Description
Caloritech™ EX Series Circulation Heaters
In-Line Electric Heating for Liquid and Gas Applications
The Caloritech™ EX Series Circulation Heater from Thermon is an engineered electric heating solution designed to provide in-line heating in forced-flow and natural-flow systems. The heater consists essentially of flange-mounted electric heating elements installed inside a welded pressure vessel, allowing the process fluid to be heated as it passes through the vessel.
The EX Series can be configured for a wide range of liquid and gas heating applications, with designs ranging from 0.6 kW to 5,000 kW, with higher power ratings available.
Key Features
- In-line electric circulation heating
- Suitable for forced-flow and natural-flow systems
- Available with copper or Incoloy® heating elements
- Standard steel pressure-vessel construction
- Available with removable flange heater assemblies
- Built-in thermostat and high-limit options
- Stainless-steel wetted-part options
- Moisture-resistant and explosion-proof housing options
- Custom designs available for different process requirements
- Pressure vessels can be designed according to applicable ASME Code sections
- Available with CRN-registered vessels and heaters for Canada.
EX Series Construction
A Caloritech circulation heater essentially consists of a flange heater mounted inside a welded vessel.
The main components include:
- Steel casing / vessel
- Removable flange
- Electric heating elements
- Heating-element flange
- Process inlet and outlet
- Thermowell
- Drain connection
- Mounting brackets
- Terminal enclosure
The standard design uses steel vessels fitted with 150 lb flanges, while larger vessels and heavier flanges can also be supplied.
This construction creates a compact in-line heating system where the process medium flows directly through the heater vessel.
EXC Series – Copper Sheath
The EXC Series is a high-density circulation heater with copper-sheathed heating elements.
It is primarily intended for heating:
- Water
- Aqueous solutions
- Other liquids that are not corrosive to copper or the steel vessel
The copper element configuration provides an effective solution for conventional water-heating applications where copper is compatible with the process fluid.
EXI Series – Incoloy® Sheath
The EXI Series uses Incoloy®-sheathed heating elements and is intended for liquid-heating applications where greater resistance to the process environment is required.
It can be used for water and aqueous solutions and is particularly useful in applications such as rinse tanks where chemical additives may be corrosive to copper.
The EXI configuration is also suitable for forced-flow and natural-flow heating loops where a safe, clean, reliable and efficient heat source is required.
Liquid Heating Applications
The EX Series can heat virtually any liquid when the system is designed to ensure that the heater vessel remains completely full of liquid during operation.
For heavier liquids or applications requiring high temperatures, forced circulation using a pump is mandatoryaccording to the Caloritech engineering documentation.
Natural-flow systems are generally limited to side-arm water-heating applications where the heater is installed vertically and the top of the heater remains below the minimum tank liquid level.
Typical applications include:
- Water heating
- Process-water heating
- Aqueous solutions
- Rinse tanks
- Process liquids
- Industrial heating loops
Gas Heating Applications
The EX Series can also be engineered for gas heating applications.
Examples include:
- Steam superheating
- Compressed-air heating
- Nitrogen heating
- Ammonia heating
- Other process-gas heating applications
For gas heating, the process flow must be sufficient to ensure that the maximum allowable vessel and heating-element sheath temperatures are not exceeded. Thermon/Caloritech engineering support can assist with heater selection for these applications.
Heating Capacity
The EX Series provides a broad range of heating capacities.
Caloritech’s product guide identifies designs from:
0.6 kW to 5,000 kW
with higher kW ratings also available.
This broad capacity range allows EX Series circulation heaters to be used for relatively small process heating systems as well as large industrial heating installations.
The final heater capacity depends on factors including:
- Flow rate
- Process-fluid properties
- Inlet temperature
- Required outlet temperature
- Operating pressure
- Required heat-up time
- Heater watt density
- Available electrical supply
Pressure Vessel Design
Because the heating elements are installed inside a process vessel, the mechanical design of the circulation heater is important for pressurized systems.
