Radio-Frequency Induction Heating for Green Chemicals Manufacture: A Systematic Model of Energy Losses and a Scale-up Case-Study

Radiofrequency (RF) induction heating has generated much interest for the abatement of carbon emissions from the chemicals sector as a direct electrification technology. Three challenges have held back its deployment at scale: reactors must be built from nonconductive materials which eliminates steel as a design choice; the viability of scale-up is uncertain; and to date the reported energy efficiency has been too low. This paper presents a model that for the first time makes a comprehensive analysis of energy losses that arise from RF induction heating. The maximum energy efficiency for radio frequency induction heating was previously reported to be 23% with a typical frequency range of 200–400 kHz. The results from the model show that an energy efficiency of 65–82% is achieved at a much lower frequency of 10 kHz and a reactor diameter of 0.2 m. Energy efficiency above 90% with reactor diameters above 1 m in diameter are predicted if higher voltage radio frequency sources can be developed. A new location of the work coil inside of the reactor wall is shown to be highly effective. Losses arising from heating a steel reactor wall in this configuration are shown to be insignificant, even when the wall is immediately adjacent to the work coil. This analysis demonstrates that RF induction heating can be a highly efficient and effective industrial technology for coupling high energy demand chemicals manufacture electricity from zero carbon renewables.