How to calculate the heating power of an electric heater

The efficiency of an electric heater fluctuates around 60%. During operation, explosion-proof electric heaters can enter their input port through pipelines in low-temperature fluid medium under pressure, and along the specific heat exchange channel inside, they are designed using the principle of fluid science to carry away the high-temperature heat energy generated during the operation of the electric heating element. The temperature of the heated medium increases, and the outlet reaches the high-temperature medium required by the process. The internal control system automatically adjusts the cut-off temperature of the output port to a uniform level based on the temperature sensor signal at the output port; When the heating element overheats, its independent overheating protection device will immediately cut off the power supply. This design is to prevent material deterioration, coking, or carbonization, and even burn out the element in more severe cases, which will affect the service life of the electric heater.
The calculation of heating power starts from the following three aspects:

1、 Power during operation. Power - the heat loss in the system. All calculations should be based on the worst-case scenario: lowest ambient temperature, shortest operation, highest cycle operation, maximum weight of temperature heating medium (flow medium as maximum flow rate).

2、 The steps to calculate the power of the heater: Draw a heating process flowchart based on the process (not involving material form and specifications).

3、 Calculate the heat required for the process. Calculate the heat and time required for system startup. Draw a heating process flowchart, consider appropriate safety factors, and determine the total power of the heater. Determine the sheath material and power density of the heating element, determine the form, size, and quantity of the heater, and determine the power supply and control system of the heater.