Utilization of Electrical Energy

SUBJECT CODE: EE402

Department of Electrical and Electronics Engineering

National Institute of Technology Puducherry, Karaikal-
609 609
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SECTION BREAK
Unit 2
Insert the title of your subtitle Here
Electric Heating
Introduction

 Electric heating is a process in which the electrical energy is converted into heat
energy.

 When current is passed through a conductor, the conductor becomes hot

(resistance heating)

 When a magnetic material is brought in the vicinity of an alternating magnetic

field, heat is produced in the magnetic material (induction heating).

 When an electrically insulating material was subjected to electrical stresses, heat

is produced in the material (dielectric heating).
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Introduction

 Domestic applications
room heaters electric irons

immersion heaters for water heating pop-corn plants

hot plates for cooking electric ovens for bakeries

Electric kettles electric toasters

 Industrial applications
melting of metals moulding of glass
heat treatment of metals like baking of insulators
annealing, tempering, soldering and
brazing etc. enameling of copper wires
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Advantages of electric heating

 Cleanliness

 Absence of flue gases

 Ease of control

 Low maintenance requirement

 Special heating requirement

 Higher efficiency
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Different Methods of Heat Transfer

Conduction

 In this mode of heat transfer, one molecule of the body gets heated and transfers
some of the heat to the adjacent molecule and so on.

 There is a temperature gradient between the two ends of the body being heated.

Convection

 Convection is the transfer of heat by the movement of a fluid (liquid or gas) between
areas of different temperature.

Radiation

 Heat transfer due to emission of electromagnetic waves is known as thermal

radiation
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Classification of electric heating methods

Power frequency heating High frequency heating

 Resistance heating  Induction heating

Direct resistance heating Direct core type induction heating

Indirect resistance heating Coreless type induction heating

 Arc heating  Dielectric heating

Direct arc heating  Infrared heating

Indirect arc heating

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Resistance Heating

Requirements of a good heating material

 High specific resistance

 High melting point

 Free from oxidation

 Low temperature coefficient

 Some commercial materials-Ni-Cr, Ni-Cr-Fe, Ni-Cu and Fe-Cr-Al

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Resistance Heating

Direct Resistance Heating

 In this method the material (or charge) to be heated is

treated as a resistance and current is passed through it.

 Two electrodes are inserted in the material or charge to

be heated. Electrodes can be connected to either a.c. or
d.c. supply.

 The material or charge may be in the form of powder,

small solid pieces or liquid.

 Two electrodes will be required in the case of d.c. or

single-phase a.c. supply but there would be three
electrodes in the case of 3-phase supply.
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Resistance Heating

Direct Resistance Heating

 When the charge is in the form of small pieces, a

powder of high resistivity material is sprinkled over the
surface of the charge to avoid direct short circuit.

 This method of heating is employed in salt bath

furnace and electrode boiler for heating water.
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Resistance Heating

Indirect Resistance Heating

 In this method of heating, electric current is passed

through a resistance element which is placed in an
electric oven (Heating Chamber).

 The heat so produced is delivered to the charge either by

radiation or convection or by a combination of the two.

 Sometimes, resistance is placed in a cylinder.

 This arrangement provides uniform temperature.

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Arc Heating

 The heating of matter by an electric arc. The matter may be gas, liquid or solid.

 An electric arc is a phenomenon in which an electric current (a flow of electrons)

is caused to flow between two electrodes separated by a gas.

 Direct arc heating-Electric arc is formed between the electrodes and the charge
(Material to be heated).

 Indirect arc heating- Radiation contributes for the heating of material.

 Electrodes used are, Carbo / graphite / self-braking electrodes.

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Arc Heating

Direct Arc Heating

 Since the arc is formed between electrodes and the

charge, heat is produced by flow of current through the
charge which offers very low resistance.

 Three phase supply is generally employed for large

capacity furnaces. These three phase supply is connected
to these electrodes spaced at the corners of an equilateral
triangle; the material forms the star point.

 The arc is controlled by either applying variable voltage or

by adjusting the arc length and the arc resistance.
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Arc Heating

Direct Arc Heating

 The most important feature of the direct arc furnace is

that the stirring action is inherent due to the
electromagnetic force setup by the current. This results in
uniform heating of material.

