceuticals and cosmetics, process heaters provide precise temperature control for ingredients sensitive to thermal fluctuations, ensuring consistent product quality.
Industrial electric heaters are also used in HVAC systems and industrial drying to deliver controlled hot air streams for dehumidification, environmental conditioning, or cleanroom operations.
Across all these sectors, the ability to design electric heat exchangers tailored to each fluid, temperature range, and process constraint makes the electric heater a highly adaptable thermal solution.
Design features and technical considerations of industrial process heaters
Designing a high-performance industrial process heater requires balancing thermal efficiency, safety, and integration into complex industrial systems. Engineers consider parameters such as power density, flow rate, fluid properties, and operating pressures to ensure each electric heat exchanger delivers reliable performance without overheating or compromising process integrity.
Material selection is a decisive factor. Stainless steel 316L and Incoloy alloys are standard for many electric tubular heaters, while titanium or PTFE-coated elements are chosen for corrosive or ultrapure environments. When required, the entire industrial electric heater assembly is built according to international standards such as ASME, PED, or ATEX for explosive atmospheres, guaranteeing both safety and compliance.
To achieve consistent thermal performance, the heater design can incorporate internal flow guides or baffles, ensuring uniform heat distribution throughout the fluid and preventing temperature stratification. In addition, applying external thermal insulation helps minimize energy losses, which not only improves overall efficiency of the process heater but also enhances operator safety by keeping surface temperatures under control.
Modern electric heaters often integrate advanced control technologies such as closed-loop regulation, solid-state relays, and thyristor-based power management to maintain precise temperature control even when process conditions fluctuate. Furthermore, multi-stage power modulation helps reduce inrush currents at start-up, while additional safety features, including thermal cut-outs, ground fault detection, and insulation monitoring, ensure a higher level of operational reliability.
Finally, a major advantage of the industrial process heater lies in its level of customization. Each unit can be engineered according to the specific fluid, pressure, power rating, and control requirements of the application. By combining expertise in thermal engineering, pressure vessel design, and industrial automation, manufacturers can deliver fully integrated, ready-to-install electric process heaters that ensure long-term performance and reliability across all process conditions.
Learn more about Quiri, designer and manufacturer of industrial electric heaters and tubular heat exchangers
As a specialist in the design and manufacture of tubular heat exchangers, Quiri Thermal Engineering offers a comprehensive range of electric heaters: gas heater, fuel heater and more. Our expertise covers every aspect of heat transfer engineering, enabling us to design and manufacture fully customized industrial tubular heaters tailored to the specific requirements of each process, including fluid type, temperature, and flow rate. For more information regarding our shell and tube heat exchangers, pressure vessels or electric heaters, please do not hesitate to contact our experts.