Hard carbon is now a popular choice for the anode material in sodium-ion batteries. Converting biochar to produce hard carbon is considered carbon neutral and of great interest since it reduces the environmental impacts of biomass waste. This procedure requires high temperatures, and induction heating provides several advantages over other heating methods and is, therefore, widely used. In this thesis, a thermochemical reactor based on the principle of induction heating is designed, and CFD simulations of fluid-thermal coupling are performed. According to the simulation results, the total energy use efficiency of the induction heating reactor is calculated and compared with that of the thermal conduction heating reactor, which is found to be much higher than that of the thermal conduction heating reactor. Furthermore, the temperature of the tube wall of the reactor and the power losses of the inlet and outlet are observed, and design improvements are suggested. Simulation results indicate that adding a layer of protector to the exterior of the workpiece effectively reduces the wall temperature and the effect would be greater as the thickness of the protector increases. Meanwhile, the change in efficiency and energy losses are essentially negligible. / Hårt kol är nu ett populärt val för anodmaterialet i natriumjonbatterier. Att omvandla biokol till att producera hårt kol anses vara kolneutralt och av stort intresse eftersom det minskar miljöpåverkan från biomassaavfall. Denna procedur kräver höga temperaturer och induktionsuppvärmning ger flera fördelar jämfört med andra uppvärmningsmetoder och är därför allmänt använd. I detta examensarbete designas en termokemisk reaktor baserad på principen om induktionsvärme, och CFD-simuleringar av fluid-termisk koppling utförs. Enligt simuleringsresultaten beräknas den totala energianvändningseffektiviteten för induktionsvärmereaktorn och jämförs med den för värmeledningsvärmereaktorn, som visar sig vara mycket högre än den för värmeledningsvärmereaktorn. Vidare observeras temperaturen på reaktorns rörvägg och effektförlusterna i inloppet och utloppet, och designförbättringar föreslås. Simuleringsresultat indikerar att att lägga till ett lager av skydd på utsidan av arbetsstycket effektivt minskar väggtemperaturen och effekten skulle bli större när tjockleken på skyddet ökar. Samtidigt är förändringen i effektivitet och energiförluster i stort sett försumbara.

This dissertation describes the electrochemical behavior of nickel and iron that was studied in different acid solutions via linear sweep voltammetry, cyclic voltammetry, and potentiostatic measurements over a range of temperatures at specific potential ranges. The presented work displays novel experiments where a nickel electrode was heated locally with an inductive heating system, and a platinum (Pt) electrode was used to change the proton concentration at iron and nickel electrode surfaces to control the periodic oscillations (frequency and amplitude) produced and to gain a greater understanding of the systems (kinetics), oscillatory processes, and corrosion processes. Temperature pulse voltammetry, linear sweep voltammetry, and cyclic voltammetry were used for temperature calibration at different heating conditions. Several other metal systems (bismuth, lead, zinc, and silver) also produce periodic oscillations as corrosion occurs; however, creating these with pure metal electrodes is very expensive. In this work, metal systems were created via electrodeposition by using inexpensive, efficient, coupled microelectrode array sensors (CMASs) as a substrate. CMASs are integrated devices with multiple electrodes that are connected externally in a circuit in which all of the electrodes have the same amount of potential applied or current passing through them. CMASs have been used for many years to study different forms of corrosion (crevice corrosion, pitting corrosion, intergranular corrosion, and galvanic corrosion), and they are beneficial because they can simulate single electrodes of the same size. The presented work also demonstrates how to construct CMASs and shows that the unique phenomena of periodic oscillations that can be created and studied by using coated and bare copper CMASs. Furthermore, these systems can be controlled by implementing external forcing with a Pt electrode at the CMAS surface. The data from the single Ni electrode experiments and CMAS experiments were analyzed by using the Nonlinear Time-Series Analysis approach.

The blast furnace process for the reduction of iron ore to pig iron faces problems such as emission of air pollutants, high investment cost and the current major problem of decreasing supplies of coke. Coke is used in large quantities to promote a combination of direct and indirect reduction within the furnace. Due to the lack of good coking coal within South Africa, and dwindling supplies worldwide, new iron-making processes, are being developed using coal and/or natural gas to replace coke as the reductant. The new processes allow efficient use of carbon, fed in the form of coal pellets (coalbased processes) or natural gas (gas-based processes), as the reducing agent. Presently, most coal-based processes Use an excess of coal, up to 500% stoichoimetric addition, and are run at temperatures up to ±1200°C, although reduction tends to proceed at ±850°C. This project developed a low temperature process using mixed pellets of fine waste iron oxide and fine domestic coal with a natural carbonaceous binder (a by-product from local pulping industry). Reduction tests performed on composite pellets in a tube furnace and thermobalance indicated, upon analysis by X-Ray Diffraction and Scanning Electron Microscope, that reduction occurred gradually at 900°C. Implementing induction heating of bulk pellets reduced heating times substantially. Induction heating also resulted in direct reduced iron [DRI] containing 75 - 80% metallic iron. Energy consumption based on coal usage amounted to 23.71 GJ/ton DRI, which compares with the calorific consumption of most coal-based processes, i.e. coal consumption range between 15 and 25 GJ/ton DRI. Energy consumed during induction heating amounted to 9.94 GJ/ton DRI, as electricity. This energy consumption value does not take into account the efficiency of the primary energy required to generate electricity. / Thesis (M.Sc.Eng.)-University of Natal, Durban, 2003.

