Case Studies

CAST-X 2500 Circulation Heater

The CAST-X 2500 is our most compact dual-tube model, a powerful and versatile mid-sized heater.

Designed and manufactured by Cast Aluminum Solutions (CAS), CAST-X heaters are designed using the latest in thermal modeling and FEA (Finite Element Analysis) technology.

The CAST-X 2500 features two helical-coiled flowpath tubes, along with low watt density heating elements, all of which are cast into an aluminum body. The aluminum body serves as the heat transfer medium between the heating elements and the process tubes carrying the liquid or gas to be heated.

The media being heated never contacts the heating elements, which is a distinct advantage of the CAST-X line: it is often used to heat flammable and hazardous liquids and gases. Another advantage is the small footprint / high output ratio.

The CAST-X 2500 is available with a variety of NEMA and ATEX certified electrical enclosures; and may be ordered in a wide range of volt, watt and circuitry configurations. Connect with a CAS Sales Engineer near you.

  • Power:
    • 2.5 kW Total to 15 kW Total
    • Voltage Range: 208V - 480V
    • Max Line Current: 30 amps

  • Tubing:
    • .625” OD (15.9 mm)
    • .065” Wall (1.7 mm)
    • Overall Process Tube Length: 130” (3302 mm)
    • 316L Stainless Steel (standard)
    • Inconel (optional upgrade)
    • Passivated or Electro-Polished (optional upgrades)

  • Max Pressure: 4000 psi (275 bar)

  • Enclosures:
    • NEMA 1 (general-purpose/dust-proof)
    • NEMA 4 (moisture-resistant)
    • NEMA 7 (explosion-proof)
    • ATEX (explosion-proof)
  • Max Working Temperatures:
    • Max Casting Temp: 662°F (350°C)
    • NEMA 1 (dust-proof/general-purpose): 662°F (350°C)
    • NEMA 4 (moisture-resistant): 572°F (300°C)
    • NEMA 7 (explosion-proof): 482°F (250°C)
    • ATEX (explosion-proof): 482°F (250°C)

  • Sensors:
    • K or J Type Thermocouples Standard
    • Snap-Action High-Limit Thermostat
    • Process and High-Limit Thermocouples

  • Options:
    • Insulating Jacket Rated to 800°F (425°C)
    • Compression Fittings

Features & Benefits


  • SS 316L Fluid Path Separate from Heating Elements
    (for safe heating of sensitive media & contamination prevention)
  • Compact Design: Replaces Much Larger Heaters
  • Self-Draining, Low-Maintenance Design
  • Dual Tubes Can Be Run In-Series or Parallel
  • Robust Cast-In Construction (for long heater life)
  • Non-Welded Design (minimizes potential leakage)
  • Wide Application Compatibility
  • Paint & Solvent Heating
  • Glycol & Heat-Transfer System Use
  • Food & Beverage Pasteurization
  • Industrial Gas Heating & Air Separation
  • Steam Generation
  • Laboratory & Analytical Applications
  • Urethane / Foam System Heating
  • High Pressure Applications

NEMA 1 enclosure
NEMA 4 enclosure
NEMA 7 enclosure
ATEX enclosure
CAST-X 2500 with
insulating jacket


The CAST-X 2500 is the newest product in the respected CAST-X family of circulation heaters. CAS has developed this line to meet the needs of liquid and gas processors across multiple industries. These highly-versatile units can fit into a wide range of applications.

For assistance in specifying your CAST-X Circulation Heater, please contact a CAS Application Engineer. We’ll analyze your flowrate, Delta-T, and chemistry to specify a CAST-X unit that meets your unique heating requirements.

Download the CAST-X 2500 Technical Brochure.



2012 M

Inc. 5000

Manufacturer of the Year 2015
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