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Inline heaters,  often referred to as circulation heaters or electric process heaters, are compact heating systems designed to heat a fluid (liquid or gas) as it flows through a piping system. Their high efficiency, precise temperature control, and closed-loop design make them essential in a wide variety of industrial processes.

The most common applications fall into the following categories:

1. Viscosity Control and Preheating

Inline heaters are crucial for heating viscous (thick) liquids to reduce their viscosity, allowing them to flow more easily through pipes, pumps, and nozzles.

• Fuel Oil and Lube Oil Preheating: Heating heavy fuel oils, crude oil, and lubricating oils before combustion, storage, or injection is necessary to maintain the correct viscosity for pumping and processing.

• Asphalt/Bitumen Heating: Heating materials used for paving and roofing to keep them molten and usable for construction applications.

• Food & Beverage Industry: Heating oils (like vegetable oils), syrups, molasses, and chocolate to control thickness for mixing, processing, and bottling.

2. Water and Chemical Processing

These heaters provide direct, efficient heat for both corrosive and non-corrosive liquids, often under pressure, in a controlled loop.

• Process Water and De-ionized (DI) Water: Heating water for industrial washing, rinsing, and sterilization processes, including high-purity water used in the semiconductor and electronics industries.

• Chemical Processing: Heating a wide range of corrosive solutions like acids and bases (using specialized sheath materials like PFA or titanium) to maintain critical temperatures for chemical reactions, blending, and purification.

• Wastewater Treatment: Heating fluids to facilitate chemical reactions or prevent freezing.

• Boiler Feedwater Preheating: Raising the temperature of water before it enters a boiler to improve overall system efficiency.

3. Gas and Steam Heating

Inline heaters are used to raise the temperature of gases for process efficiency or safety.

• Process Gas Heating: Heating industrial gases like nitrogen, air, argon, or helium for use in various manufacturing, drying, and inert atmosphere applications.

• Fuel Gas Heating: Heating gases to prevent the formation of hydrates (ice-like structures) or to dry the gas before burning (e.g., in a turbine).

• Steam Superheating: Increasing the temperature of saturated steam beyond its saturation point for use in sterilization, atomization, or power generation, boosting its energy content.

4. High-Temperature and High-Pressure Systems

Their design, which typically involves an immersion heater inserted into an insulated pressure vessel, makes them suitable for demanding conditions.

• Heat Transfer Systems: Heating thermal fluids (like oil or specialized heat transfer liquids) that are then circulated to other parts of a plant to maintain temperature in reactors, tanks, and molds.

• High-Pressure/High-Temperature Reactions: Providing precise heat for specialized industrial processes, including jacketed reactor heating and molten salt operations for thermal energy storage.