Product Types

Custom-engineered to your exact specifications for liquids, gases, and specialized applications

Flanged Immersion Heaters

Flanged Immersion Heaters

Direct immersion heating through standard or custom flanges for tanks, vessels, and process equipment.

Typical Applications: Process tanks, storage vessels, boilers, heat transfer systems

Key Products
  • Standard Flanged Heater (1″–4″ flange)
  • High-Density Flanged Heater
  • Alloy Flanged Heater
  • Custom Configuration Heater
  • ANSI/DIN flange standards
  • 304/316 SS or Incoloy sheath
  • Watt densities 10–60 W/in²
  • Output up to 500 kW
  • ATEX/IECEx available
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Threaded/Screw-Plug Heaters

Threaded/Screw-Plug Heaters

Compact immersion heaters with NPT or BSP threaded mounting for smaller tanks and tight spaces.

Typical Applications: Small tanks, hydraulic reservoirs, lubrication systems, process lines

Key Products
  • 1″ NPT Screw-Plug Heater
  • 1.5″ BSP Screw-Plug Heater
  • Low-Watt Density Threaded
  • Miniature Screw-Plug Unit
  • NPT and BSP threading
  • Compact, space-saving design
  • Quick field replacement
  • Various watt densities
  • Moisture-resistant terminals
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Electric Heat Exchangers

Electric Heat Exchangers

Circulation heaters and in-line process heaters for continuous flow applications and closed-loop systems.

Typical Applications: Glycol reboilers, thermal oil systems, water heating, gas vaporizers

Key Products
  • Circulation Heater
  • Inline Process Heater
  • Over-the-Side Heater
  • High-Pressure Unit
  • Closed-loop compatible
  • ASME pressure vessel code
  • High flow rate capacity
  • Integrated temperature control
  • ATEX certified options
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Application Matrix

Select the right heater type based on your process medium, operating temperature, and application requirements

Water / Seawater
Up to 180°C (356°F)
Suitable Products:
Flanged Threaded Heat Exchangers
Key Considerations:

Corrosion resistance, scale prevention, marine-grade materials for seawater

Oils / Thermal Fluids
Up to 400°C (752°F)
Suitable Products:
Flanged Threaded Heat Exchangers
Key Considerations:

Watt density limits, thermal stability, sheath material compatibility

Process Gases
Up to 650°C (1202°F)
Suitable Products:
Flanged Heat Exchangers
Key Considerations:

Low watt density, uniform heat distribution, flow velocity requirements

Glycol Solutions
Up to 120°C (248°F)
Suitable Products:
Flanged Threaded Heat Exchangers
Key Considerations:

Freeze protection, viscosity control, reboiler configurations

Corrosive Chemicals
Varies by fluid
Suitable Products:
Flanged Threaded
Key Considerations:

Specialized sheath materials (Teflon, titanium, Hastelloy), chemical compatibility

Liquified Gases / Vaporizers
Cryogenic to 200°C
Suitable Products:
Heat Exchangers
Key Considerations:

Pressure vessel design, thermal shock resistance, flow control integration

Need help selecting the right heater configuration for your application?

Contact Our Engineering Team

Materials & Mounting Options

Extensive selection of sheath materials and mounting configurations to match your process environment

Sheath Materials

  • Carbon Steel
    General purpose water and oil applications
  • Stainless Steel 304/316
    Corrosion resistance, food/pharma grade
  • Incoloy 800/825
    High temperature, corrosive environments
  • Titanium
    Seawater, chlorinated fluids, extreme corrosion
  • Teflon/PTFE Coated
    Highly corrosive chemicals, galvanic heating
  • Hastelloy C-276
    Severe corrosive chemical processes

Mounting Options

Flange Configurations

  • ANSI 150#, 300#, 600#
  • DIN PN10, PN16, PN40
  • Custom bolt patterns
  • Screwed/welded flanges

Threaded Connections

  • NPT 1/2″ to 2″
  • BSP threads
  • Metric threads
  • Coupling nut assemblies

Terminal Housings

  • General purpose NEMA 1
  • Weatherproof NEMA 4/4X
  • Explosion-proof ATEX/IECEx
  • Junction box with terminals

Specification Checklist

Provide these details to ensure accurate heater selection and configuration

Process Requirements

  • Medium/fluid being heated
  • Target inlet and outlet temperatures
  • Flow rate (GPM/LPM) or tank volume
  • Required heating capacity (kW/BTU)
  • Operating pressure and temperature limits

Electrical Specifications

  • Available voltage (120V, 240V, 480V, etc.)
  • Phase configuration (single, three-phase)
  • Frequency (50 Hz / 60 Hz)
  • Control requirements (on/off, SCR, PID)
  • Thermostat or sensor integration

Mechanical Configuration

  • Flange type and rating (or thread size)
  • Immersion length and diameter constraints
  • Number of heating elements required
  • Sheath material and watt density
  • Terminal housing orientation and type

Environmental & Compliance

  • Hazardous area classification (if applicable)
  • Required certifications (ATEX, UL, CSA, CE)
  • IP rating / enclosure protection
  • Installation location and ambient conditions
  • Material compatibility with process fluid
FATI by Thermon

Immersion & Process Heaters

Custom-engineered flanged heaters, threaded/screw-plug immersion heaters, and electric heat exchangers for precise temperature control in tanks, vessels, and process systems. Specify by medium, duty, materials, and mounting configuration for optimal performance in water, oil, gas, and specialized fluid applications.

Immersion & Process Heaters

Request Immersion Heater Quote

Provide your process details and our engineers will design the optimal heating solution