Energy Calculation – Heating Elements

There appears to become a large amount of thumb sucking happening within our industry when energy needs for any heating application have to be calculated. The issue lies largely using the lack of ability, reluctance, or simply plain idleness from the customer to provide sufficient data. However, too little appreciation by a few of the ‘heating experts’ available from the physics involved can also be responsible. These 4 elements usually lead to with the idea to little or excessive energy being provided, which results in modifications and/or operating costs not budgeted for. While a mix of Thyristor and PID control provides the luxury of ‘over engineering’ after which ‘throttling back’ to offer the preferred result, the issue is among greater than necessary initial capital expenditure through the customer. Besides this practice usually increase the risk for installing of more elements than necessary, it

does mean that bigger switchgear, enclosures, cabling, etc can be used.

The calculations can however be achieved scientifically and precisely, particularly when the database which we’ve developed over greater than 3 decades can be used along with our design programs. However, in addition to the material to become heated, numerous additional factors have to be considered. Included in this are things like available current, heat-up time, throughput speed, loading and unloading some time and procedure, type and weight from the conveyor system, oven materials, type and thickness of insulation and floor, cheapest ambient temperature, fume extraction, recirculation, losses, standardization of spares, easy installation, maintenance,

and repair, etc.

Another design consideration that is frequently overlooked is corrosion at elevated temperatures. Many of the prevalent within the electroplating industry where, because tanks are fabricated of mild or stainless the assumption is the heater sheath or pocket material could possibly be the same. This really is frequently and not the

situation, specifically in harsh solutions, because of the high heater temperatures.

Another design consideration that is frequently overlooked is corrosion at elevated temperatures. Many of the prevalent within the electroplating industry where, because tanks are fabricated of mild or stainless the assumption is the heater sheath or pocket material could possibly be the same.

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