Induction Coil Pipe Heating to Reduce High-Current Supply Losses
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Solution Overview
Problem
Existing methods for heating fluids in high-temperature processes, such as steam cracking and steam reforming, face challenges with high CO2 emissions and inefficiencies due to the need for large conductor cross-sections and high-current power supplies, leading to complex and costly systems.
Innovation Solution
A device utilizing electrically conductive pipelines and alternating voltage coils to induce electromagnetic fields, generating eddy currents and heating the pipelines through Joule heat, which allows for reduced current requirements and improved efficiency with precise temperature control, while using insulation to decouple electrical heating from the pipeline system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If direct electrical heating of pipes is used, then heating efficiency is improved, but electrical insulation of pipe suspensions and high-current power supplies are required, increasing device complexity
Solution Approach 1:
An electrically conductive susceptor material is introduced as an intermediary between the pipe and the heating coil. The susceptor is heated by electromagnetic induction from the coil and transfers heat to the pipe through thermal contact, eliminating the need for direct electrical connection to the pipe while maintaining heating efficiency.
Solution Approach 2:
The direct electrical heating method (mechanical/electrical system) is replaced with electromagnetic induction heating. The heating coil generates an alternating magnetic field that induces eddy currents in the conductive susceptor, which then heats up and transfers thermal energy to the pipe, replacing the need for direct electrical connection to the pipe.
2Power
If large conductor cross-sections are used for high-current power supplies, then heating power is improved, but conductor material and supply line losses increase
Solution Approach 1:
High-current direct electrical heating is replaced with low-current electromagnetic induction heating. The heating coil carries a relatively low current that generates an alternating magnetic field, which induces eddy currents in the conductive susceptor. This indirect heating method achieves the same or higher heating power with significantly reduced supply line losses.
Solution Approach 2:
The heating method changes from direct resistance heating (requiring high current through the pipe) to electromagnetic induction heating (using alternating magnetic field at optimized frequency). This parameter change allows achieving the same heating effect with lower current, reducing I²R losses in supply lines.
3Productivity
If electrical currents are applied directly to pipes, then heating efficiency is improved, but electrical insulation and contacting of pipes are required, increasing manufacturing complexity
Solution Approach 1:
The electrically conductive susceptor serves as an intermediary that receives electromagnetic energy from the coil and transfers it thermally to the pipe. This eliminates the need for electrical insulation of pipe suspensions and complex contacting arrangements, as the susceptor is simply placed in thermal contact with the pipe while being exposed to the magnetic field.
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
This solution reduces energy losses, enhances controllability, and minimizes CO2 emissions by using electrical energy instead of direct firing, maintaining mechanical and thermal decoupling of heating and pipelines, and allows for the heating of non-conductive fluids efficiently.
Implementation Method 1
the coil is configured to generate at least one electromagnetic field by applying the alternating voltage, wherein the pipe and the coil are arranged such that the electromagnetic field of the coil induces an electric current in the pipe
Implementation Method 2
which heats the pipe through Joule heat, which is generated when the electric current passes through conductive pipe material, to heat the fluid
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B
AI summary
The invention relates to a device (112) for heating a fluid. The device (112) comprises: at least one electrically conductive pipeline (120) for receiving the fluid; at least one electrically conductive coil (110); at least one alternating voltage source (114), which is connected to the coil (110) and is designed to apply an alternating voltage to the coil (110). The coil (110) is designed to generate at least one electromagnetic field as a result of the application of the alternating voltage. The pipeline (120) and the coil (110) are arranged in such a way that the electromagnetic field of the coil (110) induces an electric current in the pipeline (120), which electric current heats the pipeline (120) by Joule heat in order to heat the fluid, which Joule heat arises as the electric current passes through conductive pipe material.