Delaying quality deterioration of refrigerated prepackaged chicken breasts with an emerging microwave-assisted induction heating system

Abstract CO 2 methanation offers a practical solution for sustainable, renewable energy storage and long‐term space exploration missions. However, conventional direct solar‐driven photothermal systems suffer from thermal response hysteresis and dynamic temperature fluctuations, undermining methane yield stability and limiting their applicability under high gas hourly space velocity (GHSV) conditions. Herein, a round‐the‐clock CO 2 methanation system is pioneered that integrates photovoltaic power generation with induction heating by a rapid‐response electromagnetic metamaterial (EEM), serving as both a catalyst and a susceptor. The EMM assembles single atoms, nanoclusters, and nanotubes into a macrostructure by a 3D‐printed strategy and rapidly reaches the methanation temperature of 300 °C within just 36 s at a frequency of 297 kHz with an input power of 461 W, achieving a substantially great CH 4 space‐time‐yield of 821 mmol g cat −1 h −1 at an ultra‐high GHSV of 150 000 mL g cat −1 h −1 . The outdoor photovoltaic‐driven induction heating system maintains stable production with a cumulative CH 4 output of 1373.2 L over one week, shielding the system from environmental instability. Notably, this system exhibits a solar‐to‐chemical energy efficiency of 13% and achieves 20% energy savings compared with conventional electric heating technologies, offering a prospective avenue for efficient and stable CO 2 methanation.

Water desalination using humidification / dehumidification unit integrated with waste heat and induction heating system

This study addresses the issues of high energy consumption and low efficiency in conventional electric heating snow-melting systems for railway turnouts. A novel system is proposed that integrates electromagnetic induction heating with traditional electric heating to optimise energy transfer pathways and enhance energy utilisation efficiency. The system enables dynamic adjustment of heating power, thereby supporting adaptive operation under varying environmental conditions. Through theoretical analysis, temperature field simulations, and experimental validation, the energy regulation mechanism and performance characteristics are examined. Results show that, under full snow-cover conditions, the proposed induction heating system reduces snow-melting time by 76.9% compared with traditional electric heating, while achieving a 29% efficiency gain under snow-free conditions. Steady-state temperature rise tests demonstrate close agreement between simulations and measurements: directional heat transfer efficiency improves significantly, with the average rail temperature decreasing by 8.5% and the air temperature in the working area increasing by 15%. Additionally, the system increases the ice- and snow-melting rates by 0.4 and 0.8 times, respectively, while reducing energy consumption by 30–40%. An optimised composite thermal structure further enhances heat utilisation. This study provides both theoretical and practical insights for advancing turnout snow-melting technology and its engineering applications.

Heating Effect Evaluation of the Electromagnetic Induction Heating System at the High Temperature and Pressure Simulated Wellbore

A Full-Range ZVS Comprehensive Control Strategy for Dual-Port LLLC Induction Heating System

Smith IHHOGA PID temperature control strategy for electromagnetic induction heating system with waste wind consumption

Railway turnouts are highly susceptible to snow and ice accumulation during winter, which can cause malfunctions, resulting in train delays or, in extreme cases, derailments with potential casualties. To mitigate these risks, resistive heating (RH) systems using nichrome wires have traditionally been employed. However, these systems suffer from slow heat transfer and high power consumption. To address these limitations, this article proposes an induction heating (IH) system designed for rapid thermal response and improved electrical and thermal efficiency. The proposed system comprises a power conversion unit featuring a boost power factor correction (PFC) stage and a high-frequency resonant inverter, along with an improved IH coil. An experiment in real snowfall demonstrates the IH system’s fast heat-up capability, effective snow cover removal, and enhanced energy efficiency compared to conventional methods.

