|
|
|
|
|
|
|
 |
|
|||||
 |
 |
 |
|
|||
|
||||||
 |
 |
|
||||
 |
 |
|
||||
|
||||||
 |
 |
|
||||
|
||||||
 |
|
|||||
>> Custom Designs
TruHeat not only has the ability to mass produce heating elements through means of computer controlled technology and/or efficient cellular groups, but they also have the capability to custom design/engineer as little as one element to precision standards. They are proud to proclaim, Made in USA.
Steadfast engineering is TruHeat’s foundation, and manufacturing integration allows an unsurpassed knowledge base in the heating element industry.
There are three basic considerations in the designing of custom heating elements; desired final temperature, required sheath material, and allowable watt density.
Desired final temperature:
Tubular heating elements typically operate from ambient to 1500 degrees Fahrenheit. Principal aspects to consider are starting temperature, maximum temperature, and element temperature when media is at maximum temperature (See Graph TH4).
Required sheath material:
While Copper is a common sheath material for process water, cold rolled steel for oils, and higher grade stainless steel alloys for higher temperature air elements & corrosive immersion applications (see Table TH1), final sheath selection should include precise exposure conditions (i.e. media flow rates) , corrosion specifications, and TruHeat testing and evaluation.Allowable Watt Density:
Watt density (measure in watts per square inch) is simply the power emanating from each square inch of the heating element. See Table TH1 for recommended watt densities on various materials. As watt density is directly tied to heater life numerous factors are to be considered for optimal engineering.
- Operating temperature
- Insulation material and/or temperature limits
- Quality of either convection/conduction path (i.e. clamping, cast-in, immersion)
- Immersion
- Boiling point
- Viscosity
- Sheath corrosion rate
- Temperature of material composition
| Table TH1: Recommended Watt Densities on Various Materials. |
* Maximum |
|||
Heated |
Operating |
**Maximum |
Sheath |
Material |
Temperature |
Watt
Density |
Material |
| Acetic Acid | 180 | 40 | SS316 |
| Boric Acid | 257 | 40 | TITAN. |
| Carbonic Acid | 180 | 40 | I600 |
| Chromic Acid | 180 | 40 | TITAN. |
| Citric Acid | 180 | 23 | I800 |
| Fatty Acid | 150 | 20 | SS316 |
| Lactic Acid | 122 | 10 | SS316 |
| Levulinic Acid | 180 | 40 | I600 |
| Malic Acid | 122 | 10 | SS316 |
| Nitric Acid | 167 | 20 | SS316 |
| Phosphoric Acid | 180 | 23 | I800 |