Die vorliegende Arbeit untersucht den Einsatz einer induktiven Längsfelderwärmung im Wärmebehandlungsprozess der direkten Warmumformung automobiler Karosserieblechbauteile. Zur Charakterisierung des Erwärmungsvorgangs werden sowohl experimentbasierte Regressionsmodelle als auch ein FEM-Simulationsmodell entwickelt. Der Einfluss der induktiven Erwärmung auf die Ausbildung der AlSi-Beschichtung, die Widerstandspunktschweißbarkeit so-wie die Korrosionsbeständigkeit gefertigter Blechbauteile wird dargelegt. Abschließend wird ein Anlagenkonzept entwickelt, das durch den Einsatz der induktiven Längsfelderwärmung eine Verringerung der Erwärmungsdauer um etwa 50 % sowie eine Verkürzung der erforderlichen Ofenlänge um etwa 37 % ermöglicht. / The present thesis investigates the usage of longitudinal induction heating in the austenitization process of direct press hardening. In order to describe the induction heating procedure, experiment-based regression models as well as a FEM model are developed. The influence of an induction heating process on the properties of press hardened parts with aluminum-silicon coating is depicted. Therefore, resistance spot welding tests, paint adhesion tests and corrosion tests are performed. Finally, a heating concept for series production including a longitudinal induction heating is developed, which allows a decrease in heating time of about 50 % and a reduction of furnace length of about 37 %.

This thesis investigates a novel DC/AC resonant inverter of Induction Heating (IH) system presenting a Multilevel Neutral Point Clamped (MNPCI) topology, as a new part of power supply design. The main function of the prototype is to provide a maximum and steady state power transfer from converter to the resonant load tank, by achieving zero current switching (ZCS) with selecting the best design of load tank topology, and utilizing the advantage aspects of both the Voltage Fed Inverter (VFI) and Current Fed Inverter (CFI) kinds, therefore it can considered as a hybrid-inverter (HVCFI) category . The new design benefits from series resonant inverter design through using two bulk voltage source capacitors to feed a constant voltage delivery to the MNPCI inverter with half the DC rail voltage to decrease the switching losses and mitigate the over voltage surge occurred in inverter switches during operation which may cause damage when dealing with high power systems. Besides, the design profits from the resonant load topology of parallel resonant inverter, through using the LLC resonant load tank. The design gives the advantage of having an output current gain value of about Quality Factor (Q) times the inverter current and absorbs the parasitic components. On the contrary, decreasing inverter current means decreasing the switching frequency and thus, decreasing the switching losses of the system. This aspect increases the output power, which increases the heating efficiency. In order for the proposed system to be more reliable and matches the characteristics of IH process , the prototype is modelled with a variable LLC topology instead of fixed load parameters with achieving soft switching mode of ZCS and zero voltage switching (ZVS) at all load conditions and a tiny phase shift angle between output current and voltage, which might be neglected. To achieve the goal of reducing harmonic distortion, a new harmonic control modulation is introduced, by controlling the ON switching time to obtain minimum Total Harmonic Distortion (THD) content accompanied with optimum power for heating energy.

This thesis deals with numerical solution of an integral equation of the second kind with special singular kernel function related to induction heating. The numerical solution is based on collocation and Nyström methods. The idea of collocation methods is to choose a finite-dimensional space of candidate solutions (usually polynomials up to a certain degree). The Nyström methods are based on approximation of the integral in equation by numerical integration rule. This thesis describes and gives error estimates of both methods. Error estimates are compared to the exact solutions in simple cases.

