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.

Circulation heater is a combined unit of an Electric heater bundle inserted inside a Pressure vessel or shell, in which fluid will be flowing continuously. It is a compact heating system with fast heating of the process fluids.

The Circulation heaters are designed in such a way that cold process fluid enters the pressure vessel through inlet nozzle at a low temperature, passes though the active zone of the heater bundle and leaves the vessel through outlet nozzle at desired high temperature. The system is designed in such a way that heating element skin temperature and the pressure drop across the nozzles are maintained within permissible limits. The Circulation heater system can be designed in single stage vessel or multi-stage vessels based on the process requirements.   The System can be installed vertically or horizontally based on the requirement and space availability.

Advantages

• Environment-friendly design. No hazardous gas / smoke/ emission from the system.
• Compact design for quick heating of continuous flow.
• Can be used for short duration operation as well as continuous operation.
• Precision Temperature control
• Can be accommodated in small foot prints.
• Custom designed to meet specifications.
• Highly energy efficient and provide maximum dielectric strength.
• Compatible with standard industry piping and safety standards.
• Reliable design
• Easy to operate and maintenance-friendly
• Energy Saving
• Heating Element: Mineral filled insulated Heating Elements or Tubular heating Elements with Ni-Cr (80-20) as heating Coil and suitable outer sheaths
• Control System: Thyristor control Panel + Local control Stations for effective temperature control & safe operation. ( Safe area  or Hazardous area)
• Protection and Control: Element Skin Temperature controls, Process temperature control, Earth leakage protection, Overload current protection

Construction
Typical Circulation heaters are made of below-listed parts.
Terminal Enclosures — The Design of terminal enclosure changes based on the area of installation (Safe or hazardous). The Terminal enclosure is designed to protect the terminals of the individual elements from external impact, such as dust, moisture etc and to facilitate the connection of Incoming power supply to the heater bundle. Marathon flameproof heaters are certified to install in hazardous area zone 1 &2, Gas group IIC, IP 66

Heater Bundle : Consist of No. of  U Pin heating elements adequately supported by set of Baffles & Tie rods, designed to deliver the specified temperature at outlet by maintaining the element temperature & pressure drop within the safe limits. Heating elements can be fixed to heater flange by means of standoff sleeve pipes with brazing or by direct welding or by means of threaded couplings. Heat duty of a bundle can be divided in to many sub groups (banks) based on process conditions. This will help in better control as flexibility in the operation.

Pressure Vessel: Pressure Vessel or heater housing is a fabricated shell in accordance with ASME or equivalent international standards. The Vessel has a inlet and outlet nozzle for the process fluid to flow. The Vessels are also provided with a drain & vent nozzle for the maintenance & safe operation purpose. The Vessel can be designed for either horizontal or vertical installation with single stage or multistage configuration. It is recommended to have the vessel insulated so as to avoid excess heat loss and also to protect from any thermal shock.

Temperature Sensors: The Heater bundle will have Element skin temperature sensor for monitoring and regulating the Element skin temperature within the limits.  The Unit may also need additional sensors such as Tube sheet Temperature Sensor, Terminal Box Sensor, vessel Body temperature sensor and process fluid Temperature sensors based on case to case. The Sensors used for the system will be certified in accordance with the area of installation.

The Temperature sensors are Typically RTD or Thermocouple. A simple heater bundle can also be controlled using Thermostat protection for skin & process temperature. If the Operation pressure is High, It is recommended to have a PSV (Pressure safety Valve) installed within the Heater Vessel as an additional safety measure.

Control Panel: Heater controls Panel are designed to monitor & control the operations of the heater bundle also to ensure the safety of the equipment and operations.

The control logic can be either ON/OFF (contactor) or regulated (Thyristor) or combination of both in a single panel. The control panels can be installed in both safe area & hazardous area by following respective design guidelines & certification requirements.

The Control Panels are provided with various indication systems such as Power ON, Heater ON OFF, Trip, High Temperature etc for comfortable handling of the process. The Temperatures of Elements, Process fluid & other areas (with sensors) are displayed on the Panel for better monitoring & awareness. Control Panel will also have safety interlocks such as high element temperature, Earth fault, process over-temperature etc along with Emergency stop access for the safe operation and control.

Application Areas

• Oil & gas
• Refinery & petrochemicals
• Gas processing plants
• Air separation unit
• Power plants
• Oil heating skid
• Fuel gas /natural gas skids
• Vaporizers

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

Tempsens offers a specially designed and developed edge wound heater which is also known as a bayonet heater. Edge wound elements are used in applications where utmost power is required in a limited space. These elements replace rod elements in furnaces requiring more power and are used to convert gas-fired furnaces to electric heating. Different furnaces such as roller hearth, pit, batch, low-temperature aluminum tempering furnaces and high-temperature exothermic gas generators use these heating elements to meet their heating requirement. A nickel-chromium alloy (80/20 or 70/20) forms the basis of these heaters. It delivers maximum radiation of surface area of the element and delivers high wattage in a limited area.

Advantages

• Higher power density
• Easy to install, replace and install
• Long service life at all temperatures
• Horizontal or vertical mounting
• Repairable to extend the service life

Construction

• Heating element Nichrome 80:20, ferritic alloys Mara FeCrAl
• Diameter Up to 160 mm
• High resistance strip of edge bending in coil form which is wound on high aluminium ceramic bobbins.

Infrared radiant heaters are electric heaters specifically designed to emit infrared heat radiation, where heating by other means is not ideal. It is mostly usable application where movable object heat like float glass, movable mold heating and drying of paint etc. Different lengths and sizes are available to meet specifications. IR heaters are high intensity infrared radiation heaters and used where high temperatures are necessary. They are designed to work in large and exposed areas and heavy duty projects.

