An upgraded flow heater designed for high-temperature industrial electrification is the latest development in electric process-gas heating technology from Kanthal.

The Flow Heater Generation 3 is engineered to combine high power density, flexible operation and precise temperature control, aimed at helping industrial companies electrify demanding high-temperature processes while improving efficiency, safety and lifecycle performance. 

The device uses patented direct electric heating technology, transferring energy directly to air and process gases as they pass through the heater core. The design supports continuous and cyclic processes and combines a compact installation footprint with greater operational flexibility and scalability.

Kanthal explains that, as industrial companies accelerate decarbonisation efforts, electrifying high-temperature processes remains one of the most challenging areas of the energy transition. Many of these processes have traditionally relied on combustion-based heating, creating a need for electric solutions that can meet demanding process requirements without compromising performance.

“Electrification is moving into increasingly demanding industrial processes, and customers need solutions that can meet those requirements without compromising performance,” says Kanthal president: business unit heating systems Simon Lile. “The continued development of the flow heater supports that shift.”

By transferring energy directly to the gas stream, the flow heater enables fast response and precise temperature control while eliminating the need for on-site combustion. Its high-power density enables a compact footprint comparable to gas-burner solutions, while modular, plug-and-play scalability supports both new installations and the electrification of existing processes.

“Customers across hard-to-abate industries face growing pressure to improve efficiency, reduce emissions and maintain safe operations while keeping costs under control. The latest Flow Heater was developed to meet those requirements without compromising process performance,” says Kanthal global product manager Rishiraj Mukherjee.

The device can be used across industries including metals production, industrial furnaces, battery manufacturing, and clean-energy technologies. Designed for long-lifecycle performance, it can also be refurbished to help customers extend equipment lifetime, reduce waste, and lower total cost of ownership.