| Proponic Acid | 180 | 40 | COPPER |
| Tannic Acid | 180 | 40 | SS304 |
| Tartaric Acid | 180 | 40 | SS316 |
| Acetaldehyde | 180 | 10 | COPPER |
| Acetone | 130 | 10 | SS304 |
| Air | *** | *** | I800 |
| Alkyl Alcohol | 200 | 10 | COPPER |
| Alkaline Solution | 212 | 40 | CRS |
| Aluminum Acetate | 122 | 10 | SS316 |
| Aluminum Potassium Sulfate | 212 | 40 | COPPER |
| Ammonia Gas | *** | *** | CRS |
| Ammonium Acetate | 167 | 23 | I800 |
| Amyl Acetate | 240 | 23 | I800 |
| Amyl Alcohol | 212 | 20 | SS304 |
| Aniline | 350 | 23 | SS304 |
| Asphalt | 200-500 | 4-10 | CRS |
| Barium Hydroxide | 212 | 10 | SS316 |
| Benzene (liquid) | 150 | 10 | COPPER |
| Butyl Acetate | 225 | 10 | SS316 |
| Calcium Bisulfate | 400 | 20 | SS316 |
| Calcium Chloride | 200 | 5-8 | I600 |
| Carbon Monoxide | *** | 23 | I800 |
| Carbon Tetrachloride | 160 | 23 | I800 |
| Caustic Soda 2% | 210 | 48 | I800 |
| Caustic Soda 10% | 210 | 25 | I800 |
| Caustic Soda 75% | 180 | 25 | I800 |
| Citrus Juice | 185 | 23 | I800 |
| Degreasing Solutions | 275 | 23 | CRS |
| Dextrose | 212 | 20 | SS304 |
| Electroplating Cadmium Bath | 180 | 40 | SS304 |
| Electroplating Copper Bath | 180 | 40 | SS316 |
| Electroplating Dilute Cyanide Bath | 180 | 40 | SS316 |
| Electroplating Rochelle Cyanide Bath | 180 | 40 | SS316 |
| Electroplating Sodium Cyanide Bath | 180 | 40 | SS316 |
| Electroplating Potassium Cyanide Bath | 180 | 40 | SS316 |
| Ethylene Glycol | 300 | 30 | CRS |
| Formaldehyde | 180 | 10 | SS304 |
| Freon (gas) | 300 | 2-5 | CRS |
| Fuel Oil (Grades 1&2,distilate) | 200 | 23 | CRS |
| Fuel Oil (Grades 3&4,residual) | 200 | 13 | CRS |
| Fuel Oil (Grade 6 & bunker C, residual) | 160 | 8 | CRS |
| Gasoline | 300 | 23 | CRS |
| Gelatin (liquid) | 150 | 23 | SS304 |
| Gelatin (solid) | 150 | 5 | SS304 |
| Glycerin | 500 | 10 | I800 |
| Glycerol | 212 | 23 | I800 |
| Grease (liquid) | *** | 23 | CRS |
| Grease (solid) | *** | 5 | CRS |
| Heat transfer Oil (static) | 500 | 16 | CRS |
| Heat transfer Oil (circulating) | 500 | 23 | CRS |
| Hydrazine | 212 | 16 | SS304 |
| Hydrogen | *** | *** | I800 |
| Hydrogen Chloride | *** | *** | I600 |
| Hydrogen Sulfide | *** | *** | SS316 |
| Linseed oil | 150 | 50 | CRS |
| SAE 10, 90-100-SSU @ 130' F | 250 | 23 | CRS |
| SAE 20 120-185-SSU @ 130' F | 250 | 23 | CRS |
| SAE 30, 120-185-SSU @ 130' F | 250 | 23 | CRS |
| SAE 40, 80-SSU @ 210' F | 250 | 13 | CRS |
| SAE 50, 80-105-SSU @ 210' F | 250 | 13 | CRS |
| Magnesium Chloride | 212 | 40 | I600 |
| Magnesium Sulfate | 212 | 40 | SS304 |
| Manganese Sulfate | 212 | 40 | SS316 |
