EXPERIMENT 12

THERMAL CONDUCTIVITY OF INSULATING POWDERS UNIT

16.1 INTRODUCTION

Thermal Conductivity of Insulating Powders Unit (Model: Global HE157) consists of

three test modules, i.e. one for each insulating powder. Three tests module for kaolin and
magnesium oxide are supplied. Each test modules is properly sized to sufficiently
contain at least 100g of the insulating powders. The module is fabricated from two
concentric stainless steel cylinders. Each test module is supplied with a 200 W cartridge
heater to provide the heating source. The module is operated separately by properly
connecting the thermocouple probes to the digital indicator.

The instrumentation provided permits accurate measurement of temperature and power

supply. The power control circuit provides a continuously variable electrical output of 0
to 200 Watts. All the direct reading of the temperature sensors and power input to the
heater will be displayed by the digital indicator for ease of monitoring and data
collection. For safety purpose, the heater comes with a built-in thermocouple which is
connected to the temperature controller to prevent the heating element for burn-out.

Figure 16.1: Assembly view of Thermal Conductivity of Insulating

Powders Unit HE157

1 Cartridge Heater 7 Power Indicator

2 Teflon seal1 8 Thermocouple Selector
3 Outer cylinder 9 Heater Power Adjustment
4 Temperature Indicator 10 Main Switch
5 Heater Temperature 11 Heater Switch
Controller
6 Thermocouple Socket Panel 12 Heater Socket

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16.2 OPERATING INSTRUCTIONS

16.2.1 DESCRIPTION AND ASSEMBLY

(a) TEST MODULE – Three sets of test modules made of two concentric
stainless steel cylinders with the following dimensions:
Outer cylinder : I. D. = 102.26mm
Thickness = 6.02 mm
Length = 185 mm

Inner cylinder : I. D. = 9.9 mm

Thickness = 3 mm
Length = 175 mm

The top cover of the module is made of stainless steel and fixed with four
wing nuts. Top and bottom part of the modules are fixed with Teflon seal.

(b) HEATERS - High temperature cartridge heater with built-in thermocouple.

Specifications:

O. D. = 9.8 mm
Length = 230 mm
Power = 200 W
Voltage = 240 VAC

(c) THERMOCOUPLES - Thermocouples of type K are inserted at six

different locations for each test module (Please refer to Figure 16.2). The
sheath is made of fiber glass.

(d) CONTROL PANEL – The control panel consist of these items:

(i) Power transducer – To measure the heat input to the heater element
with the following specifications:

Voltage = 240 VAC/1 phase/50 Hz

Range = 0 to 1,000 W
Output = 4 to 20 mA

(ii) Variable transformer – To control the power input to heater

element.

(iii) Temperature controller – To set the maximum working

temperature for the purpose of heater protection.

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Input = PT 100 or Thermocouple

Output = Relay

(iv) Temperature indicator – For displaying 6 different temperature

readings.

(v) Power indicator – To display the power input.

(vi) Thermocouple female connectors – connecting the thermocouples

with the display unit via selectors.

16.2.2 OPERATING PROCEDURES

(a) Heater Power

Switch on the main power supply. To turn on the heater, simply turn the
heater power knob clockwise. The heat input, Q, to the heater will be
displayed on the power indicator on the control panel.

(b) Temperature Controller

Note: Always set the maximum allowable heater temperature before

switching on the heater. Please refer the following procedures for
adjusting temperature set points.

1. The PV value on the temperature controller indicator shows the

current temperature value while the SV value shows the
temperature set point.
2. Press the “ PF” button to select the digit.
3. Press the “ ” or “ ” button to increase or decrease the value.
4. Press the “ “ button to enter the temperature set point.

(c) Thermocouple Connections

There are six (6) thermocouple female connectors fixed on the control
panel numbered from 1 to 6. These numbers correspond to the
temperatures inside the test modules as shown in Figure 16.2.

1 = T1,1 2 = T1,2 3 = T1,3

4 = T2,1 5 = T2,2 6 = T2,3

Select the appropriate button on the thermocouple selector to display the

correct temperature.

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(d) Digital Display

(i) Temperature Indicator – Display temperature T1 or T2 in degree

Celsius (oC).

(ii) Power Indicator – Display the heat input, Q, to the heater in watt
(W).

Figure 16.2: Thermal Conductivity of Insulating Powder Test Module

16.2.3 DIMENSIONS (OVERALL)

Height = 0.95 m
Width = 1.27 m
Depth = 0.66 m

16.2.4 GENERAL REQUIREMENTS

Electrical supply : 220 VAC/50 Hz

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16.2.5 SAFETY AND MAINTENANCE

1. All operating instructions supplied with the unit must be carefully read
and understood before attempting to operate the unit.
2. Turn off the power supply to the control panel before connecting the
heater power plug.
Note: DO NOT remove the cartridge heater unless for repair or
maintenance. Removing the heater should be done when it is at room
temperature ONLY.
3. Never splash water to the control panel. This will cause injury and
damage to the equipment.
4. Never use your bare hands to test the AC power supply. It may cause
hazardous injury.
5. Do not operate the unit where explosive vapours of flammable materials
exist. Death or serious injury could result.