Caloritech documentation states that closed-system heaters can be designed according to ASME Section I, IV or VIII, depending on the application and classification.
Depending on the applicable code classification, registered vessels and heaters can be authorized to bear applicable ASME stamps. The Caloritech product guide also identifies U, U2 and N stamp options depending on the ASME classification.
For Canada, CRN-registered vessels and heaters are also available.
Temperature Control and Protection
The EX Series can incorporate built-in temperature-control and protection devices.
Available options include:
- Thermostats
- High-limit devices
- Thermowells
- Temperature sensors
- External control systems
The standard built-in thermostat is a single-pole device rated up to 240 V and 25 A. For heaters exceeding 240 V, 25 A, or for three-phase supplies, the thermostat is intended for pilot duty and is not factory wired directly to the heating elements. In these cases, an appropriate contactor and control transformer may be required.
High-Temperature Applications
For high-temperature applications, the EX Series can be supplied with stainless-steel wetted components and specially designed terminal boxes to protect electrical components from excessive heat.
This makes the EX Series adaptable to demanding industrial process-heating environments where standard construction may not be sufficient.
Hazardous Area Options
The EX Series can also be configured for hazardous-area applications.
Thermon’s documentation identifies options including:
- Explosion-proof housings
- CE/ATEX
- IECEx
- North American hazardous-location configurations
Thermon also provides an EX Series medium-voltage manual covering models with Increased Safety (Type eb)protection for CE/ATEX and IECEx applications, as well as North American Class I, Division 2, Groups A, B, C & Dhazardous locations.
The exact certification and protection method must be selected according to the hazardous-area classification and heater configuration.
Typical Applications
The Caloritech EX Series can be used in a wide range of industrial heating systems:
Liquid Heating
- Water heating
- Aqueous solutions
- Process liquids
- Rinse tanks
- Industrial heating loops
Gas Heating
- Compressed air
- Nitrogen
- Ammonia
- Steam superheating
- Process gases
Industrial Process Heating
- Chemical processing
- Manufacturing processes
- Heat-treatment systems
- Industrial utilities
- Process skids
Technical Specifications
| Attribute | Specification |
|---|---|
| Brand | Caloritech™ / Thermon |
| Series | EX Series |
| Product Type | Circulation Heater |
| Heating Method | In-line Electric Heating |
| Application | Liquid & Gas Heating |
| Flow Type | Forced Flow / Natural Flow |
| Heating Capacity | 0.6–5,000 kW; higher ratings available |
| Element Sheath | Copper / Incoloy® |
| Vessel Material | Steel; stainless-steel options available |
| Flange | Standard 150 lb; larger/heavier options available |
| Temperature Control | Thermostat / High Limit / Thermowell |
| Pressure Vessel Design | ASME Section I, IV or VIII, as applicable |
| Hazardous Area | Optional configurations available |
| CRN | Available for Canada |
| Applications | Water, Aqueous Solutions, Process Liquids, Air, Nitrogen, Ammonia, Steam |
Why Choose Caloritech EX Series?
The Caloritech EX Series Circulation Heater combines an electric flange heater with a process vessel to provide a compact and engineered solution for in-line process heating.
Its broad power range, copper and Incoloy® element options, pressure-vessel construction, temperature-control options and ability to accommodate liquid and gas applications make the EX Series suitable for many industrial heating systems.
For a properly sized EX Series heater, the most important design parameters are the process medium, flow rate, inlet temperature, required outlet temperature, operating pressure, required heating capacity and electrical supply.
Focus Keyword
Caloritech EX Series Circulation Heater
Secondary Keywords
- Thermon EX Series
- Caloritech Circulation Heater
- EXC Circulation Heater
- EXI Circulation Heater
- EXF Circulation Heater
- Electric Circulation Heater
- In-Line Circulation Heater
- Industrial Circulation Heater
- Process Circulation Heater
- Liquid Circulation Heater
- Gas Circulation Heater