La première partie de ce mémoire donne un panorama des trente années de recherche passées au sein de la R&D d’EDF dans le domaine du chauffage par induction dans l’industrie. Les différentes actions menées ont porté sur différentes thématiques : les travaux de modélisation numérique, l’expertise en chauffage par induction dans ses secteurs traditionnels, le développement de solutions innovantes dans d’autres secteurs industriels, La conduite de projet internes R&D puis projets externes avec des financements publics français ou européens, le rayonnement international et le soutien aux jeunes.La deuxième partie présente une synthèse des travaux scientifiques les plus marquants qui ont abouti à la réalisation d’un logiciel d’optimisation des installations de chauffage par induction de billettes afin d’en améliorer les performances énergétiques. La modélisation numérique du chauffage est abordée en 1D par le couplage entre un calcul électromagnétique par la méthode des éléments finis et pas à pas dans le temps et un calcul thermique transitoire par la méthode des différences finies implicites. Le domaine de validité du modèle 1D a été étendu par la mise en place de coefficients correctifs sur le champ magnétique. Les travaux concernant l’inducteur permettent de décrire précisément leur comportement électrique (résistance) et thermique (refroidissement) ; une solution de récupération est même proposée. La modélisation simplifiée de l’onduleur à résonance alimentant l’inducteur permet de décrire son comportement global sans devoir entrer dans les détails de fonctionnement de l’électronique de puissance : suivi de la fréquence de résonance du circuit oscillant, adaptation des consignes à l’impédance du circuit et aux limitations du générateur. Les données électromagnétiques des matériaux et leur évolution avec la température sont mesurées à l’aide d’un équipement conçu sur-mesure. Ces différents travaux sont validés par comparaison avec des modèles numériques plus complexes et avec des expérimentations. Des processus d’optimisation énergétique de la chauffeuse ont été élaborés agissant, soit sur les paramètres électriques de la ligne, soit sur la conception d’un nouvel inducteur.Mémoire de doctorat présenté dans le cadre de la « Validation des Acquis par l’Expérience » / The first part of this dissertation gives an overview of thirty years of research work done in the frame of EDF R&D Division in the domain of industrial induction heating. The different works concerned many themes: numerical modelling, expertise in induction heating in conventional sectors, development of innovative solutions in other industrial sectors, project management inside EDF first, then collaborative projects with French or European financial support, international recognition and support for young researchers.The second part shows a summary of the most relevant scientific works which leaded to a software of billet induction heating optimisation in order to improve its energy efficiency. Numerical modelling is approached in a 1D configuration, coupling an electromagnetic model using a finite elements and step by step in time method with a thermal transient model using an implicit finite difference method. The validity domain is extended thanks to the use of an attenuation coefficient applied to the magnetic field. Works regarding inductor allows to describe more accurately the electrical (resistance) and thermal (cooling) behaviour; a solution for energy recovery is also proposed. The simplified model of the resonant inverter supplying the inductor allows to describe globally its behaviour without going deep in the details of the power electronics: following the resonant frequency of the oscillating circuit, adapting the set points to the circuit impedance and the power supply limitations. Electromagnetic physical data of metals and their evolution with temperature are measured with a tailor-made equipment. All these works are validated by comparison with more complex numerical models or with experiments. Energy optimisation procedures for the heating device are developed, acting either on the line electrical parameters or on the design of a new inductor.PhD dissertation presented in the frame of the “Validation of Professional Experience”