16.2.6 OPTION – TESTING WITH DIFFERENT TYPE OF INSULATING

POWDERS

(a) Remove the stainless steel cover by unscrewing the four nuts. Remove also
the 2 nuts at the bottom of the supports.

(b) Remove the three thermocouples (no. 4, 5 and 6) by unscrewing the jam nuts.

(c) Take out the top Teflon seal. Be very careful with the thermocouple wires.

(d) Pull out the test module and pour out existing powder without removing the
inner cylinder and bottom Teflon seal.

(e) Put back the test module and pour in the new insulating powder to the
appropriate level.

(f) Replace the top Teflon seal.

(g) Replace the stainless steel top cover and secure the nuts back.

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16.3 EXPERIMENTAL MANUAL

16.3.1 OBJECTIVE

The Thermal Conductivity of Insulating Powders Unit enables the student to determine
experimentally the thermal conductivity of several insulating powders. Kaolin,
magnesium oxi de and m ica are supplied with the unit. Thus, students will be able to
familiarize themselves with the principles of thermal conductivity in heat transfer process
and therefore understand the importance of insulation in industrial process.

16.3.2 THEORETICAL BACKGROUND

Materials such as kaolin, magnesium oxide and mica have very low thermal conductivity
which means that only a small amount of heat will pass through the material even though
a high temperature difference may exist across it. Such materials are known as thermal
insulators and practically utilized in situations where it is required to reduce heat losses
from a hot body to the atmosphere.

Consider a cylinder of internal radius r1, and external radius r2 as shown in Figure 15.3.
Let the inside and outside surface temperatures be T1 and T2 respectively.

Figure 16.3: Heat transfer through a cylinder

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Consider the heat flow through a small element, thickness dr at any radius r where the
temperature is T. Let the conductivity of the material be k. Then, for unit length in the
axial direction, we have

q = − k A dT / dx = − k (2 π r x 1) dT / dr
i.e., q dr / r = −2 π k dT

Integrating between the inside and outside surfaces.

dr T2
q ∫ rr12 = − 2 π k ∫ dT
r T1

(where q and k are both constant).

r2
q ln = − 2 π k (T2 − T1 ) = 2 π k (T1 − T2 )
r1

2 π k (T1 − T2 )
q=
ln r2 / r1

q ln r1 / r2
So, k=
2 π (T1 − T2 )

Where q is determined from the digital power indicator while T1 and T2 are determined
from the digital temperature indicator.

16.3.3 EXPERIMENTAL PROCEDURES

1. Plug the thermocouple connector for the kaolin test module into the appropriate
sockets located at the side of the control panel.

2. Set heater power knob to zero. Switch on the main switch.

3. Set maximum operating temperature on the temperature controller to 200oC.

(Refer section 6.2.2(b) on how to set the temperature controller set point)

4. Plug in the six thermocouple male connectors for the test module into the
appropriate female connectors on the control panel.

5. Increase the heater power to the desired level, Q1.

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6. Run for a period of time allowing the unit to reach steady state condition.

7. Press the appropriate thermocouple selector to display the temperature readings.

8. When stable, record the temperature readings for T1,1, T1,2, T1,3, T2,1, T2,2, and T2,3
form the digital indicator.

9. Repeat steps 5 to 8 for higher heater power, Q2 and Q3.

10. Repeat the above steps for magnesium oxide and mica test module.

11. Set heater power knob to zero. Switch off the main switch.

12. The thermal conductivity of the insulating powders may then be readily
calculated.

16.3.4 RESULTS

T1 T2
Insulation Material
T1,1 T1,2 T1,3 T1,ave T2,1 T2,2 T2,3 T2,ave
Kaolin
Magnesium Oxide
Mica

Heat input, Q1 = __________ W

Q2 = __________ W

Q3 = __________ W

Inner radius, r1 = __________ cm

Outer radius, r2 = __________ cm

Insulation Material k1 k2 k3 kave

(W/mK) (W/mK) (W/mK) (W/mK)

Kaolin
Magnesium Oxide
Mica

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16.3.5 CALCULATION

The thermal conductivity k of each insulation material can be calculated from the
following equation:

qi ln r2 / r1
ki =
2 π (T1,ave. − T2,ave. )

Where i = 1, 2, 3.
Therefore, for each powder,

k = k ave = (k1 + k 2 + k 3 ) / 3

Note: Appropriate multiplication factors should be introduced to convert the result to

normally accepted units for thermal conductivity, i,e. W/mK.

16.3.6 POST LAB QUESTIONS

1. Compare the k values obtained from experiment with the typical values for kaolin and
magnesium oxide contained in tables of published data.

The available published data for k at temperature approximately 200oC are:

a) Kaolin : 0.0865 W/mK

b) Magnesium Oxide : 0.0796 W/mK

c) Mica : 0.71 W/mK

2. Discuss on the influence which insulators have upon the conduction of heat. How
good are these materials as an insulator?

3. Suggest some practical uses for the insulating materials tested.

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