Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Plant Optimisation Saves Energy

12.11.2010
• Heating processes use energy
• Heraeus Noblelight optimises existing plant

Can the coating dry more quickly? Is it possible to reduce the rejection rate? Does the plant use too much energy?


Dr Larisa von Riewel and Joerg Woell of the Consulting Team can often best identify optimisation opportunities for heating process directly on plant.
Copyright Heraeus Noblelight 2010


Radiation intensity is computed with Ray Tracing.
Copyright Heraeus Noblelight 2010

Many companies ask themselves questions like these. Energy and material costs are important considerations for industrial companies who wish to maintain or improve their competitiveness. At the same time, the optimisation of existing plant can often be the more sensible and cost-effective option over installing new plant. A newly established consulting team at Heraeus Noblelight now offers support through individual consultancy, practical planning and prompt implementation of measures to achieve optimisation of plant, equipment and processes.

A drying oven is often the bottleneck in a production line. In order to increase production output, a convection oven can, for example, be extended – but this is not possible in every factory. It is more efficient to replace the hot air with infrared heating or to use a combination of the two technologies, which can generally lead to savings in space and energy. However, the best way is to examine the complete system. “Recently, we have carried out detailed investigations of their system technology for one of our customers using Time-Distance diagrams,” explains Joerg Woell from the new consulting division at Heraeus Noblelight.

“In doing so, we could see immediately that a conversion of the drying process would make sense.” This showed that by using fast-acting carbon infrared emitters, with electronic linking to the conveyor system, there is an optimisation of the operating life and significant energy saving. Precise calculations showed that following the conversion only 460 kW of power was required compared with the previous 880 kW.

To carry out such calculations, the new Heraeus division also used modern numerical methods such as Ray Tracing and Computational Fluid Dynamic, in addition to the usual tests in the Application Centre and the information contained in the data banks built up over years.

Identifying and Implementing Optimisation Opportunities

The new consulting team provides consultancy and advice, planning and implementation of economical energy efficiency measures. In accordance with VDI 3922, Heraeus investigates production plants for potential improvements, using a practical approach which is independent of equipment manufacturers. Tests have been carried out for many years to analyse heating processes in our in-house Application Centre and on site. Experimental data in our databases, built up over decades, has also been useful for first assessments. Now we have added modern numerical techniques. Ray Tracing and Computational Fluid Dynamics are very valuable methods, for example, for optimising the homogeneity of heating on surfaces or minimising edge zone losses.

The use of modern infrared technology together with defined process optimisation increases the degree of utilisation of the production plant. It is important to understand the heating process precisely so that infrared heat can be used “on demand”. For example, if emitters are switched on only when a product to be heated actually requires heat, then energy is saved, operating life is optimised and efficiency is increased significantly.

“In the aforementioned case, we could not only achieve 60% energy savings but also a reduction in rework rate,” enthused Joerg Woell. The measures established are evaluated in terms of economic viability to illustrate the possible energy-saving and production opportunities.

Heraeus Noblelight GmbH with its headquarters in Hanau and with subsidiaries in the USA, Great Britain, France, China, Australia and Puerto Rico, is one of the technology and market leaders in the production of specialty light sources. In 2009, Heraeus Noblelight had an annual turnover of 71.6 Million € and employed 707 people worldwide. The organisation develops, manufactures and markets infrared and ultraviolet emitters for applications in industrial manufacture, environmental protection, medicine and cosmetics, research, development and analytical laboratories.

Heraeus, the precious metals and technology group headquartered in Hanau, Germany, is a global, private company with over 155 years of tradition. Our businesses include precious metals, sensors, biomaterials and medical products, dental products, quartz glass, and specialty