What Options Are There for Drum Heating in Hazardous Ex-zoned Areas?

Introduction

In industries such as oil and gas, mining, chemicals, and pharmaceuticals, drum heating is often essential to keep materials at the right viscosity for safe transfer and processing. But when these operations occur in hazardous, potentially explosive (Ex) environments, the heating solution must meet strict safety standards. 

In Australia, the globally preferred certification system is IECEx, which requires third-party testing by an authorised body. Other standards, such as ATEX (European) and UL/CSA (USA/Canada), are common internationally, but IECEx certification ensures compliance within the Australian regulatory environment. 

LMK Thermosafe is a global expert in drum heater technology for hazardous areas, with all key products certified to IECEx, ATEX, and other major international standards. Importantly, SBH Solutions is the exclusive Australian distributor, bringing these trusted solutions directly to local industries. 

What Are the Challenges of Heating in Hazardous or Potentially Explosive Zones?

Heating in hazardous zones is not a simple case of “plug and play.” The environment itself dictates strict limitations: 

• Zone 0: Highly volatile area, often inside a container, where an explosive environment exists. 
• Zone 1: The immediate area around explosive material, where ignition risk is high. 
• Zone 2: The surrounding space, where sparks could still ignite vapours. 
• T-ratings: These define maximum safe surface temperatures.  For instance, T3 = up to 200°C and T4 = up to 135°C

Any drum heater used in such zones must remain within these boundaries. That’s why certified products and, in many cases, specialised controllers are essential. 

Industrial Heating Options for Hazardous Potentially Explosive Area

Despite the challenges there are a number of options available which have been certified.  These vary from certified hot box, steam room, trace heating wire or band heater to insulated heater jackets and electromagnetic induction heaters.  LMK Thermosafe specialises in the design and manufacture of the last two decades because they provide maximum flexibility, cost advantage and performance. 

a. InteliHeat FlexiPlus Insulated Heating Blanket for drums and IBCs 

If flexibility is required, the InteliHeat FlexiPlus insulated heating blanket range provides the most versatile option: 

• Available in self-limiting, thermostatically controlled, or digitally controlled versions. 
• Compatible with standard drums, IBCs, and gas bottles, with custom builds possible. 
• Certified for Zone 1 and 2 environments. 
• Also available for heating IBCs. 

b. Thermosafe Induction Drum Heater (TH)

For more robust needs and speedy results, the Thermosafe induction drum heater stands out. With its IP66 rating, it is dust- and water-resistant, making it ideal for demanding hazardous locations. By indirectly heating the drum wall, and due to the eddy current effect of electromagnetic induction, it can efficiently melt solids and bring viscous liquids to process-ready conditions. 

c. Faratherm Base Heater 

The Faratherm is a drum base heater for IECEx areas. The base plate is warmed by induction, and this transfers heat to the plate to give direct contact with the drum. It can warm on its own, or when paired with a Thermosafe, provides unrivalled increase in temperature within a ferritic metal drum. By heating the drum from below, the combination significantly reduces total heating time – an important advantage in production environments where downtime equals lost revenue. 

Case Example: Heating Pour Point Depressants (PPDs)

To demonstrate performance under real-world conditions, LMK Thermosafe tested drum heating solutions on Pour Point Depressants (PPDs), a common additive in oil production with a melting point of ~40°C. Testing was conducted outdoors in 0°C ambient conditions. 

• Thermosafe Induction Drum Heater: Melted a full 210L drum in ~10 hours, with the upper half usable after just 4 hours. 
• Thermosafe Induction heater + Faratherm Base Heater: Reduced melt time by more than 50%, achieving a full melt in under 5 hours. 
• InteliHeat Flexible Insulated Heating Jacket: Liquefied most material in ~10 hours and required ~18 hours for a complete melt. 
• Faratherm base heater alone: Required ~22 hours for a full melt. 

This case highlights an important lesson: different tools deliver different outcomes. For operations needing fast turnaround, the Thermosafe + Faratherm combination is unmatched. But where cost sensitivity or lower temperatures are the priority, an insulated heating jacket remains a reliable solution.

Conclusion

Heating in hazardous zones is as much about compliance as it is about efficiency. With IECEx-certified drum heaters, insulated heating jackets, and insulated heating blankets, LMK Thermosafe provides trusted solutions that keep materials ready without compromising safety. 

SBH Solutions proudly serves as its Australian partner, making it easier than ever for local industries to access these globally recognised solutions. Talk to us today to find the safest and most efficient drum heating solution for your operation.