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16 3-digit Nrth American Industrial Classificatin System (NAICS) Electr-Technlgy Fd 311 Beverage & Tbacc 312 Textile Mills & Prducts 313; Textile Prduct Mills 314 Clthing Mfgrs 315 Leather & Allied 316 Wd Prducts Manuf 321 Paper 322 Printing & Related 323 Petrleum & Cal Prducts 324 Ind HP & MVR H H M L L H M L M M Chemical Mfg'g 325 Infrared M M H M M M H H M M Inductin L L M L L L L L L M Radi-Frequency M M H L L M M L L L Micrwave H M L L L L L L L M Direct Resistance M L L L L L L L L L Indirect Resistance H M M M M M M M M M ltavilet L L M L L M M H L L LEGEND: - Applicatin Ptential H = High M = Medium L = Lw

17 3-digit Nrth American Industrial Classificatin System (NAICS) Electr-Technlgy Plastic & Rubber 326 Nn-Metallic Mineral Prducts 327 Primary Metal Mfg 331 Fabricated Metal Prducts 332 Machinery Mfg 333 Cmputer & Electrnic Prduct Mfg 334 Elect Equip, Appliances & Cmpnents 335 Transprtatin Equipment Mfg 336 Furniture and Related Prducts Mfg 337 Ind HP & MVR L L L L L L L L L L Misc Mfg'g 339 Infrared H H M H H H H H M H Inductin M M H H H M H H M M Radi-Frequency H L L H H L H L M L Micrwave M M M L L L H L L L Direct Resistance L M H H M M M M M M Indirect Resistance M M M H M M M M M M ltavilet M L L H H H H H M M LEGEND: - Applicatin Ptential H = High M = Medium L = Lw

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30 Infrared Emitters Range Near infrared Intermediate infrared Far infrared Emitter Pwer Operating Temperature Maximum prduct temperature Tungsten filaments under vacuum Glass r quartz lamp 150 W 250 W 375 W Quartz tube with reflectr cm: 500 W cm: 1000 W cm: 5000 W Nickelchrmium wire in quartz r silica cm: W 2000 C 2200 C Quartz tubes:1050 C Silica panels: 650 C 300 C 600 C Quartz tubes: 500 C Silica panels: 450 C Steelclad elements W Elements embedded in Pyrex r ceramic W 750 C Pyrex panels: 350 C; Ceramic elements: 300 t 700 C 400 C Pyrex panels: 250 C; Ceramic elements: 500 C Reprduced with permissin f Hydr-Quebec

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35 Drying f a Mlded Pulp Prduct Parameter Infrared Furnace Cnvectin Furnace Primary Energy Electricity Prpane Drying Prcess Infrared/cnvectin Cnvectin Installed pwer 1 MW 1.1 MW equivalent Air temperature 150 C average Overall efficiency > 80% ~ 45% Drying Time ~ 9 minutes ~15 minutes Specific energy cnsumptin 0.85 kw/kg water evaprated 1.35 kwequiv /kg water evaprated Adapted frm Reference 1

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45 Ht Frging f Billets 30,000 Tns / year; 4,000 hrs per year Parameter Inductin Gas furnace Relative installatin cst 3 1 Heating Efficiency 60% 15% Material lsses 0.75% 3% Relative labur 1 2 Relative annual perating cst Adapted frm Reference 1

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65 System cnfiguratin Vulcanizing Rubber Extrusins Parameter Micrwave System Salt Bath System Cntinuus micrwave Cntinuus mlten salt heating (2450 MHz) with bath ht-air sectin Heating sectin length Operating Temperature Prcess Start up Heat transfer Extrusin size limitatins Micrwave sectin: 2.8 t 8.8 m Ht-air sectin: 6.6 m Ht-air temperature: up t 260 O C Near instant startup and heating Vlumetric heating, suitable fr thick crsssectins Crss sectins f up t abut 200 mm 2 Tank Length: 7 t 15 m Salt bath temperature: 200 t 250 O C Apprx. 2 hrs f preheat required Cntact surface heating, with cnductin heating f cre. Thickness up t 25 mm (limited by heat transfer rate) Line Speed 45 m per minute 25 m per minute (fr 50 g per m prduct) Pst-prcess Nne required prduct cleaning Salt Nne cnsumptin Adapted frm References 1 & 3 Cleaning is essential 4 t 5 kg per hur

