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Selecting Sheath Materials for Industrial Heating Elements

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The metal sheath of a tubular heating element separates the internal resistance wire and compacted electrical insulation from the process environment. It must transfer heat, resist corrosion, tolerate operating temperature and survive fabrication, welding and thermal cycling. Choosing a familiar stainless steel grade without considering the medium can lead to early leakage, pitting, oxidation or mechanical failure.

No sheath material is universally best. A suitable choice depends on the complete medium composition, concentration, operating and maximum temperature, flow, pressure, deposit tendency, cleaning chemicals and expected service life. Material tables are useful for screening, but final selection should be confirmed for the actual application.

The Sheath Has Several Jobs

A heating-element sheath provides mechanical protection, contains the compacted insulating material, transfers heat into the process and forms the wetted or exposed surface. Its thermal conductivity affects temperature distribution, while its oxidation and corrosion resistance determine how well it survives the environment. Bending, swaging and welding requirements also influence which alloys can be manufactured reliably.

The sheath should be evaluated together with the flange, supports, welds, fittings, terminal seals and vessel. A corrosion-resistant element installed through an incompatible flange can still fail at the connection. Galvanic interaction between dissimilar metals may also matter in conductive liquids.

Common Material Families
Material family Typical strengths Important limitations
Copper and copper alloys Good heat transfer and useful in compatible water service Unsuitable for many corrosive chemicals and higher-temperature duties
Carbon steel Cost-effective for selected oils and compatible processes Limited corrosion and oxidation resistance; water chemistry must be reviewed
304 or 321 stainless steel General corrosion resistance and practical fabrication Chlorides and specific chemicals can cause pitting or stress corrosion
316L stainless steel Improved resistance in some chloride and chemical services Not immune to chloride attack; concentration and temperature remain critical
Nickel alloys such as Incoloy Useful oxidation and high-temperature performance in suitable services Higher cost and grade-specific corrosion limits require careful selection

 

Temperature Changes Material Behaviour

Process temperature is not the same as sheath temperature. The sheath must be hotter than the surrounding medium to transfer heat, and deposits or low flow can increase that difference substantially. A material that is acceptable at the bulk-fluid temperature may oxidize or lose strength if the actual sheath temperature is much higher.

Start-up, shutdown and cycling also matter. Repeated expansion and contraction can stress bends, brazed joints, welds and terminal seals. High-temperature air and gas applications require review of oxidation resistance, airflow distribution and element surface loading. The maximum upset condition should be included rather than using only the normal setpoint.

Water Chemistry Is More Than the Word Water

Water applications vary widely. Chloride content, hardness, pH, dissolved oxygen, treatment chemicals and operating temperature can change corrosion and scale behaviour. Hard-water deposits insulate the sheath and increase its temperature. Chlorides can promote localized attack on stainless steels, especially as temperature and concentration rise.

For replacement heaters, a history of scale, pitting or leakage is valuable evidence. Simply reproducing the original material may repeat the same failure if water quality or operating conditions have changed. The user should provide available water analysis and the cleaning method.

Oils and Viscous Media Need Lower Surface Stress

Thermal oils, lubricants, resins and viscous products often remove heat less effectively than water. Excessive element loading can overheat or carbonize the product at the sheath surface. Material selection alone cannot solve this problem. Watt density, circulation, element spacing, control response and allowable film temperature must be reviewed together.

The medium should be identified by its exact trade name or composition where possible. Flash point, viscosity over the operating range, degradation temperature and contamination should be considered. Compatibility with cleaning fluids is also required.

Chemical Service Requires Composition and Concentration

A general description such as acid, alkaline solution or process chemical is not enough for material selection. The same chemical may behave differently at another concentration, temperature or aeration level. Mixtures and contaminants can be more aggressive than the main ingredient. Published corrosion charts are screening tools and do not replace project-specific review or testing.

Fabrication and Certification Constraints

Material availability, tube diameter, wall thickness, bend radius and welding procedure can limit feasible combinations. Some projects require traceable material certificates, positive material identification or third-party inspection. These requirements should be stated before production because they affect sourcing, documentation, cost and lead time.

For hazardous-area equipment, sheath material is only one part of compliance. Terminal enclosures, cable entries, temperature classification and the certified assembly scope must meet the project requirement. A material certificate or inspection report cannot substitute for a required explosion-protection certificate.

