Professional Documents
Culture Documents
Basics of
Electric Heaters
The simplest definition
of an electric heater is any
device that changes electrical
energy into heat energy. But
from that simple explanation,
electric heaters explode into
a myriad of types, sizes,
applications, and designs
depending upon whats being
heated, the degree of heating
needed, and the method by
which the heat is applied.
The measure of electrical
energy is called the Joule
after its discoverer, James
Prescott Joule. Through
numerous experiments, Joule
determined that the quantity
(Q) of heat transferred
from electrical energy is
proportional to the square of
the current (I 2 ) multiplied
by the resistance (R) for the
period of time (t) through
which it passes:
Q I2 R t
m H
Types of
heaters 1
Transfer of
heat 2
Heat losses 2
Basic heat
equations 3
Specific
applications 3
An application
example 4
Watt density 5
Presented by
March 2013
Type of heater 1
Basic heat equations 3
An application example 4
Watt density 5
Transfer of heat
Heat losses
March 2013
Type of heater 1
Transfer of heat 2
AS = D h or 6 5 = 941/4 in2
Q I2 R t
F
m
to reach a melting or vaporizing
point
W=
+
Equation A 3.412
calculates
Tthe amount
2 of wattage2 (W) needed
= D h ofora 6
5 =a specific
941/4 inamount in F
to raise the Atemperature
material
S
(F) in a given number Pof=hours
I 2 R(T), you first need to know
the mass (m) of the material being heated and its specific
heat
m c F2 WL/SF A
c value
F1 (c): m Hf
m
+
+m c F
+
W=
3.412 T
2
3.412 T
3.412 W
T =
AS = D h or3.412
6 5T = 941/4 in2
Sponsored by Hotwatt
March 2013
Watt density 5
T
W= W
A for the latent heat of
1hr
fusion or vaporization can beL/SF
found in the same look-up
to maintain the temperature of a material based upon its
WL/SF A
c F
m A.
tables used in Equation
known wattage loss per square foot (WL/SF) multiplied by
W=
+
3 area (A) in square feet:
m H
3.412 T
2
= 270 in.the
2 0.286 = 154.5
W =lb 0.12 BTU/lb/F (400-70)F = 1,800 W
3.412
T
Specific applications
W = WL/SF A
3.412 1hr
m H
To heat a liquid requires
W = additional energy due to losses
3.412
T by adding half of
The wattage loss per square foot is found for specific
by evaporation. This is usually covered
materials in tables located at www.hotwatt.com/heatloss.htm.
themwattage
to
maintain
the m
materials
WL/SF A
c Ftemperature
m
Hf
c Fneeded
2
1 +
5.6 lb 0.55
BTU/lb/F
Metal
(400-70)FW (Equation
+ heating period
+(Equation
A
WL/SF
A sample table is shown
Uninsulated
B)
to
that
of
its
initial
==300
W
F from
m c(Losses
3.412 T
2
3.412 T
3.412 T
m
= some materials
+H have
Surfaces). NoteWthat
different
A):
3.412
1hr
W =T
3.412
2 three
3.412
T A represents the
WL/SF A
curves identified as A, B, or
C. Curve
m c F
W
=
+
heat losses from vertical surfaces of tanks, pipes, and other
3.412 T
2
An application example 4
P = I2 R
W = WL/SF A
Type of heater 1
P = I2 R
WL/SF A
m c F
+
To heat a solid to a liquid state temperature requires
3.412three
T different2calculations. First, use the solid calculation
W=
(Equation A) from the initial temperature of the material to its melting point. Then add in the wattage needed to
AS = DC).
hFinally,
or 6use
5the=equation
941/4 in2 for a liquid material from its melting point to the
transition from solid to liquid (Equation
final temperature:
W=
m Hf
m c F1
+
+
3.412 T
3.412 T
W
c F
+
( m3.412
T
L/SF
Transfer of heat 2
m c F
For example, you want to raise the temperature
W = of solid lead from a room temperature of 70F to a molten 950F.
Tlead is 620F. That makes the first change in temperature,
From Table 1 on our Web site, the melting point3.412
of solid
F1, equal to 620 - 70 or 550F. The second change in temperature, F 2, equals 950 - 620 or 330F.
(1084) = 320 in.3 2 0.284 = 181.7 lb 0.12 BTU/lb/F (400-70)F
An application example
W=
Watt density 5
= 2,110 W
W =3.412
WL/SF
A
A steel mold is being used to form polyethylene
parts.1hr
Every hour 90 ounces of nylon is introduced to the mold. The
mold itself measures 10 8 4 in. The mold is attached between two stainless steel platens, each measuring 15 12
1.5 in. thick. The
platens are=insulated
press=mechanism
with BTU/lb/F
0.5 in. thick
(15121.5)
270 in.3 from
2 the
0.286
154.5 lb 0.12
insulation.