Construction

• Heating Element with high emissivity coating
• Stainless steel assembling plate & threaded studs for mounting
• Insulation fiber pad between element & plate
• Ceramic insulation bead between element & plate
• Terminal strip for connection

Application Areas

• Float glass heating
• Movable mold preheating
• Conveyor or batch type ovens, Drying, Curing
• Industrial applications with medium intensity infrared heat: Paint spray, Booths, Curing, and Drying Softening resins.
• High-intensity heat applications

Famously known as “flexible heaters”, silicone rubber heaters are composed of fiberglass reinforced silicone rubbers that are rugged, moisture and chemical resistant, flame retardant, have high dielectric strength and are non toxic. Wire or etched foil heating circuits are positioned between two “wafers” of silicone which provides flexibility and strength. Design versatility permits zones of higher or lower heat concentration as needed. They are capable of flexing and will conform to contoured surfaces. They can also be pre-formed to complex shapes and can withstand mechanical shock and vibration.

Strip heaters, commonly called component or clamp heaters, based on the principle of convection air heating, use surface area to transfer heat effectively. Using most advanced heat technologies, strip heaters are an outstanding industrial heating product. It comprises of a heating element, a protective sleeve or sheath, and mounting hardware and can be clamped or bolted onto objects or solid surfaces. A coiled nickel chromium element wire is placed in the center of the heater. The element wire is then embedded in magnesium oxide (MgO)-based insulation and compacted into a solid mass creating excellent heat conductivity and high dielectric strength. The heater is then enclosed in desired sheathing. Suitable to work in 500 degree F temperatures, magnesium oxide is used for increasing efficiency. Temperatures can be controlled by using a temperature controller such as a thermostat. When using strip heaters, proper sheath material for resisting rusting or oxidation and suitable watt density of the element should be selected keeping in mind the application. These can be shaped and sized according to the use. A moderately inexpensive way of heating, strip heater is a tremendous solution to meet any budget. 

Features and Benefits

• Available with or without mounting tabs
• Easy and economic to install
• Corrosion and vibration resistant
• Durable, versatile and easy to control
• Uniform Heat Distribution
• Suitable for low to medium temperatures

Applications

• Blow Molding
• Heating Rubber Platten
• Compression molding
• Heating inks
• Sealing bars
• Food warming
• Packaging and sealing
• Laboratory equipment
• Hot Plates and ovens

Construction

• Nickel Chromium Resistance Ribbon uniformly wounded for even heat distribution.
• Mica Strip specially selected mica strip for maximum heater life.
• Mica Insulation high-grade mica used for insulation, for excellent thermal conductivity and dielectric strength.
• Stainless steel sheath for oxidation and corrosion resistance in a wide variety of environments. Suitable for temperatures as high as 650°C.

Hot Rod Cartridge Heaters are designed to provide uniform heating and excellent heat transfer rate throughout the heating surface. Facilitated with individually controllable heating zones, various process requirements such as zone-specific heating and distributed wattage requirement can be achieved with precise and uniform temperatures. Heaters are constructed with minimal spacing between sheath and heating elements to maintain lower internal temperatures which result in smaller-sized heaters operating at higher watt densities.

Constructed of high-grade Nickle Chromium resistance wire wounded on specially designed cores, separated from metal sheath using high purity magnesium oxide fill, all centered and tightly compacted in SS/Inconel tubing through the refined swaging process, results in heaters with a minimal air gap, high resistance to corrosion and oxidation, and increased life which makes Marathon make cartridge heaters best in class with high performance and longer durability.

Application Areas

• Semiconductor chamber heating


• Semiconductor wire and die bonding


• Freeze protection and deicing of equipment in cold climates or applications


• Humidity control


• Patient comfort heating used in medical devices


• Metal die casting


• Seal bars used in packaging equipment


• High-temperature glass forming equipment

Construction

• High-Temperature Lead Wires for temperatures up to 550 C


• High Impact Ceramic Cap retards contamination and is suitable for high vibration applications. Deep holes in cap prevent the fraying of lead when bent.


• Nickel Chromium Resistance wire for maximum life, evenly wound for even heat distribution.


• High Purity magnesium oxide fill selected for maximum dielectric strength and thermal conductivity, highly compacted for maximum heat transfer.


• Stainless steel sheath / Inconel sheath for oxidation and corrosion resistance in a wide variety of environments.


• Tig welded end disc to prevent contamination and moisture absorption

Duct heaters are devices which are an assembly of multiple heating elements mounted in a plate or casing and used to heat the air in a non-pressurized condition. The Heater bundle is usually inserted inside a duct line or an insulated body through which air passes and get heated up to required temperature.

Duct heater elements can be of open coil, tubular or finned tubular heating elements, depending upon the application, temperature etc. If an application needs a very large capacity of heat duty, several smaller capacities the duct heater bundles can be made and assembled in series. This will help not only to get the desired temperature at varying process condition but also eases the job of maintenance and spares cost.

Features and Benefits

• Energy efficient
• Safe Design
• Environment friendly, No Hazardous smoke, NOx & SOx gas generation.
• Corrosion and oxidation resistance
• User-friendly system.Easy to install & operate.
• Durable and easy maintenance
• Rugged construction eliminates the hazard of electric shock
• The reinforced frame allows for minimum vibration
• Minimal heat loss.
• Very small footprints are required. Can be installed in any existing ducts with little access

Application Areas

• Air Drying Operations ( Paintings, pellets drying, drying application in Process)
• Air Handling Equipment
• Humidity control
• Comfort Air Heating for the building (HVAC)
• Core Drying
• Chemical pellets dry heating
• Booster Air
• Air Preheating
• Secondary heating
• Multi-zone Reheating
• Resistor Load Banks