Originally Posted by jammin
I think a 240 volt/5500 watt ULWD element would be bang on. Lots of surface area so you would get very efficient heat transfer, especially at higher flow volume (for your bigger system). Camco makes a straight, folded model that would be perfect. I have one in my 20 gallon kettle and it (dis)assembles easily in 1.5" tri clover system.
Should I run it on 240 or 120? I see a lot of people running them on 120 to cut the wattage. I can probably hit 3/4 gallon per minute on my flow rate without sticking, but I'm not sure if I can do any better than that.