| Methanol Gas | *** | *** | SS304 |
| Methylamine | 180 | 20 | I600 |
| Methyl chloride | 180 | 20 | COPPER |
| Mineral Oil | 200 | 23 | CRS |
| Molasses | 100 | 4-5 | SS304 |
| Molten Salt Bath | 800-900 | 25-30 | MONEL |
| Naphtha | 212 | 10 | CRS |
| Oil Drawn bath | 600 | 23 | CRS |
| Paraffin (Wax) | 150 | 16 | CRS |
| Perchloroethylene | 200 | 23 | CRS |
| Potassium Chlorate | 212 | 40 | SS316 |
| Potassium Chloride | 212 | 40 | SS316 |
| Potassium Hydroxide | 160 | 23 | MONEL |
| Soap (liquid) | 212 | 20 | SS304 |
| Sodium Acetate | 212 | 40 | CRS |
| Sodium Cyanide | 140 | 40 | I800 |
| Sodium Hydride | 720 | 28 | I800 |
| Sodium Phosphate | 212 | 40 | COPPER |
| Steam | 700 | 5 | I800 |
| Sulphur (Molten) | 600 | 10 | I800 |
| Therminols | 500 | 23 | CRS |
| Toluene | 212 | 23 | CRS |
| Trichloroethylene | 150 | 23 | CRS |
| Turpentine | 300 | 20 | SS304 |
| Vegetable Oil | 400 | 30 | SS304 |
| Water (process) | 212 | 60 | I800 |
| Table TH2: Kilowatts to Heat (Water) in one hour. |
|
Amount of Water by Gallons |
Temperature Rise (F) |
| 20 | 40 | 60 | 80 | 100 | 120 | 140 | |
| 5 | 0.3 | 0.5 | 0.8 | 1.1 | 1.3 | 1.6 | 1.9 |
| 10 | 0.5 | 1.1 | 1.6 | 2.2 | 2.7 | 3.2 | 3.8 |
| 15 | 0.8 | 1.6 | 2.4 | 3.2 | 4.0 | 4.8 | 5.6 |
| 20 | 1.1 | 2.2 | 3.2 | 4.3 | 5.4 | 6.5 | 7.5 |
| 25 | 1.3 | 2.7 | 4.0 | 5.4 | 6.7 | 8.1 | 9.4 |
| 30 | 1.6 | 3.2 | 4.8 | 6.5 | 8.1 | 9.7 | 11.3 |
| 40 | 2.2 | 4.3 | 6.5 | 8.6 | 10.8 | 12.9 | 15.1 |
| 50 | 2.7 | 5.4 | 8.1 | 1.8 | 13.5 | 16.1 | 18.8 |
| 60 | 3.2 | 6.5 | 9.7 | 12.9 | 16.1 | 19.4 | 22.6 |
| 70 | 3.8 | 7.5 | 11.3 | 15.1 | 18.8 | 22.6 | 26.4 |
| 80 | 4.3 | 8.6 | 12.9 | 17.2 | 21.5 | 25.8 | 30.1 |
| 90 | 4.8 | 9.7 | 14.5 | 19.4 | 24.2 | 2.1 | 33.9 |
| 100 | 5.4 | 10.8 | 16.1 | 21.5 | 26.9 | 32.3 | 37.7 |
| 125 | 6.7 | 13.5 | 20.2 | 26.9 | 33.6 | 40.4 | 47.1 |
| 150 | 8.1 | 16.1 | 24.2 | 32.3 | 40.4 | 48.4 | 56.5 |
| 175 | 9.4 | 18.8 | 28.2 | 37.7 | 47.1 | 56.5 | 65.9 |
| 200 | 10.8 | 21.5 | 32.3 | 43.0 | 53.8 | 64.6 | 75.3 |
| 250 | 13.5 | 26.9 | 40.4 | 53.8 | 67.3 | 80.7 | 94.2 |
| 300 | 16.1 | 32.3 | 48.4 | 64.6 | 80.7 | 96.9 | 113.0 |
| 400 | 21.5 | 43.0 | 64.6 | 86.1 | 107.6 | 129.1 | 150.7 |
| 500 | 26.9 | 53.8 | 80.7 | 107.6 | 134.5 | 161.4 | 188.3 |
Use equation 1 for heating flowing water.
Use equation 2 or table for heating water in tanks.
Equation 1: KW= GPM x Temperature rise (F) x .16
Equation 2: KW= Gallons x Temperature rise (F)
...........372 x Heat up time (hrs)
| Table
TH3: Kilowatts to Heat (Air) in
one hour. |
Temperature
Rise (F) |
Amount
of Air CFM |
