ABSTRACT Traditional heating of sugarcane juice to manufacture many beneficial products are highly environmental polluting, time consuming and associated with lot of energy wastage. To overcome these concerns, it is high time to adopt the latest technologies of heating. Induction heating is such fast technology that can be used for sugarcane juice heating which has no harmful environmental effects with minimized energy losses. Keeping the benefits of induction heating in view, an effort has been undertaken to examine the influence of increased heat flux (12.43, 14.92, 17.41, and 19.90 kW/m2) on the performance of induction plate heating system (IPHS) for obtaining final concentrated product (FCP) from sugarcane juice. The results obtained from this research work concludes that total energy consumption, energy required to produce 1 g of FCP, total heating time, cost of electricity and economic payback period decreases by 6.7%, 7.1%, 46.15%, 66.83%, and 47 days, respectively, with the increase of heat flux from 12.43 to 19.90 kW/m2. In a nutshell, it is concluded that the tested system found more efficient at higher heat inputs. Increase in heat flux significantly improved the heat transfer coefficients and boosted the evaporation rate by 45.9%, with 9.52 tonnes of CO2 mitigation. These experiments at different heat inputs culminate IPHS is economical and gives better thermal performance at higher heat flux.

Mold temperature control critically influences injection molding, impacting product quality and production efficiency. High mold temperatures enhance surface quality but prolong cooling, increasing cycle time, whereas low temperatures cause defects like weak weld lines and incomplete filling. This study aims to reduce cycle time and enhance tensile strength of thin-wall injection-molded products by developing an innovative mold temperature control strategy using induction heating to preheat mold inserts. The primary objective is to eliminate in-cycle heating delays while ensuring optimal mold temperatures for improved mechanical properties. However, the power consumption of this process significantly increases due to the energy-intensive nature of induction heating. Research involved numerical simulations and experimental validation. COMSOL Multiphysics analyzed thermal and electromagnetic interactions, modeling temperature distributions for heating distances (G = 5, 10, 15 mm) and times (1–8 s). Moldex3D simulated polymer flow behavior, assessing filling capabilities for materials (PC, ABS, PA6, PP). Experiments employed the external induction heating with rotational structure for mold temperature control system (Ex-IHRS), featuring a rotational mechanism to swap preheated inserts, with real-time temperature measurements via sensors and infrared cameras at points S1, S2, and S3. Tensile strength tests evaluated mechanical performance. Rapid heating within 5–8 s maintained stable mold temperatures without extending cycle time, outperforming traditional methods like resistance or steam heating. Significant tensile strength improvements occurred, with PC increasing from 111.9 MPa to 123 MPa after 6 s of heating, ABS reaching 91.3 MPa after 4 s, PA6 rising from 55.4 MPa to 62.8 MPa, and PP improving from 41.3 MPa to 47.3 MPa. Enhanced weld line integrity and reduced frozen layers drove these gains, minimizing defects in thin-wall components. Simulations showed less than 5% deviation from experimental data, validating the approach’s accuracy. Despite higher power consumption, this induction heating strategy optimizes production efficiency and enhances product quality, offering a promising advancement for thin-wall and microinjection molding applications.

Rethinking energy delivery in biomass pyrolysis: Comparative insights into conventional, microwave, and induction heating

Advancing Activated Carbon Production: Utilizing Pine Pruning Biochar via Induction Heating with CO2 and Iron-Based Catalysts

Temperature-dependent microstructure, wear, and corrosion behavior of Fe-Cr-B coatings fabricated by induction heating assisted laser cladding

Development of a high-throughput centrifugal thermal cycler by an innovative non-contact induction heating mechanism for rapid diagnosis of respiratory infectious viruses

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

Effect of Phytochemical-Mediated synthesis using Allium sativum, Zingiber officinale, and Carica papaya extracts on the Inductive heating characteristics of MnFe2O4 nanoparticles

Low-temperature 3D-Printed porous microreactors with magnetic induction heating for methanol steam reforming to hydrogen

Effect of aging levels and induction factors on self-healing ability by induction heating method in hot asphalt mixtures

Research on improving the low-temperature performance of lithium-ion battery based on electromagnetic induction heating method

