Flange Heaters

Industrial processes often require precise and reliable heating of liquids, oils, chemicals and thermal fluids. Flange heaters are one of the most widely specified electric immersion heating technologies for these applications due to their high thermal efficiency, scalable power ratings and adaptability to demanding operating environments.

Backer Cynebar Ohmic, based in Brisbane, Australia, manufactures custom-engineered flange heaters for industrial applications across the mining, water treatment, energy, chemical processing, manufacturing and infrastructure sectors. As part of the global Backer Group, we combine local engineering support with proven heating element technologies to deliver reliable, long-life process heating solutions.

A flange heater consists of multiple tubular heating elements welded or brazed into a mounting flange assembly. The heater is installed directly into a tank, pressure vessel or process system, allowing heat to be transferred directly into the process medium.

This immersion heating method offers several technical advantages:

Flange heaters can be engineered for applications ranging from small process tanks through to large-scale industrial installations requiring hundreds of kilowatts or multiple megawatts of installed heating capacity.

Water and Process Fluid Heating

Flange heaters are commonly specified for:

Their direct immersion design provides efficient energy transfer while maintaining tight temperature control.

Oil and Fuel Heating

Industrial oils often require heating to maintain proper viscosity and flow characteristics. Flange heaters are widely used for:

Correct watt density selection is critical to prevent carbonisation and maximise heater life.

Bitumen and Asphalt Storage

Bitumen storage systems require controlled heating to maintain product handling characteristics. Custom-designed flange heaters provide reliable heat input while managing sheath temperatures and preventing localised overheating.

Chemical Processing

Flange heaters are frequently used within:

Material selection is tailored to the process chemistry to ensure corrosion resistance and long-term reliability.

Selecting the correct flange heater involves more than simply choosing a power rating.

Fluid Properties

Heater design should consider:

These properties directly influence heating performance and element selection.

Watt Density

Watt density is one of the most important design parameters affecting heater lifespan.

Lower watt density designs typically provide:

Backer Cynebar Ohmic engineers carefully match watt density to the process medium and operating conditions.

Heat-Up Requirements

Proper sizing requires consideration of:

Accurate thermal calculations ensure installed power is both technically suitable and economically efficient.

Process Control Integration

Flange heaters can be supplied with:

This enables precise process temperature management and protection against over-temperature conditions.

Backer Cynebar Ohmic designs and manufactures flange heaters to suit project-specific requirements rather than relying solely on standard catalogue products.

Available Options

Power Ratings

Flange Configurations

Element Sheath Materials

Control Panels

Complete heating packages can include:

For many industrial operators, the total cost of ownership is more important than initial purchase price.

Backer Cynebar Ohmic flange heaters are designed with a focus on:

Replacement element bundles, spare parts support and local engineering assistance help reduce lifecycle costs and improve plant availability.

For Australian projects, local manufacturing offers significant advantages:

Manufacturing from our Brisbane facility also enables closer collaboration during design, commissioning and ongoing maintenance phases.

Backer Cynebar Ohmic operates under ISO 9001:2015 quality management systems, providing confidence in manufacturing consistency, traceability and product performance.

All flange heater designs can be developed to suit applicable project specifications, customer standards and industry requirements, including hazardous area applications where required.

Whether you're specifying heating equipment for a new project, upgrading an existing process, or replacing legacy equipment, Backer Cynebar Ohmic provides engineering-led flange heater solutions tailored to your application.

Our team can assist with:

Contact Backer Cynebar Ohmic today to discuss your flange heater requirements and obtain a technically optimised solution engineered and manufactured in Brisbane, Australia.