Dans un contexte de réduction des émissions de CO2 dans les systèmes industriels et d’amélioration de leur efficacité énergétique, les chauffages par induction répondent à ces critères. Le procédé consiste à plonger un corps conducteur d’électricité dans un champ magnétique variable, induisant ainsi des courants au sein de la pièce qui se met alors à chauffer par effet Joule. Cette technologie présente l’avantage d’atteindre des températures élevées de manière précise et rapide, sans contact avec la source d’énergie. Si aujourd’hui le contrôle de tels procédés passe par la structure mécanique du chauffage, de nombreuses études ont montré que l’association de plusieurs bobines alimentées par des systèmes d’électronique de puissance fournit une souplesse dans le contrôle des profils de température et une flexibilité vis-à-vis des pièces traitées. Ce travail présente deux systèmes de chauffage par induction. Le premier est un prototype réalisé par EDF considérant trois inducteurs alimentés par trois onduleurs à résonance. Nous nous y intéresserons plus particulièrement par la suite. Le second, en cours de réalisation, met en jeu six inducteurs pour du chauffage au défilé. Leurs caractéristiques, leurs alimentations et leurs fonctionnements sont abordés pour ensuite mettre en place deux modélisations des phénomènes électriques, l’une sous forme de fonctions de transfert, la seconde dans l’espace d’état. L’objectif final est le développement d’une alimentation auto-adaptative capable de contrôler en temps réel le profil de puissance injecté dans les pièces à chauffer afin d’atteindre un profil de température requis avec le minimum d’énergie consommée. L’étude se poursuit avec un inventaire des solutions existantes en termes de commande en boucle ouverte et en boucle fermée des systèmes mono-inducteurs, ainsi que des travaux, plus rares, pour les chauffages multi-inducteurs. De plus, des études ont montré que le contrôle de la température à la surface d’une pièce à chauffer passait par le contrôle des courants dans les inducteurs, en amplitude mais également en phase. C’est pourquoi nous proposons des lois de commande pour asservir les courants dans les inducteurs. Une routine d’optimisation fournit les amplitudes et les phases des courants dans les trois inducteurs permettant d’obtenir le profil de température le plus proche d’un profil de référence. Nous l’avons modifiée de façon à tenir compte de solutions énergétiquement optimisées en intégrant les pertes dans les interrupteurs et les inducteurs. Deux lois de commande originales sont proposées. La première étudie une commande robuste dans l’espace d’état par placement de vecteurs propres. La seconde met en jeu des correcteurs résonants qui confèrent à la boucle du système un module de gain infiniment grand à la fréquence de résonance de sorte qu’ils effacent les effets des perturbations agissant à cette même fréquence. Les méthodes de synthèse de ces correcteurs sont échantillonnées avec un très faible rapport fréquence d’échantillonnage/fréquence de résonance ; les performances sont détaillées et analysées pour le prototype à trois inducteurs. Pour tester plus facilement et valider en partie les lois mises en place, un simulateur analogique a été conçu, sorte d’émulateur reproduisant le comportement des courants dans les inducteurs et des tensions à leurs bornes. Il se base sur la modélisation sous forme de fonctions de transfert et ne comprend donc pas d’onduleur. Par l’intermédiaire d’une carte dSPACE intégrant un DSP, nous avons implanté et validé les deux lois de commande robustes sur le simulateur analogique. Par la suite, pour se rapprocher du système réel, nous avons mis en place une commande rapprochée transformant les trois signaux de commande en sortie des correcteurs vers les rapports cycliques des douze interrupteurs des convertisseurs alimentant les inducteurs. Cette étape a été validée par des essais expérimentaux réalisés en parallèle de nos études. / In the context of reducing carbon dioxide emissions in industrial systems and improving their energy efficiency, induction heaters meet these criteria. The method consists in immersing an electrically conductive body in a variable magnetic field, inducing currents within the piece which then begins to heat by Joule effect. This technology has the advantage of reaching high temperatures accurately and quickly, without contact with the power source. Today the control of such works with mechanical structures. But many studies have shown that the combination of several coils supplied by electronic power systems provides flexibility in controlling temperature profiles and flexibility towards the treated parts. This paper presents two systems of induction heating. The first is a prototype made by EDF considering three inductors supplied by three resonant inverters. We will focus more specifically later on this prototype. The second one, in progress, involves six inductors for scrolling heating. Their characteristics, their power supplies and their functions are discussed and then set up two models of electric phenomena, one form of transfer functions and one form in the state space. The final objective is the development of a self-adaptive power able to control real-time power profile injected into parts of heating to achieve a temperature profile required with minimum energy consumption. The study goes on with a list of existing solutions in terms of open-loop control and closed-loop control for single inductor system, as well as few rarer works for multi-inductors heaters. In addition, studies have shown that control of the surface temperature of the piece to be heated passes by the control of currents in the inductors, in magnitude but also in phase. That is why we propose control laws for controlling inductor currents. An optimization routine provides the magnitudes and phases of the currents in the three inductors to obtain the temperature profile closer to a reference profile. We modified it to take into account energy optimized solutions by integrating the losses in the switches and inductors. Two original control laws are proposed. The first one studies a robust control in the state space by placing eigenvalues and eigenvectors. The second one involves resonant markers that give the system loop gain module infinitely large at the resonant frequency so that they erase the effects of disturbances acting at the same frequency. The methods of synthesis of these markers are sampled with a very low sampling frequency / resonant frequency ratio; performance are detailed and analyzed for the prototype with three inductors. So as to test and validate easily some of the studied laws, an analog simulator was designed, a kind of an emulator, which reproduces the behaviour of the currents in the coils and the voltages at their terminals. It is based on the transfer function model and therefore does not include inverters. Through a dSPACE card integrating a DSP, we have implemented and validated the two robust control laws on the analog simulator. Thereafter, in order to be closer to the real system, we have established a close control which turns the three control signals toward the duty cycles of the twelve switches of the converters supplying the inductors. This step was validated by experimental tests carried out in parallel with our studies.

No description available.

This thesis is a part of the research work for Azelio TES.POD (Thermal energy storage. power on demand). It is a patented thermal energy storage system developed by Swedish cleantech company Azelio AB. The objective of this thesis work to find an alternative charging technology system that can be validated to be efficient and safe in operation for the charging of TES.POD. Induction heating technology is chosen as an alternative charging solution. Derived design steps to implement induction heater as a charging unit then selection of PCM container compatible with induction heater. Later simulating to evaluate total flux path in Finite Element Method Magnetics (FEMM) simulation tool which proposes the electrical results. The electrical performance of the induction heater indicates almost 9% higher electrical losses than the charging mechanism of the existing TES.POD design. However, from a safety standpoint, the alternate charging approach appears to be safer in operation than the existing system. Additionally, it reflects better intuitiveness from a manufacturing viewpoint.