Adoption of Induction Heated Rolls to Reduce Energy Consumption and Improve Quality Presented by: Michael C. Rice General Manager Tokuden, Inc.
Adoption of Induction Heated Rolls to Reduce Energy Consumption and Improve Quality
Aug 18, 2015
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Adoption of Induction Heated Rolls to
Reduce Energy Consumption and
Improve QualityPresented by:
Michael C. RiceGeneral Manager
Tokuden, Inc.
OverviewEnergy Requirements
Induction Heating Principle
Heat Pipe Principle
Roll Surface Temperature Detection
Work Environment & Review
Applications
IHJR Oil Heated Roll0
2
4
6
8
10
12 Energy Requirements
Oil PumpThermal Loss from Oil HeaterThermal Loss from Piping
Roll and Load
Heat Exchanger
Oil Heated Roll
Oil Heate
r
Pump
T0
T1 T2
T3
Piping Thermal Loss-1 T0: 220⁰C Outlet Temperature from Oil Unit T1: 219⁰C Inlet Oil Temperature to Roll T2: 210⁰C Outlet Temperature from Roll T3: 209⁰C Inlet Temperature to Oil Unit
Piping Thermal Loss-2
Oil Fluid Flow Rate: 670L / min.Oil Specific Heat: 0.5 kcal / kg ⁰COil Specific Gravity: 900 kg / m^3 Q1 = 0.670 x 60 x 900 x 0.5 x (220-219) + 0.670 x 60 x 900 x 0.5 x (210-209) = 36,180 kcal / hr. = 42 kW
Circulation PumpThe Induction-Heated JACKET ROLL® does not require a Circulation Pump; therefore, the purchase cost is eliminated and the overall operating cost is reduced. In the above example, the pump consumed over 10 KW for the oil circulation of 670L / min.Q2 = 10 kW
Radiation from the Oil UnitEven with thermal insulation, the tank surface had some radiation loss. With a surface area of 50m^2, the surface temperature was 60⁰C. In this case, the radiation loss was as follows: Q3 = 4.88E-8 x e x {(T1 +273)^4 –(T2 +273)^4} x S / 860 = 0.0000000488 x 0.5 x {(60 + 273)^4-(20 + 273)^4} x 50 / 860 = 7 kW
Radiation from the JournalsJournals of oil-heated rolls have a temperature similar to that of the roll shell surface. Induction heats only the roll shell, and the journals heat up by conduction from the roll shell. Journal temperatures of an induction heated roll are approximately half of the roll shell surface temperature. Calculating the exact amount of thermal loss is dependent on the journal design/dimensions.
ResultsPiping Loss: Q1=42 kWPump Consumption: Q2=10 kWThermal Loss from the Oil Unit: Q3=7 kWQ = Q1+Q2+Q3 = 59 kW In the example above, a total of 248 kW were consumed. Of that, 24% was wasted energy.
Further, Air Conditioners required to offset the heat released to the working environment were high energy consumers.
OverviewEnergy Requirements
Induction Heating Principle
Heat Pipe Principle
Roll Surface Temperature Detection
Work Environment & Review
Applications
Induction Heating Principle
K-Thermocouple
Induction Coil
Involute Core
Jacket Chamber
Temperature Detecting
Rotary Transforme
r
OverviewEnergy Requirements
Induction Heating Principle
Heat Pipe Principle
Roll Surface Temperature Detection
Work Environment & Review
Applications
Jacket ChamberHeader
Heat Pipe Principle-1
Heat Pipe Principle-2
TA = TB > TC and PA = PB >
PC
200
220
240
260
280Oil-Heated Roll
Temp. (⁰F)
3550mm Working Face
200
220
240
260
280Energy Efficient Alternative
Temp. (⁰F)
3550mm Working Face
610mm OD Oil 400mm OD Induction
Web Temperature
610mm OD Oil 400mm OD Induction
Roll Surface Temperature (Axially)
249
250
251
Temp. (⁰C)
Factory Data
40
50
60
70
80
90
100
110
120
130
140
150
160(℃）
1500mm OD x 2100mm FL without Jacket Chamber
External Induction Coil 510mm Wide
140
150
160
170
180
190
200
210
220
230
240
250
260(℃）
1500mm OD x 2100mm FL with Jacket Chamber
External Induction Coil 510mm Wide
OverviewEnergy Requirements
Induction Heating Principle
Heat Pipe Principle
Roll Surface Temperature Detection
Work Environment & Review
Applications
Roll Surface Temperature Detection
K-Thermocouple
Temperature Detecting Rotary Transformer
OverviewEnergy Requirements
Induction Heating Principle
Heat Pipe Principle
Roll Surface Temperature Detection
Work Environment & Review
Applications
Work Environment
Precise Temperature Control:Induction Heating Technology &
Temperature Detection System
Uniform Temperature Profile: Jacket Chamber Technology
Wide Operating Temperature Range: 40 - 400⁰C
Mechanical Accuracy maintained during Operation: Induction Heating & Jacket Chamber Technology
Review-1
Energy Savings, Clean Environment and Safety: Smallest Heat Loss and No Oil Leak
Induction Coil is Stationary: No Slip Ring to Supply Electrical Power
Power Source is Commercial Frequency 50/60 Hz:
No Inverter, No Noise Protection
Journal Temperature much lower than Roll Surface:
Bearing Lifetime Increased
Less Maintenance
Review-2
OverviewEnergy Requirements
Induction Heating Principle
Heat Pipe Principle
Roll Surface Temperature Detection
Work Environment & Review
Applications
Packaging Films Printed Circuit Boards Battery Materials
Laminating
Nonwovens
Papers
Textiles
Battery Materials
Calender/Press
Stretching
& Drying
Plastic Films
BC Fibers
Aramids
CF Precursor
Q & AGot
Induction??
TOKUDEN, INC.www.tokuden.com
Presented by:Michael C. Rice
General ManagerTokuden, Inc.
Thank You!
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