There are three main types of these heaters that differ by material: mica, ceramic and mineral insulated. They come in various sizes and each brings their own strengths to the table. These are sometimes further subdivided based on the following factors:
- Performance specifications
- Sheath material or sleeve
- Termination type
Mica Band Type Heaters
For less intense temperatures, mica insulation offers competitive dielectric strength and corrosion resistance. The maximum temperature is lower, typically around 900 degrees Fahrenheit, but the water and chemical resistance make them popular in harsh environments. Options when choosing this type of heater you may want to consider include:
- Extended flange with electrical connections
- Barrel nut strap leads without metal braid
- Barrel nut strap leads in metal braid
- Flange lock-up one-piece leads
Note that we also offer three termination options. These include fiberglass, post terminals and stainless steel over braid.
Mineral Insulated Heaters
A mineral-insulated band offers the highest temperature capabilities. These deliver more precise results than the other types and can operate under much higher temperatures. These bands can sustain temperatures that climb up to 2,000 degrees Fahrenheit and you have a max voltage of 480V. They also provide more efficient heat transfers. A magnesium oxide insulation offers excellent thermal conductivity as well. The termination options are the same as the mica type heaters. Some of the specialized options you can consider include the double conductor metal braid, two-piece construction and one-piece expandable.
Ceramic Band Type Heaters
Ceramic band type heaters are heaters that can handle extreme temperatures, typically up to 1,400 degrees Fahrenheit. The excellent insulation of a ceramic segment helps you focus heat where you need it, but the insulation also retains heat for longer, making overheating an issue. Ceramic bands reduce operations costs and energy consumption. They can sustain temperatures as high as mineral insulated heaters, but the outside temperature remains low. Thus, there is less wasted heat. For increased efficiency, you may also consider double-insulation options. To make this genius engineering possible, manufacturers construct these bands out of stainless-steel housing and then stack ceramic tiles on the inside. To add to this, they are built to last and easy to install. Finally, they also offer more termination options than mica and mineral insulated options. These include the following:
- Termination box
- Euro connectors
- Fiberglass lead
- Post terminals
These industrial heaters are used in a range of industries from medical to plastic injection molding. While the basic design and heat application remain the same, the size, insulation, maximum temperature and other factors vary to be used in the following typical applications:
- Drum heating
- Blown film dies
- Fluidized beds
- Holding tanks
- Plastic extruders
- Hot runner molding bushings
- Autoclaves and sterilizers
One common instance this type of heater comes in handy is when an engineer needs to heat the surface area of a tube or pipe. Other applications could include the utilization of heater bands for injection molding and heater bands for extruders. Improper installation or selection can damage your industrial electric heater and fail to achieve the precise temperature application you need, so be sure you choose the right heater from a leading distributor.
Band Heater Element Construction
The biggest differences between heater element construction are the cost and lifetime. Industrial heaters can reach similar temperatures with similar wattage or watt density, but a lower-grade construction style can result in a considerably higher failure rate. Compare the cost and failure rate to choose the best element construction. Other specifications are important, but these two are most altered by the materials and construction style chosen. Most band style heaters are categorized as either standard or high-temperature construction.
Band Type Heaters vs Strip Heaters vs Cartridge Heaters
Band type heaters and cartridge heaters are very similar in design and application. Strip heaters on the other hand use a straight design and often has fins to heat the surrounding air. In harsh environments, these heaters can be sealed and constructed with different elements for a more durable design. Cartridge heaters are usually designed to be inserted into a vat or sidewall of a container. Unlike cartridge heaters, they typically use a flange, business and couplings to connect and seal the thermocouple to the container. They are commonly used to heat gases or fluids, rather than cylindrical components.
How To Choose a Band Type Heater
It’s helpful to start with your application and temperature requirements. Every band heater has its own unique characteristics, but you need to know the acceptable levels of each characteristic before you make your selection. The most common features to compare in-band style heaters are durability, process temperature, start time, heater life, band size and cost. These will help you determine if a heater is cost-effective, capable of delivering the temperature you need and capable of physically fitting around your cylindrical component.
Popular Brands and Manufacturers
We believe that selling the best parts begins with partnering with the right companies. Some of the brands in our inventory include Dalton, Gefran and Vaisala. Not sure which manufacturers may best suit your business needs? As a premier distributor specializing in industrial heaters, we can help you to identify the right equipment. Talk to one of our experts today to get started.
Hi-Watt Inc. provides heating systems and products to various industries across Michigan. We process up to 50 urgent requests from our customers every month and have a track record of meeting customer deadlines more than 97% of the time. Are you looking for a reliable partner in the industry to supply the band style heaters you need at prices you love and with a fast turnaround? Contact us today.
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