Core Value: The Industrial Explosion-Proof Flanged Immersion Heater is engineered for critical safety in hazardous environments (Zone 1 and Zone 2) where flammable gases or vapors are present. Featuring a robust Ex d (Flameproof) Terminal Enclosure, this heater is designed to contain any internal explosion without igniting the surrounding atmosphere. Built to ASME standards with heavy-duty ANSI/DIN flanges, it provides reliable, high-capacity heating for the oil & gas, petrochemical, and chemical processing industries. BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE and UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS including hydrostatic pressure testing and insulation resistance verification.
- ✓ Explosion-Proof: Ex d IIB/IIC T1-T6 certified enclosure for maximum safety.
- ✓ Heavy-Duty Construction: ASME flanges (150# to 2500# rating) withstand high process pressures.
- ✓ High Power Capacity: Capable of multi-megawatt outputs for large tank and inline heating.
- ✓ Corrosion Resistant: Elements available in SS316, Incoloy 800/825, and Hastelloy.
- ✓ Precise Control: Integrated RTD/Thermocouple sensors for process and high-limit protection.
- ✓ Versatile Application: Ideal for heating crude oil, natural gas, hydrogen, and thermal fluids.
- ✓ Reliable Quality: 30+ YEARS MANUFACTURING EXPERIENCE ensures welding integrity.
- ✓ Quality Assured: UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS.
- ✓ Global Standards: CE, ATEX, IECEx, PED, ASME compliant.
Technical Specifications & Performance Data
| Parameter | Standard Value | Customizable Range | Notes |
|---|---|---|---|
| Protection Class | Ex d IIC T3-T6 Gb | Class 1 Div 1 | Explosion Proof |
| Flange Size | 3″ to 14″ ANSI | Up to 36″ | ANSI B16.5 / DIN |
| Pressure Rating | 150 lbs / 300 lbs | Up to 2500 lbs | High pressure design |
| Power Rating | 10kW – 500kW | Up to 2000kW+ | Multi-bundle design |
| Voltage Rating | 380V / 415V / 480V | Up to 690V | 3-Phase |
| Sheath Material | SS316L / Incoloy 800 | Titanium / Hastelloy | Fluid compatibility |
| Immersion Length | 500mm – 3000mm | Up to 5000mm+ | Requires internal baffles |
| Temperature Sensors | 2x RTD (PT100) | Thermocouples (K/J) | 1 for Process, 1 for Safety |
| Enclosure Rating | IP66 | IP67 / IP68 | Water/Dust tight |
| Warranty | 1 Year Standard | Quality assured | COMPREHENSIVE QUALITY ASSURANCE |
Industrial Applications & Solutions
- Oil & Gas Refineries: Heating crude oil, fuel oil, and hydrocarbon gases. Explosion-proof design ensures safety in volatile zones.
- Chemical Reactors: Maintaining temperature in chemical processing tanks. Hastelloy or Incoloy sheaths resist aggressive chemical corrosion.
- Offshore Platforms: Glycol Reboilers and dehydration units. High IP rating and corrosion-resistant paint withstand harsh marine environments.
- Hydrogen Heating: Pre-heating hydrogen gas for fuel cells or industrial processes. Requires strict Ex d IIC certification.
- Lube Oil Systems: Lube oil consoles for turbines and compressors. Low watt density design prevents oil carbonization (coking).
- Industrial Gas Heating: Nitrogen, Oxygen, or Natural Gas inline heating. High pressure vessel design capabilities.
HT-Heater vs Standard Market Heaters
| Feature | HT-Heater (Certified Ex) | Standard Market (Non-Ex) | Your Advantage |
|---|---|---|---|
| Safety Certification | Real ATEX/IECEx/CNEx | Fake or None | Legal compliance & Safety |
| Terminal Enclosure | Cast Steel / SS316 Ex d | Standard Sheet Metal | Contains internal explosions |
| Pressure Testing | 100% Hydrostatic Test | Random Check | No leaks at high pressure |
| Welding Quality | ASME Certified Welders | Standard Welding | Structural integrity |
| Manufacturing Experience | 30+ YEARS EXPERIENCE | New workshops | Engineering expertise |
| Quality Assurance | MULTIPLE RIGOROUS QUALITY CHECKS | Visual only | ZERO DEFECT DELIVERY |
Installation & Integration Guidelines
- Mounting: Typically mounted horizontally. For immersion lengths over 1000mm, internal tank supports (baffles) are required to support the element weight and prevent vibration damage.
- Cable Glands: MUST use certified Ex d cable glands or stopping boxes to maintain the explosion-proof integrity of the enclosure.
- Temperature Control: A safety control loop is mandatory. The high-limit sensor (attached to the heating element) must trip the power contactor directly to prevent overheating in case of low liquid level.
- Cold Zone: We design the “Cold Zone” length (unheated section) to ensure the terminal box does not overheat due to heat conduction from the process fluid.
Customer Success Stories
Case 1: Offshore FPSO Project (Brazil)
Application: Crude oil separation heating (Zone 1).
Challenge: Saltwater corrosion and high vibration environment.
Solution: SS316L Ex d Flanged Heaters with IP66 marine coating.
Results: PASSED DNV INSPECTION. “Robust build quality withstands the marine conditions perfectly. HT-Heater UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS.”
Case 2: Hydrogen Plant (Germany)
Application: High-pressure gas heating.
Challenge: Strict IIC Hydrogen explosion group requirement.
Solution: Ex d IIC T3 Certified Flanged Immersion Heaters.
Results: SAFE OPERATION. “Certification documentation was flawless. 30+ YEARS MANUFACTURING EXPERIENCE shows in their engineering support.”
Case 3: Chemical Refinery (Saudi Arabia)
Application: Bitumen storage tank heating.
Challenge: Preventing coking on elements.
Solution: Low watt density (0.8 W/cm²) flanged heaters.
Results: 5 YEARS CONTINUOUS RUN. “Excellent life span and reliability. Great quality assurance.”
Pricing & Procurement Options
Standard Production: MOQ 10 pieces. BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE ensures consistent quality. Discounts for 50+ units. Standard models in stock.
Lead Times: Standard: 7-10 days production. Custom: 10-15 days. Samples: 5-7 days. Rush service available for urgent requirements.
Global Logistics: Worldwide shipping via UPS, DHL, FedEx, EMS, TNT or the shipping agent as your request. Every shipment backed by 30+ YEARS MANUFACTURING EXPERIENCE.
Sample Orders: Available for testing. Contact sales for pricing. All samples UNDERGO MULTIPLE RIGOROUS QUALITY CHECKS.
Global Certifications & Compliance
- ATEX / IECEx
For Hazardous Locations
Zone 1 & Zone 2 - ASME Section VIII
Pressure Vessel Design
Code Welding - CE / PED
Pressure Equipment Directive
EU Compliance - ISO 9001
Rigorous quality control processes
Quality Documentation: Explosion-proof certificate, Hydrotest report, and material certs (3.1) available. Every unit UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS before shipment.
Comprehensive After-Sales Support
Warranty: 1 Year Standard Warranty against manufacturing defects.
Technical Support: Commissioning assistance and safety loop integration advice.
Service Network: BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE. Global technical support available.
Ready to Secure Your Hazardous Heating?
Next Steps:
- 📧 Request Custom Quote – Specify Zone, Flange, and KW
- 🔧 Free Engineering Review – Watt density & safety check
- 📦 Download Ex Certificates – Verify our compliance
- 📞 Contact Explosion-Proof Experts – Response within 2 hours
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SINCE 1990 Professional Heater Producer | Our Products Undergo Multiple Rigorous Quality Checks
