In the plastics processing industry, energy consumption is a key challenge for companies to control costs and green manufacturing. Conventional resistive heating methods have problems such as low heating efficiency, high thermal energy loss and slow response of temperature control, making it increasingly difficult to meet the demands of high efficiency and energy saving in modern production. Meanwhile, the advent of industrial electromagnetic heaters has brought significant energy savings and performance improvements to the plastics processing machinery industry.
The following is a deep analysis of how electromagnetic heating helps the plastics processing machinery industry to produce highly efficient, energy-saving products in terms of operating principles, energy-saving mechanisms, performance advantages and practical application examples.
1. Working principle: from "external heat" to "internal heat"
Conventional plastic processing machines (extrusion machines, injection molding machines, granulation machines, etc.) generally use resistance wires or ceramic heating coils to transfer heat to the material tube by contact heating. Due to the long thermal conduction path and the intense heat dissipation from the surface, the actual thermal energy utilization is often less than 70%.
On the other hand, electromagnetic heating technology is completely different. A high frequency alternating current generates a magnetic field in the heating area, inductively heating the metal material tube itself, and "metal self-heating" is realized. This non-contact induction heating method has an energy conversion efficiency of more than 90% and significantly reduces heat loss because heat is generated directly inside the cylinder.
Simply put:
Resistance heating: external heating to heat conduction, thereby increasing internal temperature
Electromagnetic heating: Direct internal heating without the need for thermal conduction, resulting in higher energy utilization efficiency
Second, energy saving mechanism: reduce energy consumption from the root
Electromagnetic heaters can significantly improve the energy utilization of plastic processing machines, mainly in the following aspects.
1. Reduce heat loss
Induction heating generates heat directly inside the metal cylinder, so there is almost no heat dissipation to the outside. By covering the surface with insulation, heat can be effectively trapped and heat loss can be reduced by approximately 60%.
2. Improve heating speed
The heating speed of electromagnetic heating is two to three times that of resistance heating, and it can reach the set temperature in a short time, which reduces the start-up standby time and improves the equipment utilization rate.
3. Dynamic energy saving operation
By adopting the PID intelligent temperature control module, the system can automatically adjust the output according to the production load and "supply energy as needed", avoiding power consumption due to long periods of full-load operation.
4. Reduce cooling burden
The external temperature rise of electromagnetic heating is low, which reduces the environmental temperature of the production plant, and reduces the energy consumption of the cooling system, which indirectly leads to energy saving.
Comprehensive statistical data shows that when an electromagnetic heating system is adopted in a plastic extruder or injection molding machine, the overall energy saving rate generally reaches 30% to 60%, and even exceeds 70% in some high-temperature environments.
Third, performance improvement: not only save power
In addition to energy saving, electromagnetic heating also offers excellent performance in terms of production stability and product quality.
1. Improved temperature control accuracy
Electromagnetic heating has a fast response rate, high temperature control accuracy, temperature variation within ±1 ° c, uniform melting of plastic, and improved product quality.
2. Extend equipment life
The non-contact heating method eliminates mechanical wear between the coil and the material tube, extends the life of the heating coil more than three times and reduces maintenance frequency.
3. Improving the working environment
The low surface temperature of electromagnetic heating, no grills and no radiation improves the temperature of the working environment and reduces the labor intensity.
4. Improve system safety and stability
The control system has multiple protection features such as over temperature, over current and out of phase, making operation more reliable.
Fourth, practical application examples: remarkable energy saving effect
For example, when a 75mm plastic extrusion line was used with a traditional resistive heating system, the total output of the entire line was about 36kW. After the conversion to a three-phase 380V electromagnetic heating system with a total output of 30kW, the actual operation results are as follows.
Heat rise time: reduced from about 50 minutes to 20 minutes, saving preheating time by about 60 percent.
Energy consumption: power savings of around 42% on average for the same production volume are achieved, and electricity costs are significantly reduced in long-term operation.
Surface temperature: the surface temperature of the material tube dropped from 120 ° c to below 50 ° c, improving the working environment on the site.
Product stability: the melt became more uniform, the variability of material flow decreased, and the failure rate of production decreased.
Investment payback period: assuming 12 hours per day and 330 days of operation per year, electricity bills can be saved by approximately 50,000 yen (about U.S. $50,000), and the investment for facility remodeling can be payback within six months.
These data clearly demonstrate that electromagnetic heating not only significantly increases energy efficiency, but also provides long-term economic benefits for companies.
Fifth, summary: energy saving environmental protection new engine
With the promotion of the "peak carbon emission and carbon neutral" policy and rising energy costs, electromagnetic heating technology has become the best choice for energy-efficient retrofitting in the plastic processing machinery industry.
Electrimagnetic heating can not only significantly improve the energy efficiency, but also optimize the production process, extend the life of the equipment, improve the working environment, and make the plastic processing machine industry intelligent and an important step in green production. It's going to be.
In the future, through the integration of control system and IoT technology, the smart electromagnetic heating system can realize remote monitoring, energy consumption analysis and failure prediction, and help plastic processing machinery enterprises to realize the new high efficiency, low consumption and intelligent production It is expected to enter the stage.
