High power reflector simulation to optimise electrical energy consumption and temperature profile

The high power reflector is a new heating solution for use in high power heating systems. It consists of a vacuum formed ceramic fibre hood with an integrated Kanthal® Super ceramic heating element. This paper describes simulations that have been performed to optimise characteristics of the high power reflector with respect to output heat power and temperature distribution. The main motivation for this task is to use this system in the annealing furnaces of Surahammar Bruks AB. Simulations of heat transfer were performed with different reflector configurations in the COMSOL® software environment. We examined six different types of proposed reflector using a two dimensional model approach. The temperature variations with distance above the reflectors and the temperature profiles in surfaces 20 cm above the elements were simulated. Optimum shapes and dimensions were found that produced the highest peak temperature, mean temperature, and uniform temperature distribution in the surface above the element. 3D simulations were performed to verify the accuracy of the 2D simulations. The maximum difference between the 2D and 3D results was about 5%. The results showed a satisfactory fit with average furnace temperatures.