 The most common application is to produce steel.

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Arc Heating

Indirect Arc Heating

 The arc is struck by short circuiting the electrodes

manually or automatically for a moment and then,
withdrawing them apart. The heat from the arc and the hot
refractory lining is transferred to the top layer of the charge
by radiation.

 The heat from the hot top layer of the charge is further
transferred to other parts of the charge by conduction.

 Since no current passes through the body of the charge,

there is no inherent stirring action due to electro-magnetic
forces set up by the current.
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Arc Heating

Indirect Arc Heating

 Hence, such furnaces have to be rocked (moved)

continuously in order to distribute heat uniformly by
exposing different layers of the charge to the heat of the
arc.

 An electric motor is used to operate suitable grinders and

rollers to impart rocking motion to the furnace.

 Rocking action (Movement) provides not only thorough

mixing of the charge.
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Arc Heating

Indirect Arc Heating

 Since in this furnace, charge is heated by radiation only, its

temperature is lower than that obtainable in a direct arc
furnace.

 Such furnaces are mainly used for melting nonferrous

metals although they can be used in iron foundries where
small quantities of iron are required frequently.
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Power Supply and control of Arc Furnace

 Power consumption of the Arc furnace is very high (about 200 kW/tonne for
large furnace, say for 50-100 tonnes capacity)

 Arc Voltage lies between 50 – 150 V, therefore current required is in the

order of several hundred ampere.

Reasons for low voltage & High Current power supply

 As heating is proportional to square of the current, to achieve higher

temperature heavy currents are essential
 From view point of insulation & safety consideration maximum secondary
voltage is limited to 275 V (L-L Open Circuit voltage)
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Reasons for low voltage & High Current power supply

 Owing to use of low voltage the electrodes are kept very near to the charge
as the arc length is very small. Arc remains away from roof, life of the roof
refractory is increased
 The use of higher voltage causes higher voltage gradient between the
electrodes causing the nitrogen atmosphere in the furnace ionized and
absorbed by the charge, which produces embrittlement.
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 A typical specification for a 3 – phase furnace transformer includes an
extended primary winding with taps there in for the secondary range 235-
220-205-190-175-160 V, with primary winding connected in delta. This
voltage range is extended from delta to star giving 58% voltage from each
tap.
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 In order to have complete furnace temperature control, both voltage &
electrode controls are employed. Rising or lowering the electrodes results
in variation of R, changing tapping results in voltage variation.
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However it is not economical

to operate arc furnace with

primary side power factor
below 0.8 lagging
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PROBLEM
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Induction Heating

 Induction heating is based on the principle of

electromagnetic induction.

 The current flows on the outer surface of metallic

disc.

 The current flow is restricted axially to that

surface of the metal with the turns of the heating
coil.

 The heat energy is transferred to the metal at an

extremely rapid rate, much faster that any
conventional method of heating metal.
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Induction Heating

 The heat is generated within the metal without any

physical contact between the source of electrical
energy.

 If the current continues to flow in the disc, the

surface would attain extremely higher temperature.

 The heat in the disc can be controlled by,

High coil current Closing spacing between the coil and work
Larger number of coil turns Magnetic material disc-High permeabillity
High frequency supply Higher electrical resistivity of the disc
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Induction Heating

Core type induction heating

 The furnace consists of hearth (Base of furnace)

in the form of a trough which contains the
material to be melted in the form an annular
ring.

 This metal ring quite large in diameter is

magnetically inter-linked with an electrical
winding which is energized from an AC source.

 The furnace is therefore a transformer in which

the material to be heated forms a single turn
short circuited secondary and is magnetically
coupled to the primary by an iron core.
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Induction Heating

Core type induction heating

 The magnetic coupling between primary and

secondary is poor. This results in high leakage
current and low PF.

 The melting rapid and clean.

 The inherent stirring action of the melt insures a

uniform temperature in the furnance.
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Core type induction heating

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Vertical Core type induction heating

 Molten metal is kept circulated round the vee by

convection current.

