High power super electrical heater reflectors usable in electrical furnaces Simulation and optimization for power loss reduction

Super heater elements concentrated in very high and clean power at temperature up to 1800 ºc is needed for aluminum melting, oil drying equipment using for power transformers and same that material. There fore, always it is need to minimize power consumption and increase effectiveness at power reflector customers. This means to minimize heat losses in the High Power Reflector, and to optimize heat performance with respect to output power and temperature distribution. This can be done by altering the size and form of the insulating ceramic fiber to have as much power as possible 'reflected' out from the module. It can also be done by altering the size and form of the element. It has been done and the t ask solved mainly by heat transfer simulations, using COMSOL and MATLAB software’s. To minimize the number of different designs (and thus the number of calculations) were studied; it is also done that statistical methods for experimental design used to determine which designs should be used in the calculations. When an optimal solution has been found, for verification, it has been tested at Kanthal's facilities, with two reference designs.

Keywords:

reflector , simulation , element