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How to Size and Specify an Industrial Electric Air Heater

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An accurate air-heater quotation begins with the process duty, not a catalogue power rating. Flow basis, temperature rise, pressure, gas composition and control requirements all affect the heater body, element arrangement and electrical system. This guide explains the information a supplier needs and the checks a buyer should make before approving a design.

Start with the required heating duty

The basic heat requirement for a gas stream can be estimated from mass flow, specific heat and temperature rise. In simplified form, heat duty equals mass flow multiplied by specific heat and the difference between outlet and inlet temperature. The final installed power also needs an allowance for heat loss, start-up conditions and reasonable operating margin. A fixed percentage should not be added automatically; the margin should reflect insulation, ambient conditions, control method and the stability of the flow.

A common source of error is treating normal cubic metres per hour and actual cubic metres per hour as the same value. Normal flow is referenced to stated temperature and pressure conditions, while actual flow describes the volume passing through the heater at operating conditions. The difference affects mass flow, gas velocity, pressure drop and casing diameter. Every request for quotation should state the flow unit and its reference conditions.

Confirm the process data before selecting equipment

The supplier should receive the normal, minimum and maximum values for the process. Designing only around one nominal point can produce slow warm-up at peak flow or unstable control at low flow. The following information forms a useful minimum data set:

  • Heating medium and composition, including moisture, dust, oil mist or corrosive traces.
  • Normal, minimum and maximum flow, with a clear statement of whether the value is mass flow, normal volume or actual volume.
  • Inlet temperature, required outlet temperature and allowable temperature tolerance.
  • Operating and design pressure, permitted pressure drop and connection standard.
  • Continuous or intermittent duty, start-up frequency and required heat-up time.
  • Installation location, ambient temperature, enclosure needs and hazardous-area classification if applicable.
  • Available voltage, phase, frequency and limits on current or power steps.
Check velocity and pressure drop

Heater power alone does not define performance. The casing diameter, element density and internal flow path determine gas velocity and pressure drop. Very low velocity can create uneven cooling around the elements, while excessive velocity can produce an unacceptable pressure loss or vibration. The heater should distribute flow across the active element area and avoid stagnant zones near temperature sensors.

Provide the available upstream pressure and the maximum pressure drop that the system can accept. The supplier can then balance connection size, casing diameter and element arrangement. If a fan or compressor has already been selected, its operating curve should be checked against the proposed heater pressure loss rather than against an assumed value.

Match the element design to the operating temperature

Outlet gas temperature is not the same as element sheath temperature. The sheath normally runs hotter than the gas, and the difference changes with velocity, element loading, fouling and control conditions. Material and surface loading therefore require a thermal review based on the complete duty. For contaminated air, the design should also consider deposits that may insulate the element surface or react with the sheath.

Buyers should ask how the element bundle can be inspected or replaced. Removable bundles, accessible terminals and defined lifting space can reduce future downtime. These mechanical details often matter more over the equipment life than a small difference in initial price.

Specify control and independent protection

A process temperature controller regulates normal operation. A separate high-temperature limit should interrupt heater power if the control loop fails or the outlet temperature exceeds the safe value. The limit sensor should be independent where the risk assessment requires it. An airflow or differential-pressure interlock should prevent heating when flow is insufficient. For compressed-air service, pressure and flow status may both need monitoring.

Power can be switched in contactor stages or modulated with a solid-state power controller such as an SCR. Staging is suitable for broad control bands and reduces control cost. SCR control provides smoother output and may suit processes that need close temperature stability, but the cabinet must be designed for heat dissipation and electrical harmonics. The final choice depends on process tolerance, switching frequency and site electrical rules.

Coordinate the electrical and mechanical installation

Confirm supply voltage, phase and frequency before the element circuits are designed. The quotation should identify installed power, full-load current, control voltage and the intended power-control method. The buyer should also confirm cable-entry direction, terminal-box orientation, control-panel location and available maintenance clearance. These points are easier to resolve on a drawing than after the heater reaches site.

Mechanical documents should state connection size and rating, casing material, insulation arrangement, support points and design pressure and temperature. If the heater is part of a pressure system, the purchaser and supplier must agree which party is responsible for pressure-code calculations, inspection and documentation before production.

Use a structured request for quotation
Data group Information to provide
Process Medium, composition, flow basis, inlet and outlet temperatures, operating pressure
Duty Normal and maximum conditions, operating hours, start-up time, allowable pressure drop
Electrical Voltage, phase, frequency, control preference and site power limits
Mechanical Connection standard, orientation, available space, insulation and support requirements
Safety High-limit philosophy, flow interlock, area classification and local standards
Documentation Drawings, data sheet, test records, inspection needs and required language

 

Conclusion

A reliable electric air-heater specification connects the heat calculation with gas velocity, pressure drop, element temperature, controls and installation constraints. Final selection should be based on confirmed operating conditions and an agreed design review, not on nominal kilowatts alone.

Runkel manufactures customized industrial electric heating equipment and heating elements under an ISO 9001 quality management system. Voltage, power, dimensions, materials and connections can be configured for confirmed conditions. OEM support, no minimum order quantity and typical 15 to 30 day lead times may be available, subject to specifications. Contact us with your operating data for a preliminary selection.

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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

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