Here’s our tests results!
We made 3 ceramic band heaters ranging from medium to high wattage whose only difference was their thermal insulation:
- One with 1/4" thick ceramic fiber paper insulation (the standard insulation for many years);
- Another with 2 x 1/4" thick ceramic fiber paper for a 1/2" total (½’’ non-existant with this product);
- The third one with ceramic wool, 1” compressed to ½” thick (band of the middle on the photo).
The bands were then mounted on a steel cylinder and heated up to 260°C in 20 minutes. Measuring the outer sheath of each band, here’s a heat depletion estimate:
- The two bands with 1/2" insulation had 30% less heat loss than the 1/4" insulation.
- The ceramic wool, not having a bonding agent, did not produce smoke and remained white. This is why we chose that option to double the band’s insulation.
|Increasing the insulation thickness helps increase the operation temperature of the band. For your band to last even longer,|
|you can also reduce the power a little. A 3.5% reduction would be sufficient. I.E.: Go from 12 600W to 12 150W.|
By combining a ½’’ insulation to lower wattage, other advantages emerge:
- Equipment operating temperature reached faster;
- Colder outer sheath of the band by approximately 100°C;
- Longer service life of the ceramic bands;
- Less maintenance shutdowns & increase in productivity;
- Decrease in energy peaks.
On our test bench: The middle band contains the 1/2" ceramic wool insulation that we have chosen. Please note that normally, the insulation is not visible when you receive your band heaters, it was only for testing purposes.
|Do not forget that energy savings also depend on the complete design and conditions of use.|
Into the blog Mica band heaters vs ceramic band heaters, we suggested that mica allowed higher wattages. With the ½’’, insulation, without increasing the wattage, you’ll reach the requested temperature in due time, while having a product that lasts. Now is the time to seriously consider that option, less expensive in various costs.
Guess what? You can ask for up to 1¨ insulation. Imagine the energy costs savings!
Starting April 1st, 2023, for all new designs, your ceramic band heater will feature the ½¨ insulation, a ¼” difference in thickness. All the old drawings will remain with a ¼” insulation, unless you request a modification.
Ceramic bands can be repaired, no matter the original manufacturer and cost 30% less than a new one.