Sebastian Tonzanu
Optimization of Electric Heating Elements for industrial applications: critical analysis of MoSi2 and exploration of hybrid alternatives.
Rel. Monica Ferraris. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Energetica E Nucleare, 2026
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Abstract
Decarbonizing high-temperature industrial processes through renewable energy integration requires the development of electric heating systems capable of delivering power levels one to two orders of magnitude higher than those currently available. Present high-temperature radiative heaters rely predominantly on molybdenum disilicide (MoSi₂) heating elements. These intermetallic compounds are characterized by a unique combination of metal-like electrical conductivity with ceramic-like robustness, enabling operation at surface temperatures up to 1800°C through the formation of a self-healing protective silica (SiO₂) layer. However, the transition to multi-megawatt industrial scaling is constrained by the intrinsic physical properties of MoSi₂, most notably its relatively low electrical resistivity. To keep the current within acceptable limits, systems must operate at high voltage, demanding heating elements with significantly increased electrical resistance.
Increasing the resistance by reducing the cross-sectional area leads to mechanically fragile geometries, unsuitable for large-scale industrial implementation
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