heatsystems Company



We are meticulous.
We admit this frankly. We are very particular with things.

The reason for that is definitely that we love what we do or our working ethos. On the other hand, we are sensible enough to know that the very high service lives and operating times of our products make happy not only our customers but also keep possible warranty events as low as possible already during the design and production.

We grant a warranty of up to five years for some devices: This means 60 months or 260 weeks or 1.825 days. Under full load, nota bene. We are very proud of this.

For there is one thing that must be known about us. We almost exclusively produce manually. Of course, we plan the plants and systems on computer basis and in 3D, if required. Just as needed by our customers. But when it is about construction, no robot and no automated production line will cross our path. Since we know that the human eye in connection with the hand and a well-working brain cannot be replaced with anything. And quality or cylinder capacity either.

As a result, almost no industry can be imagined without our electrical heating systems. If, for example, you find fried batter pearls on your dinner plate next time, you can almost be sure that heatsystems was involved. On the other hand, our huge crude oil preheaters makes supertankers afloat. And a special ship lays submarine cables on the seabed with the help of heater as a brake resistor. To mention only a few – perhaps somewhat unsual – examples.

We solve problems. We will not stop. We construct whatever is possible. We think laterally. Surely, we are not greatest. But we want to be the best. The only limit we accept is physics.

We have worked on the basis of this model with this conviction and this philosophy for almost 15 years now. Successfully and prosperously.
Company’s calendar
2000     Foundation of heatsystems GmbH & Co KG: Design, manufacture and distribution of electrical heat components for industrial applications.

Establishment of the department of electrical heaters for the pharmaceutical industry: Within a separate building complex a brand-new production area was established to ensure a consistent separation of back/white.
2004     Oval tube heaters
2005     Heat exchangers, of pharmaceutical design as well.
2012     Own explosion-proof terminal enclosures for electrical heaters
Aktuell     approx. 30 highly motivated and qualified staff members

Product Details:

Product Details N Let us talk about it! I 02265 / 99 70-0 Q B Electrical … Heat tracings keep the pipes to temperature Let us talk about it! Give us a ring! After all, we do … Heat tracings keep the pipes to temperature Let us talk about it! Give us a ring! After all, we do … Heat tracings keep the pipes to temperature Let us talk about it! Give us a ring! After all, we do … or sealing of the tank must be agreed with us. Optionally, the tank heaters can be equipped … losses II. Information text Tank heating Let us talk about it! Give us a ring! After all, we do … on the application, they will be selected by us. I. Heating elements Tubular heaters, diameter 8 … heaters Channel-type heaters Tank heaters Let us talk about it! Give us a ring! After all, we do … Heat tracings keep the pipes to temperature Let us talk about it! Give us a ring! After all, we do … Heat tracings keep the pipes to temperature Let us talk about it! Give us a ring! After all, we do … on the application, they will.

Electrical flow-type heaters

process heater in explosion proof design
horizontal process heater
horizontal process heater with side fluid connections
process heater in twin-way design
vertical heater for heavy fuel oil

Electrical flow-type heaters are designed for efficiently heating liquid or gaseous flowing fluids. The design is based on the general conditions such as the type and properties of the respective fluid, pressure and temperature as well as the desired operating points in the process.

Electrical flow-type heaters directly heat fluids, converting electrical energy in the heating rods to thermal energy. The thermal energy is then transferred from the heating rods to the fluid. Here, it is important that the design be matched to the general conditions, for each fluid has its specific properties.


For example, these fluids are heated in electrical flow-type heaters:

I. Water

Drinking water, max. surface load 4 – 6 W/cm² pending on the water
Circulating and/or heating water, max. surface load approx. 10 W/cm²
Softened water; observe the maximally admissible chloride content, max. surface load approx. 10 W/cm²
Ultra-pure water; here, a virtually low-pocket or pocket-free design with defined surface quality is useful.
Fully desalted water; here, non-ferrous heavy metals should not be used, maximum surface load approx. 10 W/cm²

II. Oil

Heavy oil, not pumpable in a cold condition, maximum surface load between 1 and 2 W/cm² depending on the quality
Hydraulics oil, maximum surface load approx. 0.6 – 1.2 W/cm²
Lubricating oil, steam turbine oil, max. surface load approx. 1 W/cm²
Insulating oil, maximum surface load approx. 0.3 – 0.6 W/cm²
Heat transfer oil, film temperature calculation acc. to DIN 4754 required, maximum surface load approx. 10 W/cm² depending on the flow velocity and oil
Fuel oil, diesel, heating to max. 40 °C, max. surface load approx. 4 W/cm²

III. Gases

Natural gas
Flue gas
Steam for overheating


The fluid to be heated and the application temperature mainly define the materials which can be used for the unheated and/or heated surfaces. Otherwise, corrosion may quickly result in a failure of the flow-type heater, for example.