Information Needed for Selection
  • Exact medium name, composition and concentration
  • Normal, minimum and maximum operating temperature
  • Flow rate, tank volume, agitation and minimum liquid level
  • Operating pressure and design pressure
  • Required power, voltage, phase and duty cycle
  • Known deposits, corrosion history and cleaning chemicals
  • Installation geometry, flange or thread and available space
  • Required material traceability, inspection and certification documents
Conclusion

Sheath material selection is a combined thermal, chemical and mechanical decision. Stainless steel, carbon steel, copper and nickel alloys each have useful applications, but their suitability changes with temperature, medium composition, flow, deposits and fabrication details. Confirming these conditions before manufacture reduces the risk of corrosion and overheating.

Runkel manufactures customized industrial heating elements and electric heaters for confirmed applications. Send process data, drawings or existing-heater information for technical selection support. Final material approval depends on verified operating conditions and project requirements.

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Top 6 Industrial Electric Heater Manufacturers in 2026 | Runkel Electric Heating
Runkel Electric Heating

Top 6 Industrial Electric Heater Manufacturers in 2026

Six brands that supply industrial and explosion-proof electric heaters, compared on origin, range and hazardous-area offer, with the checks that matter before you ask for a quote.

Published October 20, 2026 by Runkel Electric Heating. Company facts checked October 2026.

The six brands at a glance

Two of the six share an owner: Spirax Group owns both Chromalox and Vulcanic. Caloritech is the process-heating brand of Thermon. EXHEAT, Runkel and Watlow are covered one by one below.

Brand Founded Based in Core range Hazardous-area offer
Caloritech (Thermon) 1954 Austin, Texas, USA Process heaters, electric boilers, heat tracing Ruffneck explosion-proof unit and convection heaters. Not every Caloritech model is hazardous-rated.
Chromalox 1917 Pittsburgh, Pennsylvania, USA Industrial heaters, heat tracing, packaged systems, controls Ex d and Ex e heaters for Zones 1 and 2, per a UK distributor listing.
EXHEAT Not verified United Kingdom Hazardous-area heaters and controls ATEX, UKEx and IECEx products: enclosure, air, immersion and portable fan heaters.
RunkelPublisher of this guide 2015 Qingdao, China Explosion-proof, circulation, bundle and duct heaters; tubular elements; PTC; cartridge heaters Explosion-proof series, rated by model. Circulation units up to 3,000 kW.
Vulcanic 1973 Neuilly-sur-Marne, France Immersion, flow and air duct heaters, cables, controls ATEX immersion heaters, flow heaters and radiators.
Watlow 1922 St. Louis, Missouri, USA Heaters, sensors, controllers, system assemblies Not detailed in the sources we checked. Ask for model-level certificates.

Scroll sideways on a phone to see every column. “Not verified” means we could not confirm the detail from the sources listed at the end of this page.

Caloritech (Thermon)

Parent company
Thermon Group Holdings
Founded
1954
Based in
Austin, Texas, USA

Caloritech is the process-heating brand of Thermon, a US company best known for heat tracing. Thermon’s Ruffneck line covers explosion-proof electric unit heaters and convection heaters built for oil and gas sites, and the Caloritech name also appears on electric boilers.

Best fit: North American process-heating projects that also need heat tracing from the same supplier.

Check first: some Caloritech models, such as the BX convection heater, are not intended for hazardous locations. Confirm the certification of the exact model you plan to buy.

Chromalox

Parent company
Spirax Group
Founded
1917
Based in
Pittsburgh, Pennsylvania, USA

Chromalox is one of the oldest names in electric heating. Its first product was a strip heater, and it has been part of Spirax-Sarco, now Spirax Group, since 2017. It sells industrial heaters, heat tracing and packaged heating systems. UK distributor listings describe Ex d flameproof and Ex e increased-safety heaters for Zone 1 and Zone 2.

Best fit: large projects that want packaged systems and controls from one global brand.

Check first: lead time and local service cover for custom units, which can vary by region.

EXHEAT

Founded
Not verified
Based in
United Kingdom
Certification listed
ATEX, UKEx, IECEx

EXHEAT builds hazardous-area electric heating and control equipment in the UK. Its catalogue runs from small enclosure heaters and air warmers to tank immersion heaters and a portable fan heater, with ATEX, UKEx and IECEx certification listed through its UK distributor.

Best fit: smaller hazardous-area jobs, such as cabinets, workshops and compact tank heating, where UK or European certification is required.

Check first: the sources we used did not confirm EXHEAT’s founding year or ownership, so verify both directly with the company.

Runkel

Group
Yangzhong Sanhuan Electric Heating Group
Founded
2015
Based in
Qingdao, China
Quality system
ISO 9001:2015

Runkel Electric Heating was set up in 2015 as the foreign-trade arm of the Yangzhong Sanhuan group and works with group plants in Yangzhong, Shijiazhuang and Shenyang. Its 2026 brochure lists explosion-proof, circulation, bundle and duct heaters, food-grade explosion-proof heaters, tubular and liquid heating elements, PTC heaters, cartridge heaters, flexible ceramic heaters, bolt heaters and tube-production machines.