 Even small quantity charge keep the secondary

circuit closed since it very narrow vee channel.

 Addition to vee channel –U and rectangular used.

 Type of lining depends on the type of charge

Ex. Yellow brass clay- Red brass
Electric Heating Cont.,
 By means of Hydraulic , Tilting and pouring out the metal.
 It is suitable for continuous operation
 Efficiency is about 75% and size varies from 60-300kW
 widely used for brass and non- ferrous metals.
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Induction Heating

Core-less type high frequency induction heating

 The furnace consists of a ceramic crucible

(vessel in which metals or other substances are
heated) cylindrical in shape enclosed within a
coil which forms the primary of transformer and
the charge in the crucible, the secondary of
transformer.

 The flux produced by the primary winding sets

up eddy-current in the charge which flow
concentrically with those in the primary winding.

 These current heat up the charge to the melting

point and provide stirring action to the charge.
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Induction Heating

Core-less type induction heating

 The crucible and coil are relatively light in

construction and could be conveniently tilted for
pouring.

 These furnaces are used for steel production.

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Dielectric heating Material to
be heated.
 It is also called high-frequency capacitive heating
and is used for heating insulators like wood, plastics Conducting
and ceramics etc. which cannot be heated easily and Plates
uniformly by other methods.

 This method of heating is based on dielectric loss

and this dielectric loss can be derived as,

V-applied voltage magnitude εr-Relative permittivity of the medium

F-Frequency of applied voltage A-Area of the plate
D-distance between plates d-Thickness of the material to be heated
Δ-Loss angle
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Dielectric heating

 The supply frequency required for dielectric heating is between 10-50 MHz.

 The applied voltage is upto 20 kV.

 The overall efficiency of dielectric heating is about 50%.

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Dielectric heating

Applications

 For gluing of multilayer plywood boards.

 For baking of sand cores which are used in the moulding process.

 For preheating of plastic compounds before sending them to the moulding section.

 For drying of tobacco after glycerine has been mixed with it.

 For baking of biscuits and cakes etc. in bakeries with the help of automatic
machines.

 For electronic sewing of plastic garments like raincoats etc. with the help of cold
rollers fed with highfrequency supply.
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Dielectric heating

Applications

 For dehydration of food which is then sealed in air-tight containers.

 For removal of moistures from oil emulsions.

 In diathermy for relieving pain in different parts of the human body.

 For quick drying of glue used for book binding purposes.

HW: Infrared heating

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Electric welding

 It is defined as the process of joining two metal pieces, in which the electrical
energy is used to generate heat at the point of welding in order to melt the joint.

 Resistance Welding  Arc Welding

Spot Welding Carbon Arc Welding

Seam Welding Shielded Metal Arc Welding

Projection Welding Gas Metal Arc Welding

Butt Welding Submerged Arc Welding

Flash Butt Welding and Percussion Welding

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Electric welding

Resistance Welding

The term ‘resistance welding’ denotes a process in which welding heat is produced
by the resistance offered to the passage of electric current through the two metal
pieces being welded.

Spot Welding
 It consists of two electrodes which are mounted on
two arms.

 The lower arm is fixed whereas the upper one is

movable.
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Electric welding

Spot Welding

 The electrodes are made of low resistance, hard-

copper alloy and are either air cooled or water
cooled.

 Mechanical pressure is applied by the tips of the two

electrodes.

 These electrodes are used not only for providing the

pressure but also to carry the welding current and
concentrate the welding heat on the weld spot
directly below them.
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Electric welding

Spot Welding

 As the movable electrode comes down and presses

the two work pieces together, current is passed
through the assembly.

 The metals under the pressure zone get heated upto

about 950°C and fuse together.

 As they fuse, their resistance is reduced to zero,

hence there is a surge of current. This surge is made
to switch off the welding current automatically.

 Spot welding is used for galvanized, tinned and lead

coated sheets and mild steel sheet work.
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Electric welding

Seam Welding

 Seam welding is the series of continuous

spot welding.

 If number of spots obtained by spot

welding are placed very closely that they
can overlap, it gives rise to seam welding.

 It consists of two wheel type or roller

electrodes.

