A new induction barrel heating system that promises 70% reduction of energy has been developed.
The Thermal Control Solution (TCS) consists of radiant heating elements embedded in high-temperature
ceramic-fiber insulation. The heater segments are wired together in series, wrapped around the barrel
and secured with high-temperature Velcro fasteners. Unlike heater bands, the TCS does not depend on
tight contact with the barrel—it actually does not touch the barrel at all. The radiant energy is
transmitted across a small air gap between the heaters and the barrel. Insulated end rings isolate
each barrel zone. The air gap under the heaters extends along the entire zone. If cooling is required,
an optional high-suction blower draws ambient air through the end ring and exhausts the hot air, either
into the plant or outdoors. About 75% of the barrel is exposed to high-velocity cooling air, if needed.
Two key advantages claimed for the TCS are:
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The barrel is fully insulated along its length, which minimizes energy loss into the plant and also protects employees from burn hazards. |
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Heaters have low thermal mass. They heat up to set point very much faster than
band heaters and they respond to control adjustments much faster as well. The
thermal momentum of conventional barrel heating/cooling systems imposes a
sine-wave cycle of continuous heating and cooling adjustments. Since the TCS
does not have this thermal momentum, constant temperature overshoot and
undershoot is avoided. This provides tighter temperature control, minimizes the
amount of cooling necessary, and in some applications allows the temperature set
point to be lowered, which saves more energy. |