Kanthal® Flow Heater: Gen 3
The Kanthal® Flow Heater uses patented direct-heating technology to efficiently heat air and a wide range of process gases, reaching outlet temperatures of 1,100°C (2,012°F).
“Customers across hard-to-abate industries today are under a constant balancing act. They seek greater system efficiency, higher process temperatures, and robust process controls, while facing pressure to reduce emissions, improve safety, and lower total cost of ownership. The Kanthal® Flow Heater Generation 3 was developed to address exactly this shift,” explains Rishiraj Mukherjee, Product Manager, Kanthal.
How Kanthal® Flow Heater Works
The Kanthal® Flow Heater (direct heating) sends process gas directly through the heating core, enabling immediate heat transfer, faster response, more precise and higher outlet temperatures, and no on-site combustion emissions. In contrast, conventional (indirect) heating transfers heat through a chamber or tube wall before it reaches the process gas, resulting in slower response times, less precise control, combustion emissions, and a larger footprint.
Information
SELECT YOUR Kanthal® FLOW HEATER
Standard range: 10kW, 20kW & 40kW, with custom solutions for higher power requirements. Add a safety margin of 10–20% to the theoretical power.
For capacities above 40 kW, consider custom sizing or using multiple Flow Heaters in parallel—this approach is recommended for extended lifespan and easier spare parts management.
Kanthal offers customized Flow Heater solutions for applications beyond the standard range, including specific gas compositions, operating pressures, and inlet temperatures. The modular heater core can be tailored and scaled up to MW capacities. Contact your local Kanthal representative to discuss your application requirements.
Characteristics
WHY CHOOSE THE KANTHAL® FLOW HEATER
“In many applications, Flow Heaters can directly replace gas burners by providing high target temperatures, process efficiencies, and system robustness, all while eliminating on-site combustion emissions,” Mukherjee says.
Productivity
High-temperature performance — outlet temperatures up to 1,100°C (2,012°F)
Lower energy costs — over 95% thermal efficiency
Flexible process integration — high turndown ratio 10:1
Technology
Consistent product quality — ±1°C temperature accuracy
High power, compact footprint — power density comparable to gas burners
Modular and plug-and-play system — wide range of product offerings, including scalability
Maintenance
Reliable, safe operation — integrated temperature monitoring and over-temperature protection
Built for dynamic conditions — engineered to tolerate pulsating flows
Complete system — control cabinets, blowers, and insulated piping accessories included
Fully refurbishable design — backed by a maintenance program
ACCESSORIES AND SERVICES
Control cabinet — optimized for the standard Flow Heater series; custom solutions available, including PLC compatibility and standard automation protocols
Blower — variable frequency drive for flow rate control, with air filter, for safe, long-life operation
Test services — process development and optimization support, backed by Kanthal's R&D engineers
REFURBISHMENT & LIFECYCLE SUPPORT
The Kanthal® Flow Heater is completely refurbishable. Key components can be restored and reused after extended use, reducing waste and decreasing overall cost of ownership.
On-site — Periodic annual maintenance: temperature sensor replacement, performed by qualified site personnel per the IOM manual.
Kanthal factory — Major refurbishment: replace the heater core and connection plates, internal insulation, and temperature sensors to factory specifications.