Device for Forming a Hot Process Gas Flow

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This patent describes a device for creating a hot process gas flow using electrically powered induction heating. The system uses non-linearly wound electric coils around a heating element, allowing precise temperature control of the process gas (such as air, inert gases, or mixtures) to very high levels—well above 1000°C—without burning fossil fuels. The novel coil arrangement enables higher energy input where the incoming (colder) gas has stronger cooling effects, resulting in more homogeneous and efficient heating. The device can replace traditional gas burners, providing a decarbonized source of high-temperature process gas for industrial applications.

Use CasesContent extracted from patent full text and abstract with AI.

• Metallurgical processes such as melting and holding metals and glass.
• Heating of industrial furnaces and ovens for heat treatment of materials.
• Thermal treatment of bulk materials and components in manufacturing.
• Decarbonized replacement for gas-fired burners in various industries.
• Production processes where precise, high-temperature gas streams are needed.
• Applications requiring controllable and homogeneously heated process gas, such as specialty chemical manufacturing.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables process gas heating beyond 1000°C (up into MW power range), surpassing limitations of traditional electric heaters.
• Decarbonizes industrial heating processes by eliminating the need for fossil-fuel-based burners, thus reducing CO₂ emissions.
• Improved efficiency due to tailored coil winding densities, reducing energy waste and achieving uniform heating.
• Highly flexible and controllable system—temperature and gas flow can be precisely regulated.
• Material selection and construction reduce mechanical stress and extend device lifespan at high temperature.
• Can handle a variety of process gases, including inert or air, allowing adaptation to different heating needs.
• Supports sustainable industry by enabling electrification of high-temperature processes.

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Inventors & Applicants

Patent Abstract

A heating element (1) having at least one flow channel (11), through or around which the process gas flows, is provided in the device housing (2). At least one non-linearly wound electric coil (3) that is connected to an electric voltage source is arranged in the housing (2), and/or at least two electric coils (3a, 3b) are successively arranged on the outer side of the housing (2) and connected to an electric voltage source. The first electric coil (3a) is operated at a higher electric power than the at least one additional electric coil (3b). The number of windings of an electric coil (3) is selected such that in the first third of the length of the at least one heating element, at least 25 % more power can be inductively coupled into the heating element than in the region of the output (6), or in the event that at least one first electric coil (3a) and an additional electric coil (3b) are used, by means of the first electric coil (3a) at least 25 % more power can be coupled into the heating element (1) than in the region of the output (6).