DLS-ECO Laser – Heating, Drying and Curing Solution
Exhibitor: IPG PHOTONICS (ASIA) LIMITED TAIWAN BRANCH (HONG KONG)
Date: 2024-07-03
Booth No.: P202
IPG Photonics, the world leader in fiber lasers and diode technology introduces the DLS-ECO product line of high efficiency laser heaters to support sustainable manufacturing.
Up to 10% of total energy consumption by industry results from heating, drying and curing processes. At least three quarters of industrial ovens, heaters and furnaces rely on convective heating, while more than half burn fossil fuels. Convection furnaces heat or dry by blowing hot air onto a surface. Convective drying is slow, because only the surface is dried. Normally, about a third of the heat energy generated by a convection oven is transferred to the product. The rest heats the oven walls and atmosphere, or is spilled into the factory environment. When drying or curing, volumes of forced air are required to remove moisture/solvents which adds a substantial operational burden, both to scrub and exhaust the warmed air exiting the oven and to heat the cool air which replaces it.
Lasers offer a stark and attractive alternative. Radiative heating, such as lasers provide, speeds the process, because near-infrared light penetrates many materials to dry volumetrically. For the same reasons a microwave oven can bake a potato faster than a traditional oven, productivity gains from laser heaters are huge. For example, a lithium-ion battery cell factory today routinely employs gas-fired furnaces of 50-100m length to dry slurry applied to metal foils over a 30-40 minute drying period. A laser heater neatly replaces these behemoths requiring only 10-20 meters of factory footprint.
A paradigm shift results from the “cold” nature of a laser oven. The laser is highly directable enabling nearly all of its energy to be transferred to the product, while directly heating neither the oven interior or atmosphere. The “cold” nature of the laser heater significantly simplifies oven design by eliminating the need for thick, insulating walls, while enabling all sorts of instrumentation and metrology to be introduced.
Further improvements are available because lasers mainly interact with the surface without wasting energy to heat the underlying substrate. Laser heating is therefore ideal for drying coatings without impacting fragile, temperature sensitive underlying substrates or devices. This feature has attracted interest from industries which apply coatings to temperature sensitive materials such as polymers or wood.
Among laser heaters, DLS-ECO solutions from IPG provide at least a 5% energy efficiency advantage over the laser alternatives. In the context of a 500kW laser heater installation at a typical energy cost of $0.15/kW-hr, this corresponds to a quarter million dollar annual energy savings. When compared to markedly less efficient incumbent technologies like resistive or infrared lamp furnaces, annual energy savings can reach millions of dollars for a large operation.
Laser heater advantages
- Shortened process time occupying less factory floor space
- A path to sustainable net-Carbon Zero manufacturing by displacing fossil fuels
- OpEx savings based on less energy consumption, less exhaust heat impacting the factory floor and maintenance-free operation for at least 7 years
- Precision derived from new process control metrology possibilities
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