Skip To Content

Circulation Heaters

Thermal Fluid Systems is a leading supplier of electric heating systems, which are essential heating systems for industrial use. One of the electrical heating systems we can design and supply for our clients is a circulation heater.

Our years of experience in the different parts and components of an electric heating system have allowed us the necessary knowledge and expertise to offer customized solutions to our clients. Our expertise and knowledge make us one of the go-to’s for high-quality electric heat systems.

What is a Circulation Heater?

A circulation heater is a bundle of electric heating elements mounted inside a shell (usually a standard pipe). The elements are mounted through a series of baffles to ensure that the heated fluid makes good contact with the elements and that there are no dead zones with regard to flow.

As the fluid moves through the shell and across the baffles, the elements transfer heat into the fluid stream. Circulation heaters can be used to heat both liquid and gas streams, although oil and water are the most common fluids used in circulation heaters.

How to Choose a Circulation Heater?

Before choosing the most efficient electric heating system, you must consider some factors to ensure you have a circulation heater most suitable for your various operations and processes.

Here are some points that are worth noting:

Application Conditions

Circulation heaters are popular in numerous industries, such as the chemical processing, power generation, and natural gas processing industries. With this in mind, they heat various oils and gases, such as nitrogen, air, and hydrogen.

To ensure that the heater provides a lasting solution to your application, please provide our application engineer with the following:

  • Fluid to be heated.
  • Desired operating temperature
  • Flow rate.
  • Expected heat consumption (kW) (We can assist with these calculations if needed)
  • Location of installation (indoors or outdoors)
  • Space limitations if any
  • Control requirements.
  • Power supply (most heaters take 480V/3PH/60HZ power)

The Watt Density

Watt density will be determined by the characteristics provided above and is usually in the range of 20 watts/square inch.  The proper watt density will primarily determine the life of the circulated fluid.

Orientation of the System

Another factor is the heater system’s orientation because the proper orientation and space can ensure that the heating element stays fully immersed. These heaters can be orientated either horizontally or vertically depending on the available space.

Terminal Enclosures & Standoffs

Standoffs and cold zones prevent overheating of the wiring terminal head and keep all hot portions of the heating elements inside the housing.


Reliable, safe, and accurate system controls are a must for an efficient and responsive heating system. We often use a silicone-controlled rectifier (SCR) in conjunction with a PID temperature controller to accurately adjust the power applied to the heating elements and thus to the heated medium.  This maintains a constant feedline outlet temperature regardless of heat demand fluctuations.

Trust TFS to Design Your Circulation Heaters

You can trust that we can design and develop the best electric heating system for your operations here at TFS. With numerous factors to consider, you can give us your requirements, and we’ll work with you to achieve your desired outcomes.

If you have any questions or concerns about our circulation heaters, don’t hesitate to contact us today. You may also request a quote, and we can send you an estimate immediately. Together, we’ll find the best solution for your heating problems.