Before getting onto the topic of Mica Band Heater versus Ceramic Band Heater, we should be clear about the idea of industrial band heaters. Nichrome (NiCr) Wire is used as the heating element in the band heaters that help in the heating of the external surface of pipes, drums, barrels, nozzles and other similar cylindrical parts, ensuring gradual heat transfer. Further, to meet the varied and diversified needs of industrial sectors, there are two types of band heaters available by Shiva Products, namely Mica Band Heater and Ceramic Band Heater. These heaters are in great popularity as these help in effective heat transfer and high dielectric strength.
But to meet the precise needs of various industrial sectors, there are various factors that make one of the two the prior choice. Hereunder are the general differences, so that it becomes easy to make the best choice from the two, in accordance with the requirement of the application areas.
Application Areas of Mica Band Heater & Ceramic Band Heater
Temperatures:
If we talk about the temperatures, the Ceramic Band Heaters win the race as it can withstand the temperature of up to 1400?F with ceramic fiber insulation. Where on the other hand the Mica Band Heaters can withstand the temperature up to 900?F. Thus, Shiva Products is renowned as one of the major Ceramic Band Heater Manufacturers, based in India.
Watt Density
Mica Band Heaters are designed in such a way that it can have a higher watt density when compared to the Ceramic Band Heaters. Higher watt density in Mica Band Heater is due to the resistance ribbon that is tightly clamped in the middle of mica pieces. This helps in effective heat transfer ribbon to the external surface of the heater. Especially in the small band heaters, the mica band heaters will have relatively less unheated area in comparison to the ceramic band heaters.
Life Expectancy of Heater
Not always, but on a majority level, Ceramic band heaters have a longer life expectancy compared to the Mica Band Heaters. The construction of the heater includes the coiled resistance wire, fed through knuckles, commonly known as the ceramic blocks. In the mica band heater, a thin resistance ribbon is used. The ratio of the surface area is smaller in the coiled resistance wire to the internal cross-sectional area. This further does not oxidize and burn as quickly as the ribbon.
Insulation
Shiva Products Ceramic Band Heaters have a layer of 3/8? thick ceramic paper insulation above the ceramic blocks (knuckles). The same is then connected to the stainless-steel outer sheath through which heat is reflected back into the process. The construction also includes an option of 1/8? thick ceramic paper layer which is capped with a reflective stainless-steel sheath. There also are two additional layers of 3/8? thick paper which is capped by another additional sheath. The insulation ensured yielding of higher and efficient heat in comparison to Mica Band Heaters. In the Ceramic Band Heater, an option of Vented Outer Sheath is also available which allows heat to escape if required in the respective application area.
Customization
The size of the ceramic blocks (knuckles) in the ceramic band heaters restrict the option of customization, where on the other hand, the mica sheets in the mica band heaters can easily be cut into various shapes and sizes as required in the application. Where there is only option of 1/2? width increment in the ceramic band heaters, the mica band heaters can easily be customized (increased or decreased) by 1?, this all is completely dependent on the configuration of the mica band.
Cost
When it comes to cost, the ceramic band heaters are heavy on pockets when compared to the pricing of Mica Band Heaters. The knuckles (ceramic blocks) are quite expensive where on the other hand the mica sheets are quite reasonable. This may be the winning difference for the Mica Band Heaters, but the efficient working of the ceramic band heaters is not to be avoided.
Result
In order to decide the suitable band heater for your respective industrial application, one should examine the process of heating and usability. The ceramic band heaters are the winners when it comes to temperature, insulation and effectiveness. On the other hand, the mica band heaters are highly praised for watt density, life expectancy customization and affordability.
Shiva Products have carved a top-notch position amidst the popular Immersion heater manufacturers, based in India. The ceramic band heaters and mica band heaters are also our specialized products that are gaining popularity in India as well as abroad. The customer centric approach has been a huge help in making Shiva Products and its industrial heaters highly popular in the market. These heaters are available in specifications complying with the ISO 9001-2008 certification and also in the customized provisions available to meet the requirements of the industrial applications.