 These electrodes are placed over metal

pieces to be joined.
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Electric welding

Seam Welding

 When these electrodes travel over the metal pieces

which are under pressure, the current passing
through them heats the two metal pieces to the
plastic state and results into continuous spot welds.

 It is usually employed in welding of pressure tanks,

transformers, condensers, evaporators, air craft
tanks, refrigerators, varnish containers and so on.

 The materials which can be welded by this method

are High-carbon steel, stainless steel, Coated steel,
alloys of aluminium, nickel and magnesium.
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Electric welding

Projection Welding

 It consists of two electrodes and are flat metal plates

known as platens.

 The two pieces of metal to be welded are held

together in between the two platens, one is movable
and the other is fixed.

 One of the two metal pieces is run through a machine

that makes the bumps or projections of required
shape and size.
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Electric welding

Projection Welding

 When the current is passed and the electrode

pressure is applied, the projection collapses and the
sheets are welded together.

 Projection welding is used for steel radiator, coupling

elements, brake shoes and so on.

 The materials which can be welded by this method

are low carbon steel, brass, aluminium and copper.
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Electric welding

Butt Welding

 In this case, the two workpieces are brought into

contact end-to-end.

 Then, they are placed in the jaws of the machine

which presses them close together.

 When a suitable pressure is reached, the heavy

current is switched on and the current flowing
through the contact resistance between the ends
brings them to welding heat.

 Butt welding is used for welding of rods, pipes, wires

and so on.
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Electric welding

Butt Welding

 The materials which can be welded by this method

are aluminium alloys, brass, copper nickel alloys,
stainless steel, high-carbon and low-carbon steel and
gold.
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Electric welding

Flash Butt Welding

 In this method of welding, the two pieces to be

welded are brought very nearer to each other under
light mechanical pressure.

 These two pieces are placed in a conducting

movable clamps.

 When high current is passed through the two metal

pieces and they are separated by some distance,
then arc established between them.

 This arc or flashing is allowed till the ends of the

workpieces reach melting temperature.
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Electric welding

Flash Butt Welding

 Then, the supply will be switched off and the pieces

are rapidly brought together under light pressure.

 As the pieces are moved together, the fused metal

and slag come out of the joint making a good solid
joint.

 Flash welding can be used for welding many ferrous

and non-ferrous alloys except for cast iron, lead,
zinc, antimony alloys and bismuth.
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Electric welding

Percussion Welding

 It consists of one fixed holder and the other one is

movable.

 The pieces to be welded are held apart, with the help

of two holders.

 When the movable clamp is released, it moves rapidly

carrying the piece to be welded.

 There is a sudden discharge of electrical energy

which establishes an arc between two surfaces and
heating them to their melting temperature.
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Electric welding

Percussion Welding

 As the pieces come in contact with each other

under heavy pressure, the arc is extinguished
due to the percussion blow of the two parts
and the force between them affects the weld.

 The materials which can be welded by this

method are aluminum alloys, copper alloys,
stainless steel and high-carbon and low-carbon
steel.
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Electric Arc Welding

 Electric Arc Welding is the process of joining two

metallic pieces or melting of metal.

 The heat is developed by an arc struck between an

electrode and the metal to be welded or between the
two electrodes.

Carbon Arc Welding

 In this method, the arc is struck between the carbon

electrode and the metal or between two carbon
electrodes.

 In the carbon arc welding, carbon or graphite rods

are used as electrode.
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Electric Arc Welding

Carbon Arc Welding

 The arc produced between electrode and base metal

which heat the metal to the melting temperature.

 The filler metal is required for this welding method.

 If the operation required is fast and / or large amount

of filler material is to be deposited, electrode of 2.5
cm diameter with currents of the order of 500 A to
800 A are employed.

 This method of welding is suitable for non ferrous

metal.
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Electric Arc Welding

Shielded Metal Arc Welding

 This method uses flux coated electrodes.

 They consist of a metal core wire surrounded

by a thick flux coating applied by extrusion,
winding or other processes.

 The heat of the arc is used to bring the work

piece and the electrode to molten state.

HW: Gas Metal Arc Welding and Submerged Arc Welding

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