How to Choose Heating Elements

A heating element is a component that helps to distribute heat within an appliance. They can be found in a variety of appliances including toasters, hair dryers, stoves and water heaters.

When choosing a heating element, consider wattage and size as these will impact how fast it heats up and maintains temperature. Moreover, look for heating elements that are low-watt density so they last longer and reduce the chance of limescale buildup.

1. Wattage

The wattage of a heating element determines how well it will heat the material it's attached to. For example, if a heater is attached to an aluminum plate that weighs five pounds, its wattage should be about 0.21 BTUs per pound of weight at a temperature of five degrees Fahrenheit.

Alternatively, if the material is a plastic, it's recommended to use lower watt densities for safety purposes. This is because a high-density element can reach much higher temperatures, which can cause premature burning or failure of the element.

Watt density is a process-specific variable that can be influenced by a variety of factors, including the materials and conditions involved in the process. It also depends on the type of energy used to heat the elements.

2. Size

The size of a heating element is important because it can affect the amount of heat it produces. Larger elements can produce more heat and, therefore, provide a better overall heating experience.

The size, or diameter, of a heating element can vary based on the manufacturer and model of the appliance. This is why it is important to choose the correct one the first time around.

The most efficient way to determine the correct size is by removing the old one and measuring it for size. A tape measure will work well to get the diameter of the socket and a ruler can be used to determine the length of threading. A better alternative is to place a small object in the socket to see how high it can go. This will help you narrow down the selection to the optimum size and shape for your application. You may need to use a few different sizes and types to get the best fit and function for your appliance.

3. Temperature

The temperature of a heating element varies depending on the current and resistance as well as the properties of the medium that the heating element is trying to heat. The temperature of a heating element reaches a steady state when the rate of heat generation matches the rate of heat loss from the medium.

Temperature can also be affected by materials’ thermal expansion and contraction. When materials become hotter, they expand a bit because the molecules vibrate more intensely and bump into each other. This can cause cracks to form in a material’s structure.

Generally, the higher the temperature of a heating element, the more energy it will produce. However, some exceptions exist. For example, if you add heat to a liquid at the boiling point, it can convert some of that liquid into a gas without changing the temperature. This is because the energy added to the liquid goes into breaking its bonds and converting it into a different state.

4. Safety

Choosing the right heating element for your industrial heater can make all the difference in productivity and safety. It may also save you money in the long run, with energy consumption often decreasing when the right heating element is chosen.

Using the wrong element can lead to costly accidents, like in this case where a maintenance worker was trying to save a few dollars by replacing the heating element in an oil heating system with one from a water heater, a mistake that would have been avoided by carefully selecting the right replacement element for your specific application.

When it comes to the optimum heating element, you must consider the wattage, size and voltage. The most important thing to remember is that you must never exceed the rated electrical current of the heating element you are considering. The best way to do this is to check the manufacturer’s specifications before you purchase your new element.