Shear failure behavior of the interface between asphalt mixture and ice layer by electromagnetic induction heating

Numerical study of methane dry reforming in an electromagnetic induction heating reactor

Dynamic resonant frequency tracking and synchronization for induction heating using half-cycle measurement algorithm

This study aims to compare two heat treatment techniques—high-frequency induction and conventional furnace heating—applied to AISI 1040 medium-carbon steel. The effects on surface hardness, microstructure, and energy efficiency were evaluated under controlled thermal conditions at 950 °C followed by water quenching. A total of six samples were examined, varying in heating durations from 2 to 10 minutes for induction and 60 minutes for furnace treatment. A 4-minute induction process was found to be the most efficient, providing the highest surface hardness (647 HV), optimal martensitic depth (172.75 µm), and 33% lower energy consumption compared to the furnace-treated sample (613 HV). Microstructural analysis revealed a dense martensitic layer near the surface for induction-treated samples, while furnace-treated specimens exhibited a uniform ferrite–pearlite structure. This makes short-duration induction hardening a cost-effective and technically superior surface treatment strategy for medium-carbon steels.

The paper proposes an approach to design and implement a novel system based on induction heating principles in pressing plates used in rubber product manufacturing. This work aims to substitute a conventional heating system which uses heating energy through resistances radiation effect. The proposed system exhibits a better performance in terms of heating rate, energy saving, efficiency, temperature uniformity and pollution mitigation. To be able to reach an appropriate system in its primarily design stages, our study is focused on a low scale power experimental kit that emulates the industrial system counting for the generator as well as the heating load. The latter consists of a coil, metallic plate and a mold. Here, the heat is transferred by conduction effect through this metallic plate recipient of the eddy currents placed on the top of the coil, and supporting the mold containing the rubber material for processing. To support the merits of the study, an analytical approach based on energy evaluation, followed through a numerical coupled magnetic-thermal analysis. With regards to power supply, an electrical modelling simulation was performed to find the optimum power control parameters. In addition, the effect of the air-gap, flux concentrator, frequency and input power are investigated. The simulation results are compared to those determined on a low power testing bed for performance investigations. To consolidate the merits of our findings, an attempt is made to evaluate its performance in comparison to a similar workpiece, but based on resistance heating. The induction heating shows a higher efficiency with heating rate of about 31°C/min compared to 18°C/min in the heating resistance based under similar input power.

This study investigates the wear and high-temperature oxidation behavior of AISI 316L stainless steel (SS) subjected to two distinct aluminizing processes, hot-dip aluminizing (HDA) and slurry aluminizing (SA), both followed by rapid induction heating. The objective was to assess the efficiency of short-time induction heating as a diffusion treatment and to compare the resulting structural and functional properties of the coatings. Microstructural characterization was carried out by using SEM, XRD, and EBSD, while mechanical and tribological properties were evaluated by nanoindentation and wear testing. The HDA coating exhibited a uniform outer morphology, whereas the SA coating developed a lamellar structure due to localized thermal gradients during induction heating. Despite these morphological differences, both coatings consisted of Fe2Al5, FeAl, and α-Fe (Al) phases. The SA coating demonstrated a higher surface hardness (13.2 GPa vs 10.8 GPa for HDA) and a lower coefficient of friction (0.40 vs 0.52), resulting in a markedly lower wear rate (3.2 × 10-5 mm3/N·m vs 6.5 × 10-5 mm3/N·m). Isothermal oxidation at 1000 °C for 24 and 96 h revealed that both coatings transformed toward a protective α-Fe (Al) matrix with a continuous Al2O3 scale. However, the coating thickness increased more significantly in SA samples from 35 to 400 μm after 96 h compared to 230 μm for HDA, indicating superior Al diffusion kinetics in the SA process. Overall, the SA process combined with rapid induction heating exhibited superior wear resistance compared to the HDA route, whereas the HDA process combined with the same thermal treatment demonstrated enhanced oxidation resistance relative to the SA.

