Optimal Design of Internal Induction Coils
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Optimal Design of Internal
Induction Coils
Dr. Valentin Nemkov
Eng. Robert Goldstein
Dr. Vladimir Bukanin
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Types of Inductors for Internal
Surface Heating (ID Coils)
• Inductor with Central Rod
• Hairpin
• Single Turn Cylindrical
• Multi-Turn Cylindrical
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Inductor
with
Central Rod
Hairpin
Inductor
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Multi-Turn
Cylindrical
Single-Turn
Cylindrical
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Equivalent Magnetic Circuit
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Pipe ID Heating
Lw = 5.6 cm Lw = 3.0 cm
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Case Study Conditions
• Pipe – Non-magnetic Stainless Steel
– ID = 5.6 cm, OD = 6.9 cm, length = 3.0 cm (short) or 5.6 cm (long)
• Coil – 4 turns 6.4 cm square copper tubing
– Concentrator Fluxtrol 50 vs. Air
• CS Program Flux 2D – Does Not Include Return Leg
• Frequency 10 kHz
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Results of Study
Part length Core Pole U I ΔPc Psteel Ptotal η cosφ S
55.9 mm y y 33.6 900 1685 8837 10522 84.0% 0.348 30240
55.9 mm y n 32.3 1190 2512 8878 11390 77.9% 0.296 38437
55.9 mm n n 32.9 2000 4168 9285 13453 69.0% 0.204 65800
30 mm y y 30.9 790 1242 8126 9368 86.7% 0.384 24411
30 mm n n 30.2 1760 3179 8282 11461 72.3% 0.216 53152
Results do not consider return leg
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Case Study of Magnetic Core Design
• Pipe
– Non-magnetic Stainless Steel
• Coil
– 4 turns 6.4 cm square copper tubing
– Concentrator Fluxtrol 50 vs. Air
• CS Program ELTA – Takes into account whole circuitry
• Frequency 10 kHz
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Influence of Return Leg
Case Core Core Uind Iind Pind η cosφ Sind Ugen
Gap (mm) (V) (A) (kW) (kVA) (V)
1 No NA 132 1350 34 55% 0.19 178 480
2 Yes 0 220 568 25.4 77% 0.22 125 760
3 Yes 1 138 570 25.4 77% 0.36 78 460
Coil Head Voltage 85 V for All Cases
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Conclusions • Magnetic Flux Controllers Drastically Improve ID
Coil Performance
• Magnetic Flux Controller Should Consist of a Core and Poles for Optimal Performance
• Losses in Return Leg are Usually Small
• Voltage Drop due to Return Leg May Be High
• Proper Design of Magnetic Core Essential for Optimal Performance
• ID Coil Parameters May Be Found Quickly and Accurately Using ELTA Program