Heating is one of the vital processes used in manufacturing across many different industries. Heating pipes or tubes is often necessary in industrial processes so that liquid can flow through them at higher temperatures. Additionally, heating is necessary for containers and barrels with chemicals or viscous liquids. This is accomplished by ceramic band heaters, a type of heating element used in numerous industrial applications, such as semiconductor production, plastic processing, injection moulding equipment, packaging machinery, and pipeline heating. These heaters have grown significantly in significance over time, and their primary use is to indirectly (and externally) heat pipes and tubes.

In this blog, we’ll go into more detail about ceramic band heaters, including how they operate and how to choose them.

Introduction

Ceramic band heaters are ring-like heaters that clamp onto and heat cylinder-shaped surfaces from the outside. The maximum operating temperature for ceramic band heaters, which conduct heat at medium- to high-temperatures, is 600°C. They have insulation made of glass wool, which offers excellent thermal efficiency and reduces heat loss to the surroundings. By making the insulating mat thicker, efficiency can be raised even further. The combined ceramic band heater assembly provides a flexible heating system that efficiently transmits heat through both conduction and radiation.

Ceramic band heaters are completely flexible, can be made with various terminal styles, and can accommodate holes and cut-outs. Additionally, precise temperature control devices can also be accommodated by these heaters. Better insulation prevents more heat from escaping into the air, lowering the amount of electricity needed to keep the barrels at the proper temperature. It enables easier heater installation onto the pipe without being hindered by surface imperfections or a loose fit. A ceramic band heater, however, does not require a tight fit because it also heats the barrel by radiation, in addition to conduction. With a watt density of up to 35 W/inch2, ceramic band heaters are made to provide even heat distribution, ensuring that the entire surface area is heated.

They can be constructed in nearly any size or configuration, which makes them perfect for several kinds of industrial applications. Marathon, as suppliers of ceramic band heaters, places a high priority on quality while also paying close attention to both the technical specifications as well as your requirements. With the help of our in-house engineering, they can be produced in as little as one day.

Construction

• Sheath material with serrated edges made of galvanised iron, stainless steel, or aluminum-coated SS protects the core and keeps the ceramic mat in place.
• For maximum dielectric strength as well as thermal conductivity, ceramic fibre knuckles with holes are used.
• Nickel/chromium heating elements are inserted in these holes for uniform heat distribution as well as the required watt density.
• As seen in the figure, glass wool insulation is located between the knuckles and the outer sheath.
• Terminal box for connecting to the power supply and protecting the terminal wire for connection.
• Screws for joining both piece of heater

Process of ceramic band heater

Each type of heater operates differently and has distinctive characteristics. Ceramic has a high thermal conductivity due to its higher current resistance. Ceramic plates attached to heat-conducting coils make up ceramic heaters. Heat is produced in the coil as a result of the lead wire used for power supply. These heaters radiate heat as well as transfer it through conduction. The ceramic blocks will be heated by the element winding to a temperature where they will radiate energy into the equipment to be heated and conduct energy when they come into contact with it. The heat energy will then be transferred to another object by the heating band in a controlled manner. The heater can be powered by either single-phase as well as three-phase electricity. In a single-phase power supply, the heater is terminated by two lead wires; in a three-phase power supply, it is terminated by three lead wires.

How to choose the right ceramic band heater?

To prevent temperature surpassing and lengthen the heater’s life, choose a ceramic heater with the wattage that best satisfies the requirements.

There are a few things you should know before purchasing the ceramic band heater. What is the purpose of band heaters, first of all? They are frequently used to heat the barrels, pipes, and nozzles of injection moulding as well as extrusion machines. In addition, they offer quick indirect heating, which is ideal for many industries, particularly plastics. One- or two-piece heaters, different types of closures, and different types of leads or post terminals can all be chosen during configuration. Furthermore, you can categorize them based on details like installation, mounting, dimensions, termination type, sheath material or sleeve, and performance requirements. Furthermore, temperature control is also feasible with thermocouples as well as adjustable thermostats. Ceramics have a tendency to conduct heat well, but they also have a tendency for holding heat, making temperature control challenging. Due to overheating, this can interfere with the operation, especially in the plastics industry

The desired dimensions are available in diameters starting at 40mm and widths starting at 25mm. Quantity, configuration, width, inside diameter, wattage, voltage, lead length (if applicable), and any other options listed below are details we will need to fulfil your order.

Additional Options for Ceramic Band Heaters

• Holes and Notches: Possibility on customized ceramic heaters, up to any reasonable dimensionandposition.
• Temperature control: This can be accommodated to most configurations.
• Spring Clamps and Screws: For the majority of large-diameter applications, these are advised to ensure proper clamping.
• Non-Standard Lead Location: For applications where standard connections might not be possible, leads or terminals can be placed at desired locations along the heater.
• Terminal Box: Available for all heaters having post terminals.
• European Connector: Two-pole plugs can be used for connection.
• Customizable voltage as well as power ratings.
• Download our technical datasheet of ceramic band heater for more options.

We develop and manufacture band heaters in-house, according to your specific requirements. Not sure what type of band heater is suitable for your application? Send us an email at mktgphs@marathonheat.com or call our experts toll-free at +91-9116647930to get in touch with us.

Conclusion

We provide a range of ceramic band heater designs, including both standard as well as customized options. This heater undergoes a number of quality checks in accordance with industry standards to guarantee its durability as well as quality. Ceramic Band Heater is a product that is in high demand for different industrial applications. We are an established supplier and manufacturer of Ceramic Band Heaters, and we also provide our goods with guarantees. Get in touch with us right away for your industrial heating needs.