Materials of the wetted and unheated components

Carbon steel
Corrosion-resistant stainless steel
Heat-resistant stainless steel
Titanium, Hastelloy, special materials

Materials of the heating surface:

Carbon steel
Corrosion-resistant stainless steel
Heat-resistant stainless steel
Titanium, Hastelloy, special materials

Heating elements

The design of the individual heating elements is a function of the application. There are faster or slower heating elements, mechanically robust or more filigree designs. Also, a distinction is made between compacted heating elements and heating elements where the internal heating insert can be replaced without the necessity of draining the fluid.

I. Heating elements

Tubular heaters, diameter 8.5 or 16 mm
Cartridge-type heaters, diameter 16, 18 or 25 mm
Exchangeable heating elements, including a protective tube, diameter 25, 42 or 65 mm

Control equipment

Electrical flow-type heaters can both be equipped with a built-in control system (for low power) or an external switchgear cabinet or for load switching by customer-provided switchgear and control gear. The electrical heating power can be divided into one or several heating stages. This division can individually be adjusted to match the control equipment.

I. Controllers

 Electronic ON-OFF control or PID control. (-> ON-OFF control switches off the heater if the temperature is exceeded, and switches it on again when the temperature falls below its lowest value. Thus, the temperature will always oscillate around the setpoint. The algorithm of the PID controller will optimally compensate the control fluctuations.)

 Load switching by contactors or wear-free semiconductors (thyristors). (-> contactors are wearing parts and must be replaced after approx. 100,000 make/break operations; thyristors switch quickly and without any wear but generate more heat losses than contactors.)

Electromechanical control. Thermostats installed in the electrical flow-type heater are price-efficient controllers whose accuracy is sufficient for many applications.

II. Sensors

Thermal protectors and limiters as capillary thermostats (as a safety design as well).
Temperature sensors for the fluid and heating rod temperature.
Overheating protection for the heater or electrical terminal compartment.

Switching devices

The switching devices as required for the operation of the flow-type heater can optimally be matched to the process and the heating element they can be ordered from heatsystems

Also, the communication of the switching devices with the higher-level control system will of course be matched to the requirements exactly.

I. Switching devices

Flow-monitoring device
Low-water level protection
Min. and max. pressure limiter
Thermometer for indicating the temperature on site


The electrical flow-type heaters can be delivered without insulation (for a customer-provided insulation) or with insulation. The insulation can be designed as follows:

I. Insulation material

Mineral wool with a galvanized or aluminium-coated metal jacket.
Diffusion-tight or gas-tight insulation
Insulation for indoor or outdoor installation

Fluid connections

We are prepared to agree with you on the type and position of the fluid connections. The following connections are available:

I. Fluid connections

Standard flanges (DIN, ASME, SAE etc.)
Female or male thread connections
Clamp flanges
Sterile flanges
Dairy-type pipe connections

Similar products

The following products may also be of interest to you:

Heavy oil preheaters for heating heavy oil for the proper viscosity
Electrical flange heaters for heating the most different fluids
Inline heaters for a pocket-free heating of ultra-pure fluids
Tank heaters for heating storage tanks without a lateral opening in the tank wall
Combined heat exchangers for heating by electricity and other heat transfer media
Tubular heat exchangers for the transfer of heat energy between fluids
Plate heat exchangers, the compact model for heat transfer
Containers for storing heat
Mobile flow-type heaters for heating miscellaneous fluids on site
Push-in preheaters for heating liquid fuels on the tap in the tank
Ceramic sectional radiators, the heating element that can be replaced easily
Silicone radiators, for effectively heating surfaces
Heat tracings keep the pipes to temperature

Some  other Product:

Electrical flange heaters
shell and tube heat exchangers
Tank heaters
Screw-in heaters
Channel-type air heaters
Mobile flow-type heaters
Plate heat exchangers
Inline heaters
Heavy-oil preheaters
Push-in preheaters
Pharma-type flange heaters
pharma-type DTS heat exchangers
Combined heat exchangers
Heating cartridges
Coil heaters
Oval tube heaters
Tubular heaters
Ceramic heating elements
Silicone heaters
Infrared emitter
More than a simple circulation

There are many reasons why liquids must be heated::

They should be free from frost or remain pumpable or must be sterilized or sanitized. The methods for heating liquids are as numerous, ranging from a tank system via the flow method where only the currently needed volume is heated to mobile or stationary systems. Basically, there are three methods for heating liquids: Firstly, direct heating by flange heaters, screw-in heaters or flow-type heaters, secondly, heating by a heating medium, i.e. by heat exchangers, and thirdly, direct heating, i.e. a combination of the first and second one.

In addition, the control equipment must also be proper and safety must be ensured, e.g. by explosion-proof plants.

The heating of liquids of all types definitely count among our core competences. And we are prepared to share this knowledge with you.


Contact N Let us talk about it! I 02265 / 99 70-0 Q B Let us talk about it! … Contact N Let us talk about it! I 02265 / 99 70-0 Q B Let us talk … 266 5920 Fax: 02265 99 70-70 O upwards I Contact us at 02265 / 99 70-0 We will always be there for … will contact you promptly. J Get in touch with us. We will always be there for you. On the phone.




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