Industrial Heaters

Ceramic band heaters are medium-to-high temperature heaters that can deliver up to 1600°F (870°C). The heating element (Nichrome wire) is embedded in a flexible outer wall made of interlocking ceramic tiles, assembled like a brick wall. A ceramic fiber insulating mat and a stainless steel/ Aluminized Steel jacket cover this assembly. This makes them flexible, highly efficient, prevents heat loss and reduces electrical consumption by 20%. An energized ceramic heater that operates at 1200°F internally will have around 400°F on its outside shell. These durable heaters have versatile configurations which allow selection of clamping mechanism, terminal styles, holes and cut outs and perforations. Uniform heat distribution is an added advantage of ceramic band heaters. Limitations on the width of these heaters within a certain incremental range of sizes, is due to ceramic tiles that are available in specific lengths. Ceramic Band Heaters afford customers a means to heat large cylinders from intermediate to high temperatures without concern of failures due to "Hot-Spotting". A layer of thermal insulation reduces ambient heat loss and power consumption.

Advantages of Ceramic Band Heaters

• Lower Operating Cost
• Longer Heater Life
• Higher Operating Temperatures
• Flexible

Every industry in today’s world is utilizing the some or other form of heating applications. The heating is very much a part of our day to day life. As the dependency on heating application grows, there is a serious concern also expressed related to safety and environmental impact as well as efficiency of the many of the heating solutions being used. While some of the systems have a risk of fire accidents, many of the other conventional system generate a lot of carbon dioxide and other gases that contaminate the environment. Tubular Electric heater is a one of the Best option for the modern world, which is safest way to heat any fluid or surface without creating gases or hazardous releases.

Tubular heaters are typically manufactured using a resistivity coil placed inside a Metal tube and filled inside with insulating materials such as Magnesium oxide. The heating coil placed at the center with uniform pitches, separated from the outer metal sheath by a compacted Magnesium oxide ensures that No electric shock is transferred to the outer surface. At the same time the all the heat energy produced is transferred to the process through outer body. Hence the Heater is regarded as one of the highly efficient and safe way of heating.

Construction

• Nickel Chromium Resistance were uniformly coiled wire is stretched through the active length of the element. The ends are proved with the terminal pins to create cold ends.
• Magnesium oxide:High purity magnesium Oxide power is filled between the coil and outer tube in a automated filling station to ensure the right insulation, conduction as well as compactness.
• Outer sheath: Tube (welded or seamless) which acts as a outer protection for the heating Element. Selection of outer tube depends on various factors such as temperature, pressure, fluid to be heated etc.
• Terminal pins: Also known as terminal pins are extended ends of the heating elements. The SS rods of a specific diameter are fusion welded to the coils at both ends. The length of the rod depends on the nonheating length required for any application and installation.
• End Sealing: Sealing is done using the combination of Ceramic beads, soft seals & sealants. The sealing ensures that no moisture from the atmosphere enters the heating element and keeps it dry.

End Seal Options

• Teflon Seal: Teflon seal is used where effective sealing is required against moisture and oil contamination.
• Silicon Rubber Seal: Most popular and highly used sealing method. The sealing can withstand up to 200 deg C temperature and provides long lasting moisture protection.
• Epoxy Seal: Epoxy potting forms a good moisture seal with more mechanical strength than a silicon rubber seal. Recommended for a system assembly with large no of tubular elements.
• Cement: recommended for the heater which operates at very high skin temperature. Provides protection against high viscous fluids and dusts. The top layer can be provided with additional insulation to make it moisture resistance as well.

Tempsens offers Ceramic Bobbin Heaters are fabricated from high-temperature factory insulators in various diameters and lengths for any voltage or wattage within manufacturing limits. Bobbin heaters are made with sheathed and without sheathed material.

The sheath material ranges from nickel-plated mild steel, Inconel alloys and stainless steel. Resistance wire are supported on refractory insulators and connected to a terminal block at one end. Thermowell can be provided for accurate temperature sensing or other controls can be provided as well. They are normally manufactured for horizontal mounting, but may be specially designed and constructed for vertical installation.

Designed for any voltage or wattage within manufacturing limits. These Bobbin Heaters consist of elements, which are exposed partially in air for better transmission of heat. Also, when it is inserted into a radiant/immersion tube, it offers a large heated area to the liquid or semi-solid to be heated.

Advantages

• Suitable for low temperature up to 600°C furnace heating
• Wide range of lengths, voltages and power is available to meet customers’ specific requirement
• Simple and low-cost installation
• Ease of maintenance and repair
• Versatile and non-polluting
• Energy-efficient as 100% of heat generated is within the solution

Application Areas

• Water, chemicals etc
• Offer for semi-solid materials like wax, fats, oil and bitumen
• Suitable for indirect heating of gases and liquids, where it is inserted into a pocket or protection tube in the process tank, wherein, it can be repaired or replaced without draining the process tank