A Novel Microwave and Induction Heating Applicator for Metal Making: Design and Testing

The use of microwave heating in primary metallurgy is gaining an increasing interest due to the possibility to selectively process ores and to volumetrically heat large amounts of low-thermal conductivity minerals. In this paper the study, development and testing of a new applicator combining the use of microwave and induction heating for rapid reduction of metal containing oxides is described. Numerical simulation was used in order to achieve the proper control over heat generation, considering the use of microwave solid state generators. A prototype, with a capacity up to 5 liters of standard input feed but with the predisposition for continuous processing has been designed, built and tested on reference loads like iron oxide powders and pellets. Results on the microwave heating part of the applicator indicate that it allows to efficiently and rapidly process these kinds of loads, which change from dielectric to conductors as reduction proceeds. The use of variable frequency solid state microwave generators allows to maximize energy efficiency and to controllably change the heating pattern inside the load.