Burner-Integrated Induction Heating for Uniform Furnace Gas Heating
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Solution Overview
Problem
Existing furnaces for heating rolled metal products face challenges in efficiency, cost-effectiveness, and flexibility due to high electrical power demands for induction heating, uneven heating, and limited space for additional heating elements, as well as fluctuating fuel costs.
Innovation Solution
Integrate induction heaters into existing burners to heat gas before combustion, allowing flexible operation with combustible gases and inert gases, and control the heating process using a control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If induction heating is used to heat the material directly, then heating efficiency is improved, but the peak electrical power demand increases significantly
Solution Approach 1:
The patent introduces gas as an intermediary medium between the induction heater and the material to be heated. The induction heater heats the gas, which then flows over and heats the material indirectly. This mediator approach allows efficient energy transfer while distributing the power demand over time, avoiding peak electrical power surges.
2Productivity
If a sufficient number of induction heaters are installed in the furnace chamber, then heating capacity is improved, but the space required exceeds the available space
Solution Approach 1:
The patent merges the function of induction heating with the existing gas heating system. Instead of installing separate induction heaters throughout the furnace chamber, the induction heater is integrated into the gas supply system, heating the gas that already circulates through the chamber. This combines multiple functions in a single system, achieving full heating capacity without additional space requirements.
3Speed
If induction heating is used to heat the material directly, then heating speed is improved, but uniformity of heating deteriorates
Solution Approach 1:
The gas acts as a mobile intermediary that distributes thermal energy uniformly across the material surface. The induction heater rapidly heats the gas, and the flowing gas carries this heat evenly over the entire material, maintaining both high heating speed and uniform temperature distribution.
4Loss of energy
If induction heating system is installed, then heating efficiency is improved, but system complexity and installation cost increase
Solution Approach 1:
The patent combines the induction heating system with the existing gas supply infrastructure. The induction heater is integrated into the gas delivery mechanism, utilizing existing pipes, flow control systems, and distribution networks. This merging approach achieves high heating efficiency while minimizing additional complexity and installation costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, flexible, and cost-effective heating with reduced electrical power demand, avoiding uneven heating and peak loads, while maintaining metallurgical properties.
Implementation Method 1
by generating electric eddy currents
Implementation Method 2
heating devices each have an induction heater, by means of which thermal energy can be introduced into at least one gas supplied to the burner
Implementation Method 3
a gas mixture containing a combustible gas and an oxygen-containing gas can be combusted
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A furnace (1) has a furnace chamber (3) in which a material (2), in particular a rolled metal product, is to be heated. The furnace (1) has a number of heating devices (5) by means of which a hot gas (6) can be introduced into the furnace chamber (3) so that the hot gas (6) heats the material (2) located in the furnace chamber (3). The heating devices (5) each have a burner (7) by means of which a gas mixture containing a combustible gas (8) and an oxygen-containing gas (9) can be combusted. The heating devices (5) each have a supply (10) for supplying the combustible gas (8) and the oxygen-containing gas (9) or the gas mixture to the respective burner (7). The heating devices (5) each have an induction heater (13) by means of which thermal energy can be introduced into at least one gas (8, 9, 14) supplied to the burner (7) and introduced into the furnace chamber (3) via the burner (7) by generating electric eddy currents.