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73 Heating Frging Blanks Parameter Direct Resistance Heater Fssil-Fired Furnace System cnfiguratin Individual heating f blanks Batch heating f lng bars Frging-blank 1230 O C 1230 O C target temperature Temperature Autmated Operatr judgment cntrl f blank Heating time < 15 sec 15 t 20 minutes Energy efficiency ~ 85% 17% t 20% (n recuperatin) 35% t 40% (with recuperatin) Energy sage ~ 280 kwh/tn ~ 140 m 3 NG /tn ~ 70 m 3 NG /tn (with recup.) Scale frmatin Little r nne < 0.5% Significant ~ 2% Relative Operatr 0.5 x 1 x labur req d Relative plant flr 0.8x 1 x space req d Plant flr envirnment Cler & cleaner Ht, with fumes & dirt frm furnace Adapted frm References 19 & 20

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81 Insulating Refractry Materials Insulating K-factr Density Relative Cst Material Type (W/m C) (kg/m 3 ) Fibrus ceramic Insulating Cncrete Insulating Brick Cmpressed Brick

82 Heating Element Family Irn- Nickel- Chrme Allys Irn- Chrme- Aluminum Allys Nnmetallic Allys Nble metals Material Heating Element Types Maximum Temperature f Element ( C) Applicatin - Remarks Fe-20Ni-25Cr 900 Widely used because f Fe-45Ni-23Cr 1050 their availability and lw Fe-65Ni-15Cr 1100 cst 80Ni-2-Cr 1150 t 1200 Wide range f temperatures sed in xidizing atmspheres Fe-22Cr- 14.5Al 1280 Kantal AF 1400 SiC (silicn carbide) Cr2O3La2O3 (lanthanum chrmite) t 1900 Higher temp. than Ni-Cr at abut same cst Embrittlement n first heating sed in xidizing atmspheres Bars are brittle susceptible t thermal & mechanical shcks sed in xidizing r reducing atmspheres Graphite 2500 Lw cst f bars sed in neutral r reducing atmspheres, r under vacuum Mlybdenum 2300 Tungsten 2500 Tantalum 2500 Wire r plates Very high cst Only in neutral r reducing atmspheres, r under vacuum

83 Aluminum Melting in a Fundry Electric Natural Gas Parameter Resistance Melter Fired Melter Heating efficiency ~ 70% 15 t 20% Metal Lss Little r nne Very Significant; (Drss frmatin) < 1% ~ 12% Relative maintenance cst 0.72 x 1 x Relative prductin 1.1 x 1 x Adapted frm Reference 21

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90 Cycle Time Parameter Printing Line Printing & V Curing Near instantaneus curing; allws fr faster prcessing & lwer Wrk in Prgress Printing & Thermal Curing Curing times limit prcessing speeds Energy sage fr Curing - Electricity 82 kw 56 kw - Natural Gas nne 1.1 millin BT/hr Press Setup & Cleaning Time 1 hr / day 2.5 hrs / day (typical) Typical Prcess p-time fr 3-shift peratin 80% 70% (1-shift peratins benefit mre) Relative Ink/Cating Cst: - by ink vlume 2x t 3x 1 x - by vlume f prduct printed 0.7x t 1.3x 1 x Relative Capital Cst: - small system 1 x 1 x - large system 0.5x 1 x Plant Space Requirements 0.1 x 1 x Plant Envirnment Maintenance cst Cl and slvent free; pssibility f V expsure Lwer cleanup csts, & n cl-dwn time required Ht, with pssibility f slvent expsure Lng cleanup cycles, with lng cl-dwn & re-heat times Prduct Lss (Scrap) Lw Significant Waste & Envirnmental Emissins Lw Significant Adapted frm Reference 23

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