Table 1 Proposed induction heating system vs. heat exchanger-based system

Heating mechanism

Induction heating, offering localized heating, almost instantaneous response, and precise control for high-pressure in-line heating of fuel.

Heat exchangers, those rely on thermic fluid and water for heating, leading to higher thermal inertia and slower response.

Induction heating, with systems not suitable for high-pressure inline heating, requiring modifications to the resonant components and incorporating closed-loop control.

Control capabilities

Precise, with almost instantaneous response.

Limited, with slow response due to large thermal inertia.

Limited, due to manual control options. Incorporating automatic control would require modifications.

Energy efficiency

High, due to direct energy transfer, localized heating, resulting in minimal energy losses and careful selection of components.

Low, with increased energy losses due multiple heat transfer components, limited options for optimization, and wastage of energy for cooling.

Moderate, due to their generic design and lack of optimization for specific applications.

Material efficiency

Good, as the proposed system requires fewer heat transfer components, minimizing material usage and potential points of failure.

Poor, as heat exchanger-based systems use multiple heat transfer components, liquid storage elements, and its associated control components, increasing material requirements and maintenance needs.

Moderate, as the system might be oversized and would lack customization options.

Complexity

Low, due to one heat transfer component and self-contained power converter with closed-loop control.

High, due to the complexity of integrating multiple components such as heat exchangers, flow control systems, thermic fluid heating system, water cooling system, and safety requirements into a cohesive system.

Moderate, due to the modifications required for purposing the commercial induction heating system into a high-pressure inline heating setup.

Cost

Low, with a design cost of approximately ₹ 15,000.

Highly expensive, estimated to cost around ₹ 10 lakh.

High, with prices around ₹ 3–5 lakh.

Maintenance

Minimum and Easy, as the heat transfer component is just a steel pipe.

Maximum, as many components such as heat exchangers, flow control valves, heating system, and cooling system are involved.

Moderate, as the service costs would be high.

Safety

Most safe, as the system is electrically isolated from mains and uses safe length of the heating pipe with temperature protection.

Less safe, due to the potential risks of leaks, spills, and accidents associated with heat exchangers, other components, and joints.

Less safe, as the heating coils may not be isolated from the mains and the behavior of the system could be unpredictable.