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CLASSIFICATION OF HEATING METHODS

Classification of heating methods

Power Frequency Heating

High Frequency Heating

Resistance Heating

Arc Heating

Induction Heating

Dielectric Heating

Direct

Direct

Indirect

Indirect

RESISTANCE HEATING
Electric furnace is a device which converts electric energy into heat energy for industrial applications. Various types of heating methods are employed here, which we discussed earlier. One such method is POWER FREQUENCY HEATING. Power frequency method is, in turn, divided into 3 methods: 1) resistance heating 2) arc heating 3) electron bombardment heating

RESISTANCE HEATING
Working principle When electric current passes through the resistance, I2R loss takes places in the resistance. According to Joules law (H=I2Rt Joules) it appears in the form of heat. In case of resistance heating, low voltage and low frequency A.C supply is used to produce heat. In some applications heat is also obtained by D.C supply.

TYPES OF RESISTANCE HEATING

1. 2.

Direct resistance heating Indirect resistance heating

DIRECT RESISTANCE HEATING


H = I2RT joules R = Resistance of charge I = Current through charge A t = Time T = Temperature of furnace = 1000C to 1500C V = Supply voltage required = 2 to 15 V ( AC or DC ) I = Current up to 3000 A

CONSTRUCTION
The furnace is constructed by using heat insulating material such as firebrick and is supported on metal framework. The electrodes are inserted from top or from both sides of the furnace according to the requirement. Between these two electrodes the charge (material to be heated ) is placed . This charge maybe in form of powder, pieces or liquid.

DIRECT RESISTANCE FURNACE

OPERATION
In direct resistance heating, charge acts as a conductor between two electrodes hence electric current passes through it. Heat is generated in the charge according to joules law, i.e. H = I2RT joules R = Resistance of charge I = Current through charge A t = Time This method is most efficient method as the heat is generated in charge itself thus uniform heating of the charge is obtained.

Heating in this furnaces eliminates oxidation and gives rapid


and uniform heating. As the temperature of bath increases , its resistance goes down. Therefore these furnaces are started with highest tap, as heat proceeds, this is brought to lower taps to limit the current. When highly conductive materials are to be heated, it acts as direct circuit. To avoid this, highly resistive powder is sprinkled between the surfaces of pieces. The temperature of furnace is maintained between 1000C to 1500C. The supply voltage required is between 2 to 20V and current up to 3000A.

APPLICATIONS
This method employed in salt bath furnaces and in electrode boiler for heating water. Generally these types of furnaces are used for the purposes of carbonizing, tempering, quenching and hardening of steel tools.

INDIRECT RESISTANCE HEATING


In this type of heating, electric current is passed through resistive element. When electric current is passed through resistance it produces IR loss, further according to joules law heat is produced H = IRTJoules Where R = Resistance of heating element. I = Current through heating element.A t = Time Heat generated in the heating element is then transferred to the charge mainly by radiation and convection. e.g. room heater, hair dryer, electric kettle, water heater etc.

INDIRECT RESISTANCE HEATING

APPLICATIONS
The low temperature furnaces (300C to 1050C) are used for drying varnishes, vulcanising and hardening of synthetic material. High temperature of 1050C to 1350C are used for hardening purpose.

ELECTRIC ARC HEATING


When the sufficient high voltage is applied between two electrodes containing air as a media between them, then air gets ionised and current flows through the air is known as arc. The heat generated thus can be utilized to melt the material. A very high voltage is required to generate the arc but small voltage is sufficient to maintain the arc. In arc furnace arc is produced by short circuiting the two electrodes momentarily and withdrawing them back. Thus high voltage is not required at start. Temperature obtained by these furnaces arc 1,000C and 3500C depending upon the electrodes used.

TYPES OF ARC FURNACE


According to method of producing the arc, furnaces are classified as: 1. Direct arc furnace 2. Indirect arc furnace 3. Submerged arc furnace

DIRECT ARC FURNACE


In direct arc furnace arc is struck between the electrodes and charge In this type of furnace heat is produced by two means. 1. Due to the arc which is struck between electrode and arc is in direct contact with charge 2. Since the circuit getting completed through charge; therefore current flows through the charge. this current produces heat as IRT Joules where, I= Current flowing through charge in AMP R= Resistance of charge in s T= Time in sec Due to these two reasons charge can be heated to highest temperature.

DIRECT ARC FURNACE

In case single phase arc furnaces two electrodes are taken vertically downward as shown in fig. Through the roof of furnace to the surface of charge. In case of three phase arc furnace three electrodes are separated at the corners of an equilateral triangle, thus three arcs are formed. Stirring action are automatic as current passing through charge produces electromagnetic field. The size of furnace is about 5 to 10 tonnes. For one tonne furnace power required is 200 kW. Power factor of these furnaces are about 0.8 lagging.

These furnaces are commonly used for production steel.

INDIRECT ARC FURNACE


The furnace is made of cylindrical shape and electrodes projecting through the chamber from each end as shown in fig. In these furnace arc is struck between the two electrode above the charge and heat generated is transferred to the charge by radiation. Temperature obtained by these furnaces is lower than that of direct arc furnace.

INDIRECT ARC FURNACE

Since the current does not flow through the charge there is no stirring action.
These furnaces are used for melting of non powers metals. These furnace are available in 0.25 tonnes to 3 tonnes.

Power factor of these furnace is about 0.85 lagging.


Power consumption of these furnaces is about 400 kWh per tonne.

SUBMERGED ARC FURNACE


These are cylindrical furnaces in which arc is formed between the carbon electrodes and hearth electrodes. The hearth lining is of magnesite which becomes comparatively good electrical conductor when hot. The stirring action is inherent due to electromagnetic force set up by the current resulting in uniform heating of charge. These furnaces are used for the manufacture of Ferro-alloys like Ferro-chrome and Ferro-manganese. Power factor of these furnace is about 0.8 lagging.

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