Methods and systems for cooling a heating element
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Solution Overview
Problem
Electric heating elements in thermal process cycles deteriorate faster due to high temperature change rates, leading to a trade-off between efficiency and longevity, necessitating improved cooling methods to extend element life and reduce cycle time.
Innovation Solution
A method and system for cooling heating elements in electric heaters that involves a two-stage cooling process: a first slow cooling rate from a high temperature to a lower temperature, followed by a faster cooling rate, achieved by adjusting power and fluid flow, with a temperature sensor and processing circuitry to control these rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fast cooling rate is used to reduce cycle time, then productivity is improved, but the heating element deteriorates faster due to high temperature change rates
Solution Approach 1:
The cooling process is divided into multiple stages with different cooling rates. The first stage uses a slower cooling rate from initial temperature to intermediate temperature, and the second stage uses a faster cooling rate from intermediate temperature to final temperature. This segmentation allows the system to balance element longevity with productivity by applying appropriate cooling rates at different temperature ranges.
Solution Approach 2:
The cooling rate is dynamically adjusted based on the current temperature of the heating element. The control system monitors temperature and automatically transitions between different cooling rates, making the cooling process adaptive rather than static. This dynamic approach optimizes both element life and cycle time.
2Reliability
If a slow cooling rate is used to extend heating element life, then reliability is improved, but cycle time increases reducing productivity
Solution Approach 1:
The cooling process is divided into multiple stages with different cooling rates. The first stage uses a slower cooling rate from initial temperature to intermediate temperature, and the second stage uses a faster cooling rate from intermediate temperature to final temperature. This segmentation allows the system to balance element longevity with productivity by applying appropriate cooling rates at different temperature ranges.
Solution Approach 2:
The cooling rate parameter is changed based on temperature conditions. The system transitions from a first cooling rate to a second cooling rate as the heating element cools from initial temperature through intermediate temperature to final temperature. This parameter change optimizes both element life and cycle time.
3Productivity
If high power is applied to heat the heating element quickly, then productivity is improved, but temperature change rates increase causing element deterioration
Solution Approach 1:
The power application to the heating element is made periodic rather than continuous. The control system cycles power on and off in controlled intervals during the heating phase, allowing the element to heat up efficiently while avoiding sustained extreme temperature rates that would cause deterioration. This periodic action balances heating speed with element life.
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 approach extends the life of heating elements from approximately 1200 to 2000-7000 thermal cycles and reduces cycle time from 36 minutes to 14 minutes, mitigating deterioration caused by rapid temperature changes.
Implementation Method 1
the heating elements are positioned in tubes within the electric heaters and the fluid flows through the electric heater whereby heat is transferred
Implementation Method 2
The method comprises the steps of cooling the heating element at a first cooling rate from a first temperature to a second temperature
Data Source
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AI summary
Disclosed is a method for cooling a heating element (11) of an electric heater (1) in a thermal process cycle. The method comprises the steps of cooling (102) the heating element (11) at a first cooling rate from a first temperature to a second temperature and cooling (106) the heating element (11) at a second cooling rate from the second temperature to a third temperature, wherein the second cooling rate is faster than the first cooling rate.