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An inline heater, also commonly known as a circulation heater or electric process heater, is a specialized industrial device used to heat a liquid or gas as it flows through a pipeline or closed-loop system.

It is named "inline" because it's installed directly into the process piping, ensuring that the fluid is heated on-the-fly before it is used or recirculated.

Key Components and Function

An inline heater is essentially a self-contained unit that includes:

1. Immersion Heating Element: This is a set of electric heating elements (like screw plug or flange immersion heaters) that convert electrical energy into heat.

2. Pressure Vessel (Housing/Shell): A steel or alloy chamber that houses the heating elements. The fluid being heated flows through this vessel.

3. Inlet and Outlet Nozzles: Connections that allow the process fluid (liquid or gas) to enter and exit the heater.

4. Insulation: An outer shroud that covers the vessel to minimize heat loss to the surrounding environment, maximizing energy efficiency.

5. Controls: Thermocouple sensors and control systems (like thermostats and high-limit cutoffs) that regulate the temperature precisely and safely.

How it Works

The process fluid is pumped into the inlet nozzle and flows across the surface of the heating elements inside the pressure vessel. This direct contact provides highly efficient heat transfer. Once the fluid reaches the desired temperature, it exits through the outlet nozzle and continues along the process line.

Advantages and Applications

Inline heaters are widely used in a variety of industries—including petrochemical, chemical, oil and gas, food processing, and pharmaceuticals—because of several key benefits:

• High Efficiency: They directly heat the flowing fluid, virtually eliminating standby heat loss associated with large storage tanks.

• Precise Control: They allow for accurate and immediate temperature regulation, which is critical for many chemical and manufacturing processes.

• Safety: The elements are fully contained and the unit can be equipped with explosion-proof or corrosion-resistant materials for use with hazardous or volatile fluids (like fuel oils, corrosive chemicals, or high-pressure gases).

• Versatility: They are customized to heat a wide range of substances, including water, oils, steam, and industrial gases, to control viscosity or facilitate chemical reactions.