Induction and process heat: a guide for businesses
Direct answer
Induction heating is an electric heating technique in which an alternating magnetic field induces currents in a conductive material, which then heats up from within. No flame or combustion gas is involved. The technique is fast and precise to control and is used in industry for process heat, for example when melting, hardening and brazing metal.
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Induction and process heat: scattered information versus Energy Intelligence
Many Dutch businesses still produce process heat with natural gas: a gas furnace heating shafts until they glow, a burner under a melting crucible. Companies that want to reduce gas consumption and CO2 emissions look at electric alternatives. For metalworkers, machine builders and other producers with hot processes, induction heating is then a serious candidate. This page explains how the technique works, what it is suited for, and what to consider when fitting it into your process and your grid connection.
- A coil carrying alternating current creates a magnetic field that induces currents in a conductive workpiece; the heat is therefore generated inside the material itself.
- Induction is fast and precise to control and releases no combustion gases; typical applications are melting, hardening, brazing and welding metal, and heating vessels and pipes.
- Within electrification, induction sits alongside e-boilers, resistance heating and industrial heat pumps; its strength is high temperature, targeted and directly in the material.
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How does induction heating work?
Induction heating uses a coil through which an alternating current flows. That current creates a rapidly alternating magnetic field. If you place a conductive workpiece in that field, electric currents arise inside it, known as eddy currents. The material has resistance, so those currents generate heat inside the workpiece itself. The heat does not have to be transferred via a flame, hot air or a contact surface. As a result, induction responds almost immediately to the power setting and the temperature can be controlled precisely. The frequency of the alternating current determines where the heat is generated: a higher frequency mainly heats the surface, a lower frequency heats deeper into the material. No combustion gases are released on the work floor.
- The heat is generated inside the workpiece itself, not in a furnace or via a flame.
- The power follows the setting almost immediately; heating, dosing and stopping is fast.
- A higher frequency mainly heats the surface, a lower frequency heats deeper into the material.
- No combustion gases are released by the process itself.
What is induction used for?
Induction is mainly applied where metal has to become hot quickly or locally. Think of melting metal in an induction furnace, hardening gears and shafts, preheating forgings, and brazing or welding joints, for example the seam of a welded pipe. Because the heat is generated inside the workpiece itself, you can heat one zone without making the whole product hot. That is exactly what surface hardening requires. In addition, there are induction systems that bring or keep vessels, pipes and moulds at temperature via a conductive wall or jacket. You may know the principle from the induction hob at home: the pan gets hot, the hob itself hardly does.
- Melting metal in induction furnaces, for example in foundries.
- Surface hardening of gears, shafts and tools by heating them locally.
- Brazing and welding joints, such as the seam of welded pipes.
- Heating vessels, pipes and moulds via a conductive wall or jacket.
What does induction mean for your electrification plans?
Induction is one of the electric routes to process heat, alongside e-boilers, resistance heating and industrial heat pumps. Each technique has its own working range. Heat pumps are mainly suited to lower temperatures and upgrading residual heat. E-boilers produce hot water or steam for an entire process. Resistance elements heat via a hot surface. Induction stands out because the heat is generated at high temperature directly inside the material, targeted at the spot where you need it. Keep three points in mind. Only electrically conductive materials can be heated directly; other substances are heated indirectly via a conductive vessel or element. Electrification increases your electricity demand, so check your connection and contracted capacity with the grid operator, especially in areas with grid congestion. And integration requires design: coil and workpiece have to be matched to each other.
- Heat pumps mainly serve lower temperatures, e-boilers produce hot water or steam, induction delivers high temperature directly in the material.
- Only electrically conductive materials can be heated directly; other substances are heated indirectly via a conductive vessel or element.
- Check your connection capacity and contracted transport capacity with the grid operator in advance, especially in congestion areas.
- Coil and workpiece have to be designed for each other; fitting induction into an existing line requires engineering.
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