Thermal analysis of twin-channel induction furnaces

Twin-channel induction furnaces (TCIFs) are used extensively in many processing industries due, mainly, to their relatively low operating costs. However, thermal stresses in the refractory lining caused by high temperatures during the loading cycle can cause erosion of the lining and premature inductor failure. Prevention of premature failure by close monitoring of the thermal regime of the inductor is very important to operators and relatively simple and reliable tools need to be developed to this end. The present work is an attempt to develop such a tool using thermal modeling software and unidirectional axial channel flow estimation from analysis based on the first law of thermodynamics. This avoids the complications and uncertainties associated with the coupled multiple field analysis approach. The results of the analysis show plausible agreement with the reported flow data and a comprehensive set of scenarios can be devised on the basis of the developed approach to simulate start-up, transient operation, and steady-state operation of TCIFs.