Enhanced modeling of load behavior in high-efficiency dual-coil induction heating systems

FEM simulation and experimental validation of a high-frequency induction heating system with COMSOL Multiphysics

Silicon carbide (SiC), a wide-band gap semiconductor,is essentialfor applications in electric vehicles, 5G communications, and aerospacedue to its outstanding physical properties. However, their high productioncosts limit their widespread industrial applications. The growth oflarger diameter and thicker crystals, particularly 8 in. crystals,offers the potential to reduce these costs. Therefore, large-diameterPVT crystal growth equipment with resistance heating has become afocal point of research in this field. In this paper, a novel double-flapresistance furnace design is proposed for the first time, and thethermal field is systematically studied by three-dimensional COMSOLMultiphysics modeling to optimize the growth of 8 in. 4H-SiC singlecrystals. It is found that the resistance heating system significantlyoutperforms the induction heating system by providing a lower radialtemperature gradient necessary for large-diameter SiC crystals. Additionally,the influence of key parameters such as the crucible, the distancebetween the heater and the crucible, and the growth power on the thermalfield distribution in the crucible was also systematically studied.The influence of the distance from the surface of the source materialto the crystal surface and the distance from the center of the crystalto the edge on both the axial and radial temperature differences isalso analyzed. Based on the simulation results, the crystal growthscheme was further optimized and an 8 in. SiC crystal with a thicknessabove 20 mm and resistivity uniformity was successfully obtained usingthe novel resistance furnace. This is of great significance for thegrowth of large-diameter SiC crystals.

An Induction Heating System for Plate Heating Applications Using a Double-D-shaped Auxiliary Work Coil

Localized electromagnetic induction heating system for rapid soldering of interfaces between integrated circuit and printed circuit board

Abstract The study focuses on calibrating a system for inductive heating of samples before performing dynamic compression tests using a Split Hopkinson Pressure Bar (SHPB). In the proposed set-up, the crucial role is played by the pyrometer, which could continuously control the temperature of the specimen during the test. The coupling of the experimental test together with numerical simulations (including thermal and mechanical simulations) is performed to calibrate the considered system. The key outcomes of the coupled experiment and simulation analyses are the shortest heating time required to achieve a uniform temperature in the neck of the sample and the change in the temperature field during cooling (after the heating ends). This procedure will also be used in real experiments to predict the temperature sensitivity of the material under dynamic compression under precisely controlled thermal conditions for a temperature range of 250 °C to 730 °C.

This paper reviews the current state of research on half-bridge (HB) inverters used in induction heating power supplies, emphasizing their topological structures, output power control methods, and switching strategies. The study explores various control techniques to regulate low power levels in a series resonant inverter (SRI) configured with an HB structure for induction heating applications. Pulse frequency modulation (PFM) is commonly employed to regulate standard power levels by adjusting the operating frequency relative to the resonant frequency. As the operating frequency increases beyond resonance, the output power decreases. However, in certain scenarios, achieving low power levels necessitates high frequencies, which introduces significant control challenges. To address these issues, it is crucial to develop alternative approaches that ensure efficient power reduction, without compromising system performance. This work evaluates and compares multiple solutions tailored for a high-frequency induction heating system delivering 18 kW at an operating frequency of approximately 100 kHz. The study places particular emphasis on optimizing key component sizing and analyzing inverter losses to enhance overall system efficiency and reliability.

Article Development of an Injection Nozzle Heating System to Produce Automotive Control Cables João Pedro Madureira Pinto 1,†, Raul Duarte Salgueiral Gomes Campilho 1,2,*,†, Francisco José Gomes da Silva 1,2,†, Mehmet Serkan Kirgiz 3,† and Mariusz Salwin 4,† 1 CIDEM, ISEP—School of Engineering, Polytechnic of Porto, R. Dr. António Bernardino de Almeida, 431, 4200-072 Porto, Portugal 2 INEGI—Pólo FEUP, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal 3 Department of Civil, Architectural and Construction Engineering and Management, Academia of ACMCEN, 4017, Beaverton, OR 97075, USA 4 Faculty of Mechanical and Industrial Engineering, Institute of Organization of Production Systems, Warsaw University of Technology, 85 Narbutta Street, 02-524 Warsaw, Poland * Correspondence: raulcampilho@gmail.com; Tel.: +351-228340500 † These authors contributed equally to this work. Received: 28 October 2024; Revised: 21 January 2025; Accepted: 7 March 2025; Published: 11 March 2025 Abstract: The automotive industry plays a vital role in the global economy, significantly contributing through job creation, resource utilization, and driving technical and technological advancements. Control cables play an indispensable role in various vehicle mechanisms, including the control of windows, doors, and critical functions such as the handbrake and throttle. The terminals attached to these control cables are small, die-cast components, most commonly fabricated from light alloys with low melting temperatures, such as the zinc-based alloy Zamak. One of the key challenges encountered in the production of these terminals is the difficulty in maintaining consistent heating of the injection nozzle, which can hinder the smooth removal of parts from the mold. This research proposes an innovative method to improve the heating of injection nozzles used in the manufacturing of zamak control cable terminals by employing electromagnetic induction. Typically, the heating process is conducted using electrical resistors, which lack precision in temperature regulation and respond slowly to fluctuations in nozzle temperature. The solution introduced in this study involves an induction heating system, tuned to operate at 155 kHz and 410 W of power. The system’s design features a multi-coil solenoid inductor, optimal for cylindrical components, and incorporates a pyrometer for continuous temperature monitoring. Finite Element Method (FEM) analysis revealed that maintaining an injection nozzle temperature of 550 °C requires the surrounding injection set to reach 600 °C. The return on investment for implementing this induction heating technology was calculated to be around 7 years and 8 months.