50 | 100 | 150 | 200 | 250 | 300 | 350 | 400 | 450 | 500 | 600 |
| 100 | 1.7 | 3.3 | 5.0 | 6.7 | 8.3 | 10.0 | 11.7 | 13.3 | 15.0 | 16.7 | 20.0 |
| 200 | 3.3 | 6.7 | 10.0 | 1.3 | 16.7 | 20.0 | 23.3 | 26.7 | 30.0 | 33.3 | 40.0 |
| 300 | 5.0 | 10.0 | 15.0 | 20.0 | 25.0 | 30.0 | 35.0 | 40.0 | 45.0 | 50.0 | 60.0 |
| 400 | 6.0 | 13.3 | 20.0 | 26.7 | 33.3 | 40.0 | 46.7 | 53.3 | 60.0 | 66.7 | 80.0 |
| 500 | 8.3 | 16.7 | 25.0 | 33.3 | 41.7 | 50.0 | 58.3 | 66.7 | 75.0 | 83.3 | 100.0 |
| 600 | 10.0 | 20.0 | 30.0 | 40.0 | 50.0 | 60.0 | 70.0 | 80.0 | 90.0 | 100.0 | 120.0 |
| 700 | 11.7 | 23.3 | 35.0 | 46.7 | 58.3 | 70.0 | 81.7 | 93.3 | 105.0 | 116.7 | 140.0 |
| 800 | 13.3 | 26.7 | 40.0 | 53.3 | 66.7 | 80.0 | 93.3 | 106.7 | 120.0 | 1333.3 | 160.0 |
| 900 | 15.0 | 30.0 | 45.0 | 60.0 | 75.0 | 90.0 | 105.0 | 120.0 | 135.0 | 150.0 | 180.0 |
| 1000 | 16.7 | 33.3 | 50.0 | 66.7 | 83.3 | 100.0 | 116.7 | 133.3 | 150.0 | 16.7 | 20.0 |
| 1100 | 18.3 | 36.7 | 55.0 | 73.3 | 91.7 | 110.0 | 128.3 | 146.7 | 165.0 | 183.3 | 220.0 |
| 1200 | 20.0 | 40.0 | 60.0 | 80.0 | 100.0 | 120.0 | 140.0 | 160.0 | 180.0 | 200.0 | 240.0 |
For Free Air: Use equation or table
Free Air: KW= CFM x Temperature rise
3000
Compressed Air: KW= CFM* x Density* (lbs. /cu.ft.) x Temperature rise
228
| Table TH4: Kilowatts to Heat (Oil) in one hour. |
|
|
Amount of Oil by Gallons |
Temperature
Rise (F) |
| 50 | 100 | 200 | 300 | 400 | 500 | ||
| 5 | 0.3 | 0.7 | 1.4 | 2.1 | 2.8 | 3.5 | |
| 10 | 0.7 | 1.4 | 2.8 | 4.2 | 5.5/8 | 7.0 | |
| 15 | 1.0 | 2.1 | 4.2 | 6.3 | 8.4 | 10.5 | |
| 20 | 1.4 | 2.8 | 5.6 | 8.4 | 11.2 | 14.0 | |
| 25 | 1.7 | 3.5 | 7.0 | 10.5 | 14.0 | 17.4 | |
| 30 | 2.1 | 4.2 | 8.4 | 12.6 | 16.7 | 20.9 | |
| 40 | 2.8 | 5.6 | 11.0 | 16.7 | 22.3 | 27.9 | |
| 50 | 3.5 | 7.0 | 14.0 | 20.9 | 27.9 | 34.9 | |
| 60 | 4.2 | 8.4 | 17.0 | 25.1 | 33.5 | 41.9 | |
| 70 | 4.9 | 9.8 | 20.0 | 29.3 | 39.1 | 48.8 | |
| 80 | 5.6 | 11.0 | 22.0 | 33.5 | 44.7 | 55.8 | |
| 90 | 6.3 | 13.0 | 25.0 | 37.7 | 50.2 | 62.8 | |
| 100 | 7.0 | 14.0 | 28.0 | 41.9 | 55.8 | 69.8 | |
| 125 | 8.7 | 17.0 | 35.0 | 52.3 | 69.8 | 87.2 | |
| 150 | 10.0 | 21.0 | 42.0 | 62.8 | 83.7 | 105.0 | |
| 175 | 12.0 | 24.0 | 49.0 | 73.3 | 97.7 | 122.0 | |
| 200 | 14.0 | 28.0 | 56.0 | 83.7 | 112.0 | 140.0 | |
| 250 | 17.0 | 35.0 | 70.0 | 105.0 | 140.0 | 174.0 | |
| 300 | 21.0 | 42.0 | 84.0 | 126.0 | 167.0 | 209.0 | |
| 400 | 28.0 | 56.0 | 112.0 | 167.0 | 223.0 | 279.0 | |
| 500 | 35.0 | 70.0 | 140.0 | 209.0 | 279.0 | 349.0 |
Use equation or table
Still Oil: KW= Gallons x Temperature rise (F)
860 x heat-up time (hrs.)
