Rishiraj Mukherjee, Product Manager at Kanthal, notes, "What we hear from our customers today is a constant balancing act. They need greater process efficiencies, higher process temperatures, and tighter control, all while facing pressure to reduce emissions and lower energy costs."
This challenge is central to many industrial electrification projects today, especially in hard-to-abate sectors where process heat accounts for a significant portion of total energy demand and carbon dioxide emissions. Therefore, electrifying high-temperature process gas heating applications has become a key focus across various industries.
The Kanthal® Flow Heater was developed to address exactly this shift.
So, what exactly is the Kanthal® Flow Heater?
The Kanthal® Flow Heater is an electric heater designed specifically for heating air and process gases as they pass through its core. It can achieve process temperatures
Rishiraj Mukherjee, Product Manager, Kanthal. of up to 1,100°C (2,012°F).
Unlike traditional indirect heating systems that first heat a chamber, tube wall, or surrounding surface, the gas flows directly through the heating section. This allows heat to transfer directly from the heating elements into the process gas before it reaches its intended application.
Mukherjee highlights, “This direct heating principle is one of the most significant differences between a Flow Heater and many conventional heating systems.” He further explains, “In many applications, Flow Heaters can directly replace gas burners by providing comparable temperatures, efficiency, and stability, all while eliminating on-site combustion emissions.”
Kanthal offers Flow Heaters as standard products from 3.5 kW to 60 kW, along with custom solutions for higher power ranges.
The system can also be supplied with matched components such as control cabinets, blowers, and related accessories.
Built-in temperature sensors help improve operational reliability while reducing the risk of overheating and unplanned downtime.
What makes the Kanthal® Flow Heater stand out?
Several characteristics separate the Kanthal® Flow Heater from conventional electric gas heaters.
- Outlet temperatures up to 1,100°C
The Flow Heater can deliver outlet gas temperatures up to 1,100°C (2,012°F), approximately 25% higher than those of many conventional electric process gas heaters.
- Precise outlet gas temperature control
Direct heating of the process gas enables tighter control over outlet temperatures, helping improve process consistency and product quality.
- Compact design with high power density
The Flow Heater combines high power density with a relatively compact footprint, simplifying integration into existing production systems.
- Cleaner operation
Because the system operates electrically, there are no combustion emissions at the point of use, supporting cleaner operation and industrial decarbonization efforts.
- Flexibility across operating conditions
The system supports both continuous and cyclic operations across different process environments.
- Built-in reliability
Integrated temperature sensors enhance operational reliability and minimize downtime risks in challenging operating conditions.
Top applications of Kanthal® Flow Heater
The Kanthal® Flow Heater is used across a growing number of industrial applications where controlled high-temperature gas streams are required.
- Localized heat treatment
These processes require controlled heating in specific zones without affecting the surrounding materials. Flow heaters provide stable and precise high-temperature heating in these applications.
- Aluminum processing
Both primary and secondary aluminum processing rely significantly on thermal operations. Electric heating via process gas can enhance temperature control while promoting cleaner operation compared to combustion-based systems.
- Power-to-X applications
Power-to-X technologies require stable high-temperature heating, and they are becoming one of the fastest-growing areas for electric process gas heating.
- Solid Oxide Fuel Cells (SOFC)
These systems operate under demanding thermal conditions where temperature stability directly affects system performance. Flow Heaters help maintain controlled operating temperatures throughout the process.
- Li-ion battery cathode powder calcination
Battery material production depends heavily on thermal consistency during cathode powder processing. Controlled gas heating helps maintain product quality and process repeatability during calcination.
- Regenerative Thermal Oxidizers (RTOs)
RTO systems used in automotive and industrial applications require high-temperature operation for emissions treatment. Electric process gas heating offers a cleaner alternative to combustion-based heating in these systems.
- MLCC de-binding
The de-binding stage in multi-layer ceramic capacitor production requires carefully controlled heating conditions. Stable outlet gas temperatures help maintain process consistency during production.
- Research and development
Flow Heaters are also widely used in:
- Pilot plants
- Laboratory environments
- Testing systems
- Advanced process development
A growing role in industrial electrification
Industrial heating systems are undergoing a broader transition as manufacturers look for alternatives to fossil-fuel-based process heating. Gas burners have long dominated industrial operations, but decarbonization goals, regulatory pressure, supply chain uncertainty, and energy market volatility are pushing industries to rethink how process heat is generated.
In this environment, electric process gas heating is gaining attention not only as an alternative to combustion but also for the control, stability, and operational flexibility it can offer. When powered by renewable electricity, it also creates a pathway toward substantially lower operational emissions, and the growing adoption of technologies such as the Kanthal® Flow Heater reflects this broader shift.