(400-70)FOperating temperature
1,800 W
of the mold is 400F and must reach this temperature in 1 hour from an ambient temperature of=70F.
3.412
1hr
From Table 1: Properties of Metals
m H
W=
Specific heat of steel: 0.12 BTU/lb/F
3.412 T
Specific heat of stainless steel: 0.12 BTU/lb/F
5.6 lb 0.55 BTU/lb/F (400-70)F
Converting cubic inches into pounds (density lb/in2)
= 300 W
3.412 1hr
WL/SF A
m c F
+
3.412 T
2
W
m c F
+
(
3.412 T
1.5 15 4 + 1.5 12 4
c Heat
F1 Lossesm Hf
m for
From Graph 1: Guide
+
+
W=
Heat losses curves: A + 3.412
B @ 400F
T
3.412 T
144 in.2/ft2
L/SF
= 700 W
To heat the polyethelyne (90 oz / 16 oz/lb = 5.6 lb): (700W + 385W + 350W + 250W) 0.20 = 340 W
5.6 lb 0.55 BTU/lb/F (400-70)F
= 300 W
3.412 1hr
Compensation Factor: 20%
(2,101 + 1,800 + 300) 0.20
= 840 W
AS = D L
Total wattage needed for heat-up
=
5,050
W
2
3.1416 0.75 9 = 21.1 in
10 4 4 + 8 4 4
144 in. /ft
2
Sponsored by Hotwatt
1.5 15 4 + 1.5 12 4 4
2
= 700 W
March 2013
= 1,
Type of heater 1
ESTABLISHED
HOTWATT
IS A LEADER
5.6 lb 0.55 BTU/lb/F (400-70)F
(15121.5)
= 270 in.3 IN
2 1952,
0.286 = 154.5
lb 0.12 BTU/lb/F
(400-70)F
=
= 1,800 W
m H RESISTANCE HEATING
IN MANUFACTURING
3.412
1hr
W=
3.412
1hr
3.412
TOVER
ELEMENTSFOR
60 YEARS.
5.6 lb 0.55 BTU/lb/F (400-70)F
= 300 W
WL/SF A
3.412 1hr
10 4 4 + 8 4 4
m c F
= 2 ft2 350 W/ft2/hr
W=
+
2
2
3.412
at
T operating2 temperature (See graphs: Guide for Heat Losses)
Equation B: Wattage
losses
144 in. /ft
350
W/ft
/hr =
700
W
m c F2 WL/SF A
2
2
m Hf
m c F1
144 in. /ft
+
+
+2
W=
144 in.2/ft
3.412 T
2
3.412 T
3.412 T
Transfer of heat 2
10inthe
4 mold
4 + would
8 4AS
=4D theL2
The number of holes
dictate
= 2 ft 350 W/ft2/hr = 700 W
500W 21.1 in2 = 23.7W /in.2
2 the
2 wattage by the
number of heaters required. Dividing
1443.1416
in. /ft 0.75 9 = 21.1 in2
number of heaters will equal the wattage rating of each
heater.
Our Web site at www.hotwatt.com/watt.htm lists
1.5 15 4 + 1.5 12 4
2
suggested
wattW
densities for use with various materials.
= 1.1 ft2 350 W/ft
/hr = 385
Watt density
2
144 in.
/ft2 21.1 in2 = 23.7W /in.2 Safe values vary with operating temperature, flow
500W
Watt density is the rated wattage of the heater divided
velocity, and heat transfer rates. In general, the higher the
by the overall area being heated. The watt density permitted
material temperature, the lower the watt density should
for any given application
depends
on
how
well
the
material
be, especially those materials which coke or carbonize,
15 12 2 - (10 8 2) = 1.3 ft2 250 W/ft
2
350Watt
W densities should be low if a material is
being heated distributes its heat throughout
its volume.
such/hras =
oils.
2
2
/ft
144
in.
Water, light oils, and metals typically have high heat
being heated to a temperature near the change of state
AS = D L
March 2013
An application example 4
1hr
= D
(700 + 385 + 350 + 250) 0.20
W L
(700W + 385W + 350W + 250W) 0.20 ==A340
340
W
S
Total wattage losses at operating temperature
= 2,025 W
3.1416 0.75 9 = 21.1 in2
Total wattage required for heat-up
= 5,050 W
Total wattage required
= 7,075 W