| Table TH5: Amperage Conversion Table. |
|
| Watts | Volts Single Phase |
Volts 3 Phase Balanced Load |
||||
Watts |
120 | 240 | 480 | 240 | 480 | Watts |
| 100 | 0.83 | 0.42 | 0.21 | 0.24 | 0.13 | 100 |
| 150 | 1.25 | 0.63 | 0.31 | 0.36 | 0.18 | 150 |
| 200 | 1.67 | 0.83 | 0.42 | 0.49 | 0.25 | 200 |
| 300 | 2.5 | 1.25 | 0.63 | 0.73 | 0.37 | 300 |
| 350 | 2.92 | 1.46 | 0.73 | 0.85 | 0.43 | 350 |
| 400 | 3.33 | 1.67 | 0.84 | 0.97 | 0.49 | 400 |
| 450 | 3.75 | 1.88 | 0.93 | 1.1 | 0.55 | 450 |
| 500 | 4.17 | 2.08 | 1.04 | 1.2 | 0.6 | 500 |
| 600 | 5 | 2.5 | 1.25 | 1.45 | 0.73 | 600 |
| 700 | 5.83 | 2.92 | 1.46 | 1.7 | 0.85 | 700 |
| 750 | 6325 | 3.13 | 1.56 | 1.81 | 0.91 | 750 |
| 800 | 6.67 | 3.33 | 1.67 | 1.93 | 0.97 | 800 |
| 900 | 7.5 | 3.75 | 1.87 | 2.17 | 1.09 | 900 |
| 1000 | 8.33 | 4.17 | 2.1 | 2.41 | 1.21 | 1000 |
| 1100 | 9.17 | 4.58 | 2.3 | 2.65 | 1.33 | 1100 |
| 1200 | 10 | 5 | 2.51 | 2.9 | 1.45 | 1200 |
| 1250 | 10.4 | 5.21 | 2.61 | 3.1 | 1.55 | 1250 |
| 1300 | 10.8 | 5.42 | 2.71 | 3.13 | 1.57 | 1300 |
| 1400 | 11.7 | 5.83 | 2.91 | 3.38 | 1.69 | 1400 |
| 1500 | 12.5 | 6.25 | 3.12 | 3.62 | 1.82 | 1500 |
| 1600 | 13.3 | 6.67 | 3.34 | 3.86 | 1.93 | 1600 |
| 1700 | 14.2 | 7.08 | 3.54 | 4.1 | 2.05 | 1700 |
| 1750 | 14.6 | 7.29 | 3.65 | 4.22 | 2.1 | 1750 |
| 1800 | 1530 | 7.5 | 3.75 | 4.34 | 2.17 | 180 |
| 1900 | 15.8 | 7.92 | 3.96 | 4.58 | 2.29 | 1900 |
| 2000 | 16.7 | 8.33 | 4.17 | 4.82 | 2.41 | 2000 |
| 2200 | 18.3 | 9.17 | 4.59 | 5.3 | 2.65 | 2200 |
| 2500 | 20.8 | 10.4 | 5.21 | 6.1 | 3.05 | 2500 |
| 2750 | 23 | 11.5 | 5.73 | 6.63 | 3.32 | 2750 |
| 3000 | 25 | 12.5 | 6.25 | 7.23 | 3.62 | 3000 |
| 3500 | 29.2 | 14.6 | 7.3 | 8.45 | 4.23 | 3500 |
| 4000 | 33.3 | 16.7 | 8.33 | 9.64 | 4.82 | 4000 |
| 4500 | 37.5 | 18.8 | 9.38 | 10.84 | 5.42 | 4500 |
| 5000 | 41.7 | 20.8 | 10.42 | 12.1 | 6.1 | 5000 |
| 6000 | 50 | 25 | 12.5 | 14.5 | 7.25 | 6000 |
| 7000 | 58.3 | 29.2 | 14.59 | 16.9 | 8.5 | 7000 |
| 8000 | 66.7 | 33.3 | 16.67 | 19.3 | 9.65 | 8000 |
| 9000 | 75 | 37.5 | 18.75 | 21.7 | 10.85 | 9000 |
| 10000 | 83.3 | 41.7 | 20.85 | 24.1 | 12.1 | 10000 |
