ABOUT
Introduction
Bobbin heaters are highly effective heating devices designed for use in industrial applications utilizing resistance wire wrapped around ceramic insulator materials. A ceramic bobbin heater consists of ceramic blocks with accompanying nichrome or ferritic alloy heating elements that produce excellent thermal distribution and long-term durability. Tempsens bobbin heaters are manufactured in various diameters and lengths, accommodating custom voltage and wattage requirements up to 12kW. Bobbin heater element have the capability to provide direct or indirect heat to liquids, semi-solids, gases, etc., which makes them typically used in process heating applications. Bobbin heaters operate at temperatures from ambient up to a maximum of 600° Celsius, and watt densities between 1 W/cm² and 10 W/cm²; thus providing the most energy-efficient performance while generating 100% of the heating efficiency of the heater within the heated medium. Bobbin heaters manufactured by Tempsens Instruments meet the ISO 9001-2015 certification standards and are available in both sheathed and unsheathed designs for industrial usage.
About Bobbin Heaters
Advantages of Bobbin Heaters
- Energy efficiency: Energy savings are incredible because 100% of the heat generated goes into heating the solution with zero heat loss and significantly reduced operational cost.
- Wide Temperature Range: The bobbin heater can function efficiently upto 600°C, making them suitable for use in various applications in heating the furnace.
- Easy Installation: The simplicity of mounting provides for easy, cost-effective installation and allows for minimal downtime of the existing system.
- Easy Maintenance: The bobbin heater’s modularity allows for ease of repair/replacement without major disruption to the overall system or requiring emptying the process tank.
- Versatile Applications: Water/chemical/oil/wax/fat/bitumen heating services that do not produce emissions; various applications within all industries.
- Customisable Options: Long lengths, high voltages, high wattage are available for max operator flexibility with customer process specifications.
- Optimised Heat Transfer: Elements partially exposed to the air or immersed in radiant tubes produce large heating surfaces for the best thermal transfer.
- Durable Construction: Superior-quality refractory insulation and quality resistance wire create a longer life in harsh conditions.
Download Data Sheet – Link
Bobbin Heater Applications
- Indirect heating of liquids and gases in tanks to protect them from contamination.
- Controlled heating of chemical solutions requiring exact temperature control while remaining free from contamination during processing.
- Efficiently heating viscous materials such as wax, fat, oil, and bitumen to enable processing.
- Low- to medium-temperature furnaces operated at temperatures of up to 600 degrees Celsius using bobbin heater technology for heat treatment processes in industry.
- Cost-effective, dependable electric heating for industrial use to heat water (water heating systems).
- Oil and petroleum companies use bobbin heater technology to heat oils/petroleum products for viscosity reduction/processing needs.
For More Information related to Bobbin Heaters you can refer to our Guide – Understanding Bobbin Immersion Heater: A Comprehensive Guide.
Specification for Bobbin Heaters
| Temperature Range | Up to 600°C |
| Heating element | Ferritic alloys wire mar FeCrAl and non-ferritic wire NiCr 80-20, NiCr 70-30 |
| Bobbin size | Standard: 25,30,36,42,45,57,93 other customize size available |
| Watt density | 1 to 10 W/cm² |
| Power | Up to 12kW |
| Heater Parameters | Customized – power rating, voltage, resistance, length, diameter, and other dimensions |
| Radiant Tube/Immersion Tube | Stainless Steel SS Grade, Incolay, Cast Alloys |
| Thickness of Tube | 1.5 to 3mm |
| Length of Tube | 300 to 2800mm customize |
| Terminal Box | MS, IP54 standard, IP66 waterproof terminal box |
| Control | Thermocouple, RTD, Thermostat for temperature control |
Construction of Bobbin Heaters
- Ceramic Insulator Assembly: The ceramic blocks are refractory ceramic blocks assembled to the length specified, providing excellent electrical insulation and thermal resistance.
- Resistance Wire Element: The nichrome heating element is inserted into the ceramic blocks and wound evenly to provide uniform heat distribution and maximum service life.
- Sheath Material Options: The sheath options are nickel-plated mild steel, Inconel alloys, and stainless steel grades for corrosion resistance.
- Mounting Configuration: Bobbin heaters are generally manufactured for horizontal mounting; however, different mounting configurations are available for applications requiring vertical mounting.
- Terminal Block Design: The refractory insulator supports the resistance wire and connects to robust terminal blocks at one end, providing a dependable electrical connection.
- Thermowell Provision: Thermowell provision will be available as the optional method for temperature sensing and process control.
- Sheathed Version and Unsheathed Version: Both sheathed and unsheathed versions will be available based on specific applications and heat transfer requirements.
Why Tempsens Is the Leading Manufacturer Of Bobbin Heaters
- Cutting edge facilities at our manufacturing facility, we use advanced methods to manufacture bobbin heaters. Our precision engineering guarantees consistently high-quality bobbin heater products.
- Custom Designed Products for required application’s rated capacity (power), voltage, resistance, length and diameter; we also produce custom designs for every application.
- For over 30 years we have designed and manufactured heating elements used in many thermal applications.
- We provide Technical Assistance for the selection, installation and ongoing operation of your heaters.
- Globally known as a leader in bobbin heater manufacturer, Tempsens is at the forefront of providing energy-efficient heating solutions.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Bobbin Heaters.
Bobbin immersion heaters have resistance wire wrapped around ceramic insulators that are partially out of the casing for a better transfer of heat. Tubular heaters encase the entire heating element in a steel sleeve with no direct contact to the outside air; therefore, bobbin heaters are typically better for radiant tube applications and radiators used in furnace applications.
Yes, the Ceramic bobbin heater is specifically manufactured and produces the most efficient heat output in the furnace at maximum temperatures of 600° Celsius and is designed to withstand extremely high temperatures, up to 1200° Celsius, without breaking down. Its ceramic construction coupled with insulative properties provides the Ceramic Bobbin Heater with maximum performance longevity within a furnace system.
The maximum watt density for bobbin heaters is as high as 10 Watts/cm². The sheath material could be nickel-plated mild steel, stainless steel (SS grade), Inconel, or Incoloy based on the operating temperature and corrosive environment requirements of the application.
