Electric Radiant Element Structure for Low-Emission Furnace Heating
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Solution Overview
Problem
Existing heat treatment systems in industries, particularly in steel and automotive sectors, face high emissions of NOx and CO2, aggressive flame behavior, and inefficiencies in maintaining combustion parameters, leading to frequent maintenance needs and system failures.
Innovation Solution
A radiant element powered electrically or by alternative heating means, such as electric induction, with a unique hollow shape and continuous wall design, eliminating the need for burners and ensuring uniform thermal radiation and reduced emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gas burners are used to heat radiant tubes, then high temperature heat treatment can be achieved, but emissions of NOx and CO2 increase significantly
Solution Approach 1:
The patent replaces the gas burner combustion system with an electric heating system. The radiant element is heated electrically instead of through flame combustion, eliminating the need for fuel burning and thus eliminating NOx and CO2 emissions while maintaining the capability to achieve high heat treatment temperatures through electrical energy conversion to thermal radiation.
Solution Approach 2:
The patent changes the energy source parameter from chemical energy (gas fuel) to electrical energy. This parameter change transforms the heating mechanism from combustion-based to electric resistance or induction heating, achieving the same temperature output without the harmful byproducts of combustion.
2Power
If flame burners are used for heating, then high power output can be achieved, but flame aggressiveness causes deformations and cracks in radiant tubes
Solution Approach 1:
The patent replaces the flame-based heating system with an electric heating system. The radiant element is heated through electrical resistance or induction heating rather than direct flame exposure, eliminating the aggressive thermal and chemical environment that causes deformations and cracks, while maintaining high power output capability through electrical energy input.
Solution Approach 2:
The patent introduces an intermediate heating mechanism (electric heating elements or induction heating) between the energy source and the radiant element. Instead of direct flame contact, electrical energy serves as an intermediary to heat the radiant element uniformly without the mechanical and thermal stress of aggressive flames.
3Productivity
If traditional radiant tubes are used, then heat treatment function is achieved, but frequent maintenance and system failures occur due to combustion parameter instability
Solution Approach 1:
The patent replaces the complex combustion system (burners, flame control, air-fuel mixing) with a simplified electric heating system. Electric heating elements or induction heating require minimal maintenance compared to combustion systems, eliminating issues related to flame stability, burner tuning, and combustion parameter control, while maintaining full heat treatment productivity.
Solution Approach 2:
The patent extracts and removes the combustion system components (burners, fuel supply, air intake, flame control mechanisms) from the heating system, retaining only the essential radiant element function. This extraction eliminates the maintenance-intensive combustion subsystem while preserving the core heat treatment capability through electric heating.
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
The solution achieves reduced emissions, improved thermal efficiency, longer element lifespan, and uniform temperature distribution, minimizing maintenance and operational costs while enhancing heat treatment quality.
Implementation Method 1
A radiant element powered electrically or in general by means of a heating means
Implementation Method 2
These tubes are usually connected to a gas burner (or other fuels such as hydrogen, methane or other are also used) which generates the temperature and power necessary for their operation and for the treatment to be carried out. These burners release a very hot flame (up to and beyond 1300° C.) inside the radiant tubes, which by radiation (hence the name radiant tube) heat the strip
Implementation Method 3
The at least one heating means, for example electric or fuel powered, is capable of heating the radiant element
Implementation Method 4
The at least one heating means, for example electric or fuel powered, is capable of heating the radiant element
Data Source
AI summary
Radiant element, usable in at least one furnace for heat treatment, and/or for continuous galvanizing and annealing lines of sheet metal strips or plates and/or other products made of steel and/or other metals and/or for the modernization of at least one pre-existing furnace, wherein the radiant element is used to emit and/or radiate heat, wherein the radiant element has a main longitudinal extension (L) and a transversal extension (M), perpendicular to the main longitudinal extension (L), and includes a shaped wall which defines an external surface, an internal surface and an internal cavity, in addition to at least two main hollow seats, adapted in use to house at least one heating means and at least one connection seat; radiant system and use of this radiant element.