Srinivasan,SL/EEE,KLNCE,Madurai
ELECTRIC HEATING
A.Srinivasan,SL/EEE,KLNCE,Madurai
Advantage of Electric Heating
1. Transfer of heat is accurately controlled in
heating by electrical methods.
2. Production of heat is not accompanied by any
combustion.
3. Any temperature can be reached, provided the
material can withstand that temperature.
4. It is quite cleans
5. No flue gases are produced and ambient
temperature is not affected.
6. The desired temperature is obtained fast and
temperature control is easy.
7. It is easy to maintain and is safe.
8. The efficiency of electric heating is high.
A.Srinivasan,SL/EEE,KLNCE,Madurai
Methods of Heat transfer
1. Conduction.
2. Convection.
3. Radiation.
A.Srinivasan,SL/EEE,KLNCE,Madurai
Conduction
A.Srinivasan,SL/EEE,KLNCE,Madurai
Convection
This is a process where the
transfer of heat from one point to
another is duo to the actual motion of
the molecules of a fluid. This is due to
the different in the fluid density at
different temperature. Thus, for nature
convection in air we have
A.Srinivasan,SL/EEE,KLNCE,Madurai
RADIATION
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Requirements of heating material
A.Srinivasan,SL/EEE,KLNCE,Madurai
Design of Heating element
Normally, the wires of circular cross section or rectangular cross
section ribbons are used as heating element.
Under steady state condition
A heating element dissipates as much heat from its surface as it
receives the power from the electric supply. Power input P=Heat
dissipated
Heat dissipated according to Stefan's law
H=5.72X104Ke((T1/1000)4-(T2/1000)4)Watt/m2 1
Electrical input=V2/R
R=ρl/a= ρl/(πd2/4)=4ρl/ πd2 for a circular wire
Heat dissipated=π d l H
A.Srinivasan,SL/EEE,KLNCE,Madurai
Since at steady temperature
Power input P=Heat dissipated
P =πdlH
π d2 V2 / 4 ρ l =πdlH
d / l2 = 4 ρ H / V2 ----------------------- 3
Solving expression 2 and 3 length and diameter of wire can be
determined.
For ribbon type of conductor let ω be the width and t be the
thickness.
Electrical input P=V2/R=V2/(ρl/ a )= V2 /( ρl/ ωt)
= V2ωt / ρl
l / ωt = V2 / ρP
Since at steady temperature
Power input P=Heat dissipated (2ω l H )
V2 /( ρl/ ωt)= 2ω l H
t / l2 = 2 ρ H / V2 ------------------------------------- 4
So by solving the two equations 3 and 4 ,length l and width ω
for a ribbon of thickness t will be evaluated.
A.Srinivasan,SL/EEE,KLNCE,Madurai
CLASSIFICATION OF
ELECTRIC HEATING
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Classification of
Electric heating
Direct Indirect
Direct arc Indirect arc Direct induction Indirect induction
resistance resistance
Infra red
or
radiant
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Resistance heating
1. Direct resistance heating
High Resistive
Powder
Charge
A.Srinivasan,SL/EEE,KLNCE,Madur
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1. Direct resistance heating
The material or charge to be heated is taken as
resistance and current is passed through it.
The charge may be in the form of powder, pieces or a
liquid.
Two electrodes are immersed in the charge and
connected to supply in case of D.C or single phase ac
supply.
When some pieces of metals are to be heated some
highly resistive powder is sprinkled over the surface of
pieces to avoid direct short circuit. The current flows
through the charge and heat is produced.
This method has high efficiency since heat is produced in
the charge itself.
It is used in salt bath furnaces and in the electrode boiler
for heating water.
A.Srinivasan,SL/EEE,KLNCE,Madur
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Indirect heating
Resistive
Element
Charge
A.Srinivasan,SL/EEE,KLNCE,Madurai
Indirect heating …
The current is passed through a wire or other higher
resistance material forming a heating element.
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Infra red or Radiant heating
A.Srinivasan,SL/EEE,KLNCE,Madurai
ARC HEATING
A.Srinivasan,SL/EEE,KLNCE,Madurai
Direct arc furnace
In this furnace , charge acts as one of the
electrodes and the charge is heated by producing arc
between the electrodes and the charge.
A.Srinivasan,SL/EEE,KLNCE,Madurai
Direct arc furnace
Electrodes
ARC
Charge
A.Srinivasan,SL/EEE,KLNCE,Madur
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Direct arc furnace
A.Srinivasan,SL/EEE,KLNCE,Madurai
Indirect Arc Furnace
The arc is formed between two electrodes above the
charge. Heat is transmitted to the charge solely by
radiation.
