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<p>In response to the high costs, frequent failures, and low efficiency of conventional medium-to-high frequency electromagnetic heaters, this study introduces a novel water-cooled, power–frequency, high-voltage, high-power electromagnetic coupling heating unit. The design operates directly at power frequency, fundamentally eliminating the dependence on vulnerable and expensive power electronic converters while providing a highly reliable alternative for large-capacity industrial heating. A 10&#xa0;kV/1&#xa0;MW electromagnetically coupled heating unit was designed and numerically evaluated through 3D transient electromagnetic-thermal coupled simulations. The results demonstrate that the output medium temperature meets the 100&#xa0;°C requirement with a heating efficiency of 95.7%. Two key innovations were implemented to further enhance performance. First, a water-cooled primary winding recovers waste heat from winding losses to preheat the heating medium, boosting the thermal efficiency by an additional 1.4%. It is estimated to save approximately $8780 in annual operating costs, while simultaneously extending the unit’s lifespan by mitigating temperature rise. Second, to improve thermal uniformity, a turbulence ring was integrated into the pipeline, successfully reducing the medium’s maximum temperature differential from 60 to 36&#xa0;K. In conclusion, the proposed power–frequency unit offers an inherently simpler, more cost-effective, and reliable design. The integration of the water-cooling system and turbulence ring significantly elevates its heating efficiency. This technology exhibits substantial potential to supersede existing electromagnetic heaters and electrode boilers, providing critical theoretical and practical insights for the advancement of high-voltage, high-power electromagnetic heating applications.</p>

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Water-cooled power frequency high voltage and high-power electromagnetically coupled heat generation unit and structural optimization

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Feng Zhou,
  • Zhenyang Wen,
  • Dali Zhang,
  • Xin Tong

摘要

In response to the high costs, frequent failures, and low efficiency of conventional medium-to-high frequency electromagnetic heaters, this study introduces a novel water-cooled, power–frequency, high-voltage, high-power electromagnetic coupling heating unit. The design operates directly at power frequency, fundamentally eliminating the dependence on vulnerable and expensive power electronic converters while providing a highly reliable alternative for large-capacity industrial heating. A 10 kV/1 MW electromagnetically coupled heating unit was designed and numerically evaluated through 3D transient electromagnetic-thermal coupled simulations. The results demonstrate that the output medium temperature meets the 100 °C requirement with a heating efficiency of 95.7%. Two key innovations were implemented to further enhance performance. First, a water-cooled primary winding recovers waste heat from winding losses to preheat the heating medium, boosting the thermal efficiency by an additional 1.4%. It is estimated to save approximately $8780 in annual operating costs, while simultaneously extending the unit’s lifespan by mitigating temperature rise. Second, to improve thermal uniformity, a turbulence ring was integrated into the pipeline, successfully reducing the medium’s maximum temperature differential from 60 to 36 K. In conclusion, the proposed power–frequency unit offers an inherently simpler, more cost-effective, and reliable design. The integration of the water-cooling system and turbulence ring significantly elevates its heating efficiency. This technology exhibits substantial potential to supersede existing electromagnetic heaters and electrode boilers, providing critical theoretical and practical insights for the advancement of high-voltage, high-power electromagnetic heating applications.