Heater Element

A heater element is a component used to generate heat in many electric devices, primarily for heating purposes. These elements are typically made of metal alloys and produce heat through the flow of electric current. When electric current passes through the heater element, heat is generated due to resistance. This heat can be focused on a specific area of the device to achieve the desired temperature. For instance, heater elements are utilized in electric heaters, stoves, water heaters, and ovens. Heater elements are known for their durability and long lifespan. They are designed to be used safely and effectively in heating devices.

Ceramics for Heaters

Resistance ceramics are materials used to provide high resistance at high temperatures. These materials can be used as heating elements in high temperature environments in industrial applications. Resistance ceramics can generally be defined as a type of material in which ceramic materials are used to provide higher resistance at high temperatures. Resistance ceramics include many different materials produced for high temperatures. These materials include various materials such as alumina, liquid nitrate ceramics, magnesium oxide and zirconium oxide.

Resistance ceramics can be used as heating elements in high temperature environments in industrial applications. For example, resistance ceramics can be used as heating elements in the metal casting industry, in the chemical industry for heating chemical reactions, as heating elements in the automotive industry, in the sterilization of surgical instruments, in power generation, and as heating elements in the electronics industry. It can also be used for machine parts operating at high temperatures.

Selection of Resistance Ceramics

Resistance ceramics are materials with high resistance at high temperatures. They are commonly used in electric vehicles, industrial processes and power generation plants. Some points to consider when choosing resistance ceramics are as follows:

1. Temperature Range: Resistance ceramics can work in certain temperature ranges. The ceramic material you choose should be higher than the temperature range required.
2. Mechanical Strength: Resistance ceramics should have high mechanical strength. Because these materials are used in industrial environments and can be exposed to high mechanical stresses.
3. Chemical Resistance: Resistance ceramics can come into contact with chemicals, therefore, their chemical resistance must be high.
4. Thermal Conductivity: Resistance ceramics should have high thermal conductivity. This allows the ceramic material to conduct heat quickly and dissipate heat more effectively.
5. Electrical Resistance: Resistance ceramics must be of high electrical resistance. This ensures low losses and low energy expenditure of the ceramic material while conducting electric current.

What are the Advantages of Resistance Ceramics?

Resistance ceramics have many advantages. These may include:

• High temperature resistance: Resistance ceramics can operate at very high temperatures and therefore have a wide range of uses in industrial environments.
• Mechanical durability: Resistance ceramics have high mechanical strength and can therefore be used in high-stress environments.
• Chemical resistance: Resistance ceramics can come into contact with chemicals and therefore their chemical resistance is high.
• Thermal conductivity: Since resistance ceramics have high thermal conductivity, they can transmit heat quickly and dissipate heat more effectively.
• Electrical resistance: Since resistance ceramics have high electrical resistance, they have low losses and low energy consumption while conducting electric current.
• Durability: Resistance ceramics are very durable and have a long life.
• Environmentally friendly: Resistance ceramics do not contain toxic substances and do not harm the environment.

Types of Resistance Ceramics

Resistance ceramics can be produced in different varieties and this variety depends on factors such as the chemical composition of the material, its structure and production method. For instance;

Alumina (Al2O3) ceramics: They are known for their high thermal resistance, electrical conductivity and mechanical durability.

Zirconia (ZrO2) ceramics: are known for their high thermal resistance, electrical conductivity and mechanical durability.

Silicon Carbide (SiC): ceramics are known for their high thermal resistance, high mechanical strength and electrical conductivity.

Steatite (MgO) ceramics: It is known for its high thermal resistance, mechanical durability and electrical conductivity properties.

Mullite (3Al2O3.2SiO2) ceramics: Known for their high thermal resistance, mechanical durability and electrical conductivity.

Heater Working Principle

The working principle of heaters relies on serving as a resistance element through which electric current passes. Heaters are typically made of long, thin wires or elements composed of metal alloys. When electric current passes through the heater, electrical energy converts to heat due to resistance. The resistance of the heater is determined by the properties and design of its material. The higher the electric current and resistance, the more heat is generated. This heat can be used to achieve the desired temperature inside or around the device. For example, a heater in an oven or water heater can be used to heat the environment it is in. This principle is widely used to produce heat in many devices.

Heater Technical Specifications

• Material: Generally made of ceramic or glass.
• Shape: Can be spherical, cylindrical, or rectangular.
• Size: Diameter varies between 2 mm and 10 mm.
• Power: From 1 W to 100 W.
• Voltage: From 12 V to 480 V.
• Temperature range: From 0°C to 650°C.
• Heating element type: Nickel-chromium wire, iron-chromium-aluminum wire.
• Terminals: Copper, brass.
• Protection class: IP40, IP65.

Some common heater types and their technical specifications:

• Ceramic heaters:
  • Material: Aluminum oxide, silicon carbide, magnesium oxide.
  • Operating Temperature: Up to 650°C.
  • Resistance: Between 1.0 Ωm and 10.0 Ωm.
  • Thermal Conductivity: Between 10 W/mK and 100 W/mK.
  • Density: Between 3.0 g/cm³ and 4.0 g/cm³.
• Glass heaters:
  • Material: Borosilicate glass, quartz glass.
  • Operating Temperature: Up to 450°C.
  • Resistance: Between 10.0 Ωm and 100.0 Ωm.
  • Thermal Conductivity: Between 1.0 W/mK and 10 W/mK.
  • Density: Between 2.5 g/cm³ and 3.0 g/cm³.

Materials Used in Heater Manufacturing

• Nickel-Chromium Alloys: The most commonly used heater material.
• Iron-Chromium-Aluminum Alloys: Resistant to high temperatures and provide electrical resistance.
• Nickel-Aluminum Alloys: Used in specific applications.
• Platinum and Gold: Can be used in precise industrial equipment.

Heaters Stones Industrial Applications

• Food Industry: Heaters stones are used in food processing equipment such as ovens, grills, pizza ovens, and other heating devices.
• Plastic and Rubber Industry: Heaters stones are used for heating plastic and rubber materials in extrusion machines, molding machines, and other process equipment.
• Chemical Industry: Heaters stones are used for heating in chemical reactors, evaporators, and other process equipment for controlling chemical reactions.
• Packaging Industry: Heaters stones are used for heating and cutting in hot cutting machines, thermoforming machines, and other packaging machines.
• Automotive Industry: Heaters stones are used in furnaces and other heating equipment for the heat treatment of automotive parts.
• Textile Industry: Heaters stones are used for heating in drying fabrics, printing machines, and other textile equipment.
• Energy Production: Heaters stones are used in boilers, water heaters, steam generators, and other energy production equipment.
• Medical and Laboratory Technologies: Heaters stones are used for heating in laboratory furnaces, incubators, and other laboratory equipment.

Heaters Stones Advantages

• High Heat Resistance: Heaters stones can generally withstand high temperatures.
• Fast Heating and Cooling: Heaters stones can be heated and cooled quickly.
• Durable: Quality heaters stones can have a long working life.
• High Precision: Heaters stones can control desired temperature values precisely.
• Flexibility for Various Applications: Heaters stones can be used in many different industrial applications.
• Easy Installation and Maintenance: Heaters stones are generally easy to install and maintain.