Transport Phenomena - Heat Transfer Problem :

Maximum current in an electric wire

Problem.
An electric wire with radius r0 of 0.50 mm is made of copper [electrical conductivity =
5.1 x 107 ohm-1 m-1 and thermal conductivity = 380 W/(m K)]. It is insulated (see figure)
to an outer radius r1 of 1.50 mm with plastic [thermal conductivity = 0.350 W/(m K)].

Figure. Heating of an insulated electric wire.

The ambient air is at 38.0oC and the heat transfer coefficient from the outer insulated
surface to the surrounding air is 8.500 W/(m2 K). Determine the maximum current in
amperes that can flow at steady-state in the wire without any portion of the insulation
getting heated above its maximum allowable temperature of 93.0oC.

Solution.
Click here for stepwise solution

Click here for stepwise solution

Step. Thermal resistance representation for insulation and air

Step. Thermal resistance representation for insulation and air

In general, the heat flow is given by Q = ∆ T/Rth, where ∆ T is the temperature driving
force (thermal potential difference). The thermal resistance for a cylindrical annulus is Rth
= ln (r1/r0)/(2 π kL) and the thermal resistance for a fluid film at a solid-fluid interface is
Rth = 1/(hA). Here, k is the thermal conductivity, h is the heat transfer coefficient and A is
the surface area for convection.

The thermal resistances for the insulation and air film are in series as shown in the figure
below.
 Figure. Thermal resistance representation of insulation and air film.

Based on the above thermal resistance representation, the heat flow is

(1)

where k is the thermal conductivity of the plastic insulation.

Step. Heat flow due to current in wire

Step. Heat flow due to current in wire

The flow of an electric current results in some electrical energy getting converted to
thermal energy irreversibly. The heat generation by electrical dissipation per unit volume
is given by S = I 2/ke where I is the current density (in amp/m2) and ke is the electrical
conductivity (in ohm-1 m-1).

The total heat generated within the wire is simply the product of S and the volume of the
wire. At steady-state, all this heat generated within the wire by electrical dissipation must
leave through the wire surface and therefore the heat flow is given by

(2)

Step. Expression for current

Step. Expression for current

On eliminating Q from the above two equations, the current density is

(3)

On multiplying the current density by the cross-sectional area of the wire, the current is
obtained from
 (4)

For the maximum current, the temperature T0 must be maximized.

Step. Substitution of numerical values

Step. Substitution of numerical values

On setting the temperature T0 to 93.0oC (i.e., the maximum allowable temperature for the
insulation), the maximum current that can flow through the wire may be calculated as
13.027 amp.

The numerical values substituted in the equation are given below.

The values below may be changed and the problem solution recalculated with the new
values provided in consistent units.

Variable name Symbol Value Unit

electrical conductivity ke ohm-1 m-1
o
maximum temperature T0 C
o
ambient temperature T2 C
outer radius r1 m
wire radius r0 m
plastic thermal conductivity k W/(m K)
heat transfer coefficient h W/(m2 K)
Calculated Variable Symbol Value Unit
Maximum current 13.027 amp

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