The growing demand for batteries, coupled with evolving regulatory requirements, calls for efficient and sustainable recycling strategies. The current industrial recycling method primarily relies on mechanical shredding, a multi-step process in which battery modules, cells and housings are fragmented. While this approach is cost-effective, it leads to a mixture of materials including valuable active components, complicating the separation and recovery. In contrast, dismantling-based processes enable a cleaner separation of battery components allowing the targeted extraction of the active materials prior to comminution, improving material purity and recovery yields. In this context, direct recycling has emerged as a promising alternative. Standing in conceptual and practical contrast to the shredding, direct recycling offers potential reduction in cost and CO2 emission gaining significant attention in recent years as a pathway towards a circular and sustainable battery life cycle.The study presents a systematic evaluation of three different separation processes for the recovery of the active materials from lithium-ion batteries, based on experimental investigations. Freshly produced electrodes as well as electrodes extracted from cycled pouch cells were used to assess the effectiveness of the different methods.An ultrasonic bath is used for a chemical separation of the electrode coating from the current collector by applying different solvents, varying temperatures and adjustable ultrasonic intensities. This approach aims to achieve an efficient and thorough detachment of the active material while optimizing the process parameters based on the specific electrode composition. By varying these factors, the separation efficiency can be enhanced, ensuring minimal damage to the recovered materials and improving their potential for reuse in new electrode coatings.A thermal separation is performed using induction heating, where the electrode is rapidly heated to the decomposition temperature of the binder, facilitating the detachment of the coating. The process is optimized to achieve efficient separation within short heating times while preventing thermal decomposition of both the active material and the current collector and ensuring a effective material recovery without compromising its reuse potential.In additon, a laser based ablation process is used to vaporize and degradate the binder, causing the electrode coating to detach from the current collector. Using various laser parameters, different ablation patterns are generated to achieve a clean separation without damaging the recovered active material. The optimization process focuses on ensuring a residue-free current collector while preserving the structural integrity of the separated particles.By correlating process properties of the separation processes with material quality and electrochemical cell properties obtained from cell test with recycled active material, this work enables a qualitive and quantitative evaluation of the separation processes.

Currently majority of metal additive manufacturing components in use rely on direct energy deposition and powder bed fusion, both of which have problems of residual stress, distortion from excessive heat input, difficulty in processing highly reflective materials like aluminium, and powder waste as a raw material. Induction heating can be used to address these problems in a wire additive manufacturing process that utilises induction heating’s potential. This paper evaluates the investigation of extruder material for printing aluminium through extrusion-based additive manufacturing. A pilot study has been conducted with four cases of extruders. In this context, an extruder manufactured solely from cast iron and a composite cast iron extruder incorporating three additional materials—alumina, quartz, and tungsten—were examined. The insert used for composite cast iron extruders is based on their low wettability with liquid aluminium. The extruder is an essential component of the system, and due to the highly reactive nature of metals like aluminium, care must be taken in choosing the extruder material. The extruder behaviour under induction heating has been investigated using FEM, and their applicability has been evaluated through experimentation. As a result of simulations and experiments, cast iron has been found suitable as a susceptor and tungsten as an insert material in composite extruder material for printing aluminium 5356 material among the four material cases taken for the study. The properties of tungsten, namely high thermal conductivity, high thermal shock resistance, and low wettability with liquid aluminium, made it suitable insert material for a composite extruder for printing Al5356 alloy.

This study proposes an efficient electromagnetic induction heating approach to overcome the limitations of conventional curing processes for carbon fiber reinforced polymer (CFRP) wound circular tubes, such as complex procedures, high energy consumption, and high cost. Two external heating configurations, namely the copying coil and the cover-type coil, are investigated through an electromagnetic–thermal coupled finite element model validated by experiments. The model reveals the eddy current distribution, heating behavior, and temperature field evolution under different coil structures. The relative standard deviation (RSD) is introduced to evaluate temperature uniformity, while rotating speed, coil turns, and output current are selected as key process parameters. A multi-objective response surface model is developed with RSD, maximum temperature ( T max ), and maximum temperature difference ( Δ T max ) as response variables. By integrating weighted decomposition and non-dominated sorting, the Egret Swarm Optimization (ESO) algorithm is extended for multi-objective optimization to determine the Pareto-optimal parameter set. Results show that the optimized parameters significantly improve temperature uniformity while maintaining sufficient heating performance. This work provides theoretical and methodological guidance for efficient and energy-saving induction heating curing of CFRP wound circular tubes.