Temperature of the charge is therefore lower than
direct arc furnace.
Arc Electrodes
Charge Heating
chamber
A.Srinivasan,SL/EEE,KLNCE,Madurai
Indirect Arc Furnace
Since, In this furnace current does not flow
through the charge, so there is no stirring action and
the furnace is required to be rocked mechanically.
i.e The furnace is made of cylindrical
shape, with the electrodes projecting through the
chamber from each end and along the horizontal
axis.
Application: Melting of non-ferrous metals like Cu,
bronze,etc.
Size varies from 0.25 to 3 tonnes.
Power factor is 0.85
A.Srinivasan,SL/EEE,KLNCE,Madur
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Induction heating
This heating process makes use of current
induced by the electromagnetic action in the charge
to be heated.
A.Srinivasan,SL/EEE,KLNCE,Madur
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Types of induction heating
A.Srinivasan,SL/EEE,KLNCE,Madur
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1.Direct core-type induction furnace
Secondary
(charge)
Supply voltage
Primary
Magnetic core
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The primary winding which is supplied from an a.c
source is magnetically coupled (iron core) to the charge
which act as the short circuit of single turn. The charge
is kept in the crucible.
The current in the charge is very high, of the order of
several thousand ampere.
Drawbacks 1.Magnetic coupling between py and sy circuit is poor,
therefore, leakage reactance is high and power factor is low. it
is overcome by employing supply of frequencies as low as 10hz
for operation of such furnaces. For obtaining low frequency
supply motor-generator set or frequency changer is required,
which involves extra cost.
2. If the current density exceeds about 5A/mm2 the pinch effect
(formation of bubbles and voids etc.) due to electromagnetic
forces may cause complete interruption of the secondary
circuit and so of the supply.
3. The crucible for charge is of odd shape and convenient from
the metallurgical point of view.
A.Srinivasan,SL/EEE,KLNCE,Madurai
Vertical core type induction furnace
This is an improved form furnace of direct core type
induction furnace.
It employs a vertical channel instead of horizontal one
for the charge.
The convection currents keep the circulation of molten metal
round the V portion.( In certain case U or rectangular
shape
This V channel is narrow, so even a small quantity of
charge is sufficient to keep the secondary circuit closed.
Hence the chances of discontinuity of the circuit are less.
Due to pinch effect the adjoining molecules carrying
current in same direction will try to repel to each other, but
because of the weight of the charge they will remain in
contact and chances of interruption will be reduced.
A.Srinivasan,SL/EEE,KLNCE,Madurai
High frequency coreless Ajax-Wyatt furnace
Charge
Central
iron core
Primary winding
A.Srinivasan,SL/EEE,KLNCE,Madurai
Coreless induction furnace
Crucible
Charge
Primary winding
A.Srinivasan,SL/EEE,KLNCE,Madurai
Coreless induction furnace….
The furnace consists of a ceramic crucible cylindrical in
shape enclosed within a coil which forms primary of
transformer & the charge in the crucible, the secondary of the
transformer.
The flux produced by the primary winding sets up eddy
currents in the charge which flow concentrically with those in
the primary winding.
These currents heat up the charge to the melting point &
provide stirring action to the charge.
Since the frequency of the supply is high, the skin effect in
the primary coil increases the effective resistance of the coil
& hence the cu losses tend to be high and artificial cooling is
necessary. The coil is ,therefore, made of hollow cu
conductors through which cooling water can be circulated.
A.Srinivasan,SL/EEE,KLNCE,Madurai
Coreless induction furnace….
The stray magnetic field due to current in the primary coil
may induce eddy currents in the metal supporting structures
and cause over heating of these structures.
Advantages:
They are fast in operation.
It is used for all industrial applications.
The speed of heating and the precise control of power into the
charge result in uniform quality of product unattainable be any
other method of heating.
The working condition around the furnace are far better than
any other type of furnace.
Application:
Used for steel production.
Used for melting of non-ferrous metals like brass,
bronze, Cu, aluminium etc..
A.Srinivasan,SL/EEE,KLNCE,Madur
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DIELECTRIC HEATING
It is also called high frequency capacitive heating.
It is used for heating of insulating material (non-
metallic) such as wood, plastics, ceramics, glass etc.
The material to be heated is placed as a slab
between metallic plates or electrodes connected to high
frequency a.c supply. (from valve oscillator)
A.C Supply
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DIELECTRIC HEATING
A.Srinivasan,SL/EEE,KLNCE,Madurai
DIELECTRIC HEATING
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A.Srinivasan,SL/EEE,KLNCE,Madurai