Energy Efficient High-Power Radio Frequency Generators for Industrial Heating

The GreenHeat project will contribute significantly to the goal of reaching carbon neutrality by promoting the electrification of industrial heating processes and by increasing the efficiency of existing ones. This is of paramount importance since the energy used by these processes constitutes a large portion of the total energy usage: 6% in Denmark [1] (fig. 1) and 20% worldwide [2]. Today, industrial heat processes employ induction or dielectric heating techniques that require radiofrequency (RF) generators. However, most existing RF generators are inefficient and affected by a need for frequent maintenance, because they are based on old technology employing vacuum tubes.

The project will utilize new concepts of scalable RF generators with semiconductor materials, to develop and manufacture full-scale demonstrators for use in two industrial applications: the production of ultra-pure silicon for the electronics industry and the production of cross-laminated wood. The demonstrator will outperform existing RF technology and will
- deliver a minimum of 40 kW of heating power, scalable up to above 100 kW
- reduce electrical energy consumption by at least 40% by increasing the electrical efficiency from the typical 50% to at least 90%
- require less maintenance by using components that have an estimated lifetime longer than the limited lifetime of vacuum tubes
- be future proof by using components that are expected to still be present in the market for the next many decades
- be between 30% and 50% cheaper than existing solutions, with an expected initial cost of 25 DKK/W to be further reduced to 15 DKK/W.

The demonstrator will be tested and employed for production both at Topsil on machines for producing ultra-pure silicon crystals and at Kallesoe on machines for producing cross-laminated wood. This project will make both companies more competitive in the market by lowering production costs and will support sustainable manufacturing in the electronics and wood industry.