PROBLEM3.

86
KNOWN: Diameter, resistivity, thermal conductivity, emissivity, voltage, and maximum temperature
of heater wire. Convection coefficient and air exit temperature. Temperature of surroundings.
FIND: Maximum operating current, heater length and power rating.
SCHEMATIC:
T = 50 C
o
oo
h = 250 W/m -K
2
T =
o
T
max
Nichrome wire
D = 1 mm, L
I
= 10 -m
e
-6
O
k = 25 W/m-K
= 0.20 c
T = 1200 C
max
o
Air
V = 110 V
T 1200 C
s
o
T
sur
= 50 C
o
ASSUMPTIONS: (1) Steady-state, (2) Uniform wire temperature, (3) Constant properties, (4)
Radiation exchange with large surroundings.
ANALYSIS: Assuming a uniform wire temperature, T
max
= T(r = 0) T
o
~ T
s
, the maximum
volumetric heat generation may be obtained from Eq. (3.60), but with the total heat transfer
coefficient, h
t
= h + h
r
, used in lieu of the convection coefficient h. With
( )
( )
( )
( )
2
2 2 8 2 4 2 2 2
r s sur s sur
h T T T T 0.20 5.67 10 W / m K 1473 323 K 1473 323 K 46.3 W / m K co

= + + = + + =
( )
2 2
t
h 250 46.3 W/ m K 296.3W/ m K = + =
( )
( )
( )
2
9 3 t
max s
o
2 296.3W/ m K
2h
q T T 1150 C 1.36 10 W/ m
r 0.0005m

= = =
Hence, with
( )
( )
2
2 2 2
e c
e e e
2 2
2 c
c
I L/ A
I R I I
q
LA
A
D / 4

t
= = = =

( )
1/ 2
1/ 2 2
2 9 3
max
max
6
e
0.001m
q D 1.36 10 W/ m
I 29.0A
4 4
10 m
t
t

| |
| |
| = = =
|
|
O \ .
\ .

<
Also, with AE = I R
e
= I (
e
L/A
c
),
( )
( )
2
c
6
max e
110V 0.001m / 4
E A
L 2.98m
I
29.0A 10 m
t

(
A (

= = =
O
<
and the power rating is
( )
elec max
P E I 110V 29A 3190W 3.19kW = A = = = <
COMMENTS: To assess the validity of assuming a uniform wire temperature, Eq. (3.58) may be
used to compute the centerline temperature corresponding to
max
q and a surface temperature of
1200C. It follows that
( )
( )
9 3 2 2
o
o s
1.36 10 W / m 0.0005m q r
T T 1200 C 1203 C.
4 k 4 25 W / m K

= + = + =

With only a
3C temperature difference between the centerline and surface of the wire, the assumption is
excellent.