Circulation heater units are listed at 380 V up to 3,000 kW, and high-temperature duct heaters from 10 to 3,000 kW at 220 to 380 V.

Best fit: buyers who want a China-based maker to engineer custom explosion-proof, circulation or duct heaters to a specification, with price as a deciding factor.

Check first: the certificates shown in Runkel’s brochure are issued to group manufacturing companies, so request the one that names your model, zone and temperature class.

Two explosion-proof bundle electric heaters, one with an orange terminal housing and one with a grey housing
Explosion-proof bundle heaters from Runkel’s 2026 product brochure.

Vulcanic

Parent company
Spirax Group (since 2022)
Founded
1973
Based in
Neuilly-sur-Marne, France

Vulcanic has made electric heating and cooling equipment since 1973. Its range includes immersion heaters, flow heaters, air duct heaters, heating cables and controls, with ATEX versions of the immersion and flow heaters. Spirax Group agreed to buy it in 2022, so it now sits alongside Chromalox.

Best fit: European sites that need ATEX-marked immersion or flow heaters.

Check first: the notified body and certificate number printed in the ATEX marking of your model.

Watlow

Founded
1922
Based in
St. Louis, Missouri, USA

Watlow designs industrial heaters, sensors, controllers and system assemblies. That mix of heating and control hardware suits projects that need the whole thermal loop from one supplier.

Best fit: equipment makers and process lines that need heaters matched with sensors and controllers.

Check first: the sources we used did not detail Watlow’s hazardous-area range, so ask for model-level certificates.

How to choose an electric heater manufacturer

Start with the hazardous area. The zone tells you how often an explosive gas atmosphere is present, and it sets the protection type and certificate you need.

  • Zone 0 More than 1,000 hours a year Explosive gas is present continuously or for long periods.
  • Zone 1 10 to 1,000 hours a year Explosive gas is likely to appear in normal operation.
  • Zone 2 0.1 to 10 hours a year Explosive gas is not expected in normal operation and, if it appears, is brief.
Protection type Ex d flameproof, Ex e increased safety or another type, matched to the zone and the heater design.
Certificate ATEX, IECEx, UKEx or the national scheme of the destination country. It should name the exact model, not just the product family.
Medium and temperature What is being heated, the target temperature, the working pressure and the temperature class required.
Power and supply Total kW, supply voltage, phases and the number of heating stages.
Protection devices Overcurrent, overvoltage, phase-loss and over-temperature protection, and whether the heater connects to a DCS.
Documents and support Drawings, test reports, lead time, spare parts and who handles site questions.

Frequently asked questions

Who are the top industrial electric heater manufacturers in 2026?

This guide compares six brands: Caloritech (Thermon), Chromalox, EXHEAT, Runkel, Vulcanic and Watlow. They are listed alphabetically rather than ranked, because the best fit depends on hazardous-area rating, power range, region and budget.

What is the difference between Ex d and Ex e electric heaters?

Ex d (flameproof) heaters use an enclosure that can withstand an internal explosion and stop it igniting the atmosphere outside. Ex e (increased safety) heaters add design measures that prevent arcs, sparks and excessive temperatures during normal operation.

Do Chromalox and Vulcanic belong to the same company?

Yes. Both are owned by Spirax Group, which bought Chromalox in 2017 and acquired Vulcanic in 2022.

What should I ask a manufacturer before buying an explosion-proof heater?

Ask for the certificate that names your exact model, the hazardous zone and temperature class it covers, the maximum medium temperature and pressure, and the protection devices fitted. Also confirm lead time, drawings and spare-part support.

Send us your heater specification

Share the medium, target temperature, power, voltage and hazardous zone, and Runkel’s engineers will reply with a proposal and quotation.

Email info@runkel.cn
Telephone
+86 13360463744, +86 13904545333
Email
info@runkel.cn
Address
46th Floor, Qingdao Wanbang Center, No. 2 Hong Kong Middle Road, Shinan District, Qingdao, Shandong Province, China

Sources and method

Facts were checked in October 2026 against the pages below and Runkel’s own 2026 product brochure. Company details can change, so confirm them with each vendor.

Top 6 Industrial Electric Heater Manufacturers in 2026

Top 6 Industrial Electric Heater Manufacturers in 2026

Industry News

Selecting Sheath Materials for Industrial Heating Elements

The metal sheath of a tubular heating element separates the internal resistance wire…

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