Introduction. For many modern manufacturing processes, induction heating provides an attractive combination of speed, consistency and control. Multi-inductor (zone) systems with continuous billets feed are the most promising, which keep the billet cross sectional average temperature equal. It allows to avoid overheating at low throughputs and reduces the number of rejected billets. Problem. With zone induction heating systems for metal billets developing it is necessary, at the design stage, to perform a quantitative analysis of the main characteristics of the electrothermal process and provide recommendations for optimal parameters and heating modes selections. Accurate calculations for induction heating systems involve considering the distribution of the magnetic field, current density, and changes of material properties throughout volume of the heated billet. The goal of the work is to develop the numerical model and analyze the coupled electromagnetic and thermal processes in zone induction heating system for metal billets to determine the optimal power ratio of the inductors and choose rational heating modes for the billets. Methodology. The spatiotemporal distribution of the electromagnetic field and temperature throughout the volume of the billet during the induction heating process is described by the system of Maxwell and Fourier equations. For numerical calculations by the finite element method, the COMSOL Multiphysics 6.1 software package was used. All three methods of heat transfer are taken into account – conduction, convection, and radiation. Multiphysics couplings use electromagnetic power dissipation as a heat sources, and the billet material properties are specified by temperature functions. The operation of the inductors’ coils is modeled using the «Multi-Turn Coil» function, which uses a homogenized model. The translational motion of the billet is modeled by using the «Translational Motion» function. Results. The numerical 3D-model of coupled electromagnetic and thermal processes in the zone induction heating system for metal billets has been developed. Modeling was carried out for the design of a four-inductor system with the nominal capacity of 5000 kg/h. Data on the spatial distribution of the electromagnetic and temperature fields in the moving heated steel billet were obtained. Originality. Three-dimensional graphs of electrical conductivity and relative magnetic permeability change inside the moving heated steel billet are presented. Results of the temperature distribution calculations along the length of the steel billet for different inductors power ratios are provided. It is shown how the change in the power distribution of the inductors affects the billet heating parameters. Practical value. Analysis of the obtained data allows to determinate the necessary inductors powers to ensure the required heating mode. The results make it possible to reduce the time and resources required for the development, optimization of the design and improvement of the technological process of zone induction heating for metal billets. References 20, table 1, figures 13.

This study demonstrates rapid carbon nanotube (CNT) synthesis using a 150 kHz induction heating system, enabling precise temperature and pressure control in thermal chemical vapor deposition processes. CNT growth optimization at temperatures between 887 and 955 °C and pressures from 1 to 700 Torr reveals that an optimized temperature (887 °C) and pressure (100 Torr) yield enhanced field emission performance. The 150 kHz induction heating provided faster heating rates and a more consistent temperature distribution across the substrate, significantly enhancing growth efficiency. CNT grown using the induction heating system demonstrated high emission currents and outstanding stability during field emission tests. The induction heating approach reduces synthesis time, offering an efficient pathway for scalable production of field emission devices.

A Three-Phase AC Input Induction Heating System With Heat Distribution Control Capability

A comparative study of AVC-PDM and AVC-PWM based cyclo-inverter fed induction heating systems