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Band Heaters

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Band heaters are ring-shaped heating appliances that clamp over a cylindrical element. The conductive approach is used to transmit heat from band heaters. Usually, band heaters wrap around a cylindrical element’s outside diameter and heat it from the outside. However, some devices are designed to clamp around a pipe’s inner diameter. To decrease heat loss to the environment, band heaters are usually supplied with ceramic or mineral insulation. Read More…

Band Heaters Band heaters are thin, circular electric heaters that clamp around cylinders, pipes and nozzles to provide direct or radiant heating. Similar in construction and application to strip heaters, band heaters are used mainly in plastic and metal forming processes, particularly extrusion. Available in a virtually limitless range of widths, diameters, thicknesses, sealing capabilities and clamping options, band heaters, also known as "knuckle heaters" and "barrel heaters," provide direct heating at temperatures anywhere between 300º and 1400ºF.
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Leading Manufacturers

Danvers, MA  |  978-777-0070

Backer Hotwatt is a superior designer & manufacturer of electric heaters and related heater accessories for various OEM & industrial applications.

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Backer Hotwatt, Inc. $$$

Columbus, IN  |  812-372-0281

For more than 70 years, Ulanet™ has been engineering and manufacturing electric heaters, cartridge heaters, immersion heaters, tubular heaters, miniature strip heaters and bolt hole heaters, as well as industrial heaters and appliance thermostats.

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Ulanet™ $$$

Rochester Hills, MI  |  888-852-3611

Working in the production of infrared heating products since 1965, Combustion Research is sure to be able to meet the infrared heater needs for your application. Our products (Reflect-O-Ray®, Omega II® and Synergy® brands) are known for their "big three" — comfort, efficiency and economic operation.

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Combustion Research Corporation $$$

Houston, TX  |  800-460-5200

Process industries have relied on Gaumer since 1962 for the design and manufacture of industrial heaters, electric heaters, heating systems plus controls. Circulation heaters, component heaters (radiant heaters, strip heaters, cartridge heaters), comfort heaters and immersion heaters are the offerings.

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Gaumer Process Heaters, Systems & Controls $$$

Charlotte, NC  |  800-438-4936

Space-Ray is an international manufacturer of infrared radiant gas heating products. We are a division of the Gas Fired Products Group of companies which manufactures energy efficient overhead radiant heating, space heating, infrared heaters and process heating systems in the UK and USA. We design and manufacture energy efficient gas heating products that will stand the test of time.

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Space-Ray, Inc. $$$
placeholder image Backer Hotwatt, Inc. Ulanet™ Combustion Research Corporation Gaumer Process Heaters, Systems & Controls Space-Ray, Inc.

Band heaters, as well as other small heating equipment, are required for any industrial process. They deliver direct, adequate heat in tight, irregularly shaped spaces where conventional heaters would be ineffective. Features of band heaters include cooling choices, probe holes or cuts on the band, insulated shrouds, and expanding heaters.

Band Heaters

Materials used

Insulation materials in-band heaters are the same as those used in strip heaters.

  • Resistance wire, an electric insulating substance, and a steel sheath are used to make all band heaters.
  • They may be made of various materials, including minerals, mica, and ceramics.
  • Mineral insulated heating bands with structural stainless steel may achieve extreme temperatures; some can generate temperatures up to 1400 °F (760 °C).

Construction of Band Heaters

  • The general-purpose terminal box provides good protection for exposed terminals. A standard conduit or flexible armor cable connections can be used.
  • Screw terminals of stainless steel are coupled to solid nickel pins to give maximum amperage carrying capacity.
  • All-ceramic bands include built-in ceramic fiber insulation, which reduces power usage by 25 to 30%. Using specially designed mounting brackets, the heating element assembly is uniformly and tightly drawn against the cylinder's width.
  • Nickel-chrome resistance wire is helically wrapped and threaded through specially constructed ceramic insulating bricks.
  • Serrated edges on the stainless-steel enclosure provide optimum installation flexibility. The method for making electrical contacts to the heater is called termination type. Armor cable leads, flexible conduit leads, braided metal leads, insulated leads, fast disconnects, and terminal boxes are all options for band heater terminals.

Working of Band Heaters

  • Ceramic band heaters use infrared radiation to transport heat through the air to the object to be heated, needing no physical touch. The interior temperature of the ceramic ring is capped at roughly 1650 °F (898.9 °C).
  • Mica bands transmit heat from the band to the area to be heated via conduction. The interior temperature of a mica band is restricted to roughly 900 °F (482.2 °C).

Types of Band Heaters

There are four main types of band heaters.

  • Tubular band heaters

    These are wide and cover a wider surface area to provide higher heat to cylinders or nozzles with smaller diameters. These heater bands are generally appreciated for their quick, easy clamp-on installation and for how quickly they produce heat.

    Tubular Band Heaters
  • Mica band heaters

    Mica band heaters are used where a lower maximum temperature is required. It's a good insulator for heaters because it's corrosion-resistant and has good dielectric strength. It also resists chemicals and water, can be somewhat elastic, and can hold up to some bending. However, the mica band heater is less expensive.

    Mica Band Heater
  • Ceramic band heaters

    They can handle high temperatures up to 1200-1400°F (648.9-760 °C). The ceramic segments used in these types of heaters make excellent insulators. In comparison, mica bands are expensive.

    Ceramic Band Heater
  • The mineral-insulated heaters

    These are great for high-temperature applications exceeding 2000 °F (1093.3 °C). They are also considered to have very high watt densities. The typical material used is magnesium oxide, a compacted mineral that coats the band heater and provides excellent thermal conductivity.

    The Mineral-Insulated Heaters

Benefits of Band Heaters

The significant advantages of using a band heater include:

  • In surface heating, heating vessels or pipes could be curved into an arc or ring-shaped cladding by winding, while large-scale steel sections can use the pavement cover. Furthermore, band heaters may be used to heat steel in a variety of geometric forms.
  • They provide a high working temperature, quick warm-up, high heat efficiency, and precise heating with an autonomous control system.
  • Band heaters have a long service life due to high impact toughness, strong thermal, dielectric strength, and broad surface area.
  • They have low application cost due to ease of installation and maintenance, as the exterior ceramic components may be recycled even if the interior hot raw material is destroyed.

Applications of Band Heaters

  • While band heaters are often used to direct conductive heating to materials such as polymer metals and plastic, they may also be used to heat conventional air.
  • Convective heating transmits heat via gasses and liquids; band heaters are commonly used to heat tiny quantities of air in manufacturing and processing equipment.
  • In eavestroughs and gutters, band heaters may also be employed as ice melters. They can keep drains clear of snow and ice even during harsh winters if adequately insulated and powered.
  • Nearly all extrusion processes require heating; most plastic and metal extrusion procedures require the plasticization or melting of the materials to be extruded. During extrusion procedures, band heaters enhance the heat created by friction.
  • Plastic extrusion, plastic injection molding, metal injection molding, front-end extrusion heating, blown film extrusion, chemical, wire processing, and food processing are some of the other band heating applications.

Band Heater Informational Video

 

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