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You are right Simon - higher frequency and filters and shielding would work to give you a near DC output - one small step to using a buck converter - meaning a type of switch mode power supply. Not the first thing I would consider for a heater given the more complex design, but actually worth looking at since you can design them to be reasonably quiet. (not on Veroboard though!)
Cheers,
Peter
P.S. twisted pair actually works quite effectively in reducing radiated emissions. Not much good for conducted emissions though, that needs filter components tailored to requirements.
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