When looking at kettle heating elements, the most common material used is Nichrome insulated elements. Although Nichrome is malleable and has low deformation under high heat, another type of alloy can be more suitable to this application; namely a Fe-Cr-Al alloy.
BrewHardware.com heating elements are 100% stainless steel from the the tubular sheath down to the hex and threaded bushing part. They do not have the same problems with the screw in base rusting such as the elements found on Amazon and in the home improvement stores.
Alibaba.com offers 2,790 electric kettle heating element products. About 66% of these are electric kettles, 11% are industrial heater, and 10% are electric heater parts. A wide variety of electric kettle heating element options are available to you, such as free samples, paid samples.
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Lets take an 800W kettle as an example: V = 230V (UK mains voltage), R = (230 x 230) / 800 = 66.1 Ohms; P = 800W, If you don't know the value of the voltage used by the element you could measure the voltage between the terminals of the heating element with the device powered and on.
This places the element just below the 5 gallon marker in the boil kettle so 5 gallons is the minimum volume of beer we can produce with this setup. We typically brew 10-13 gallons. We chose to install the heating elements on opposite sides of the kettles to keep the electrical boxes out of the way as seen in the photo below. In the end it ...
Such hidden element work very well, but still holds disadvantages, one being that when the element burns out it cannot be replaced and a new kettle has to be bought. When the kettle is plugged into an electrical outlet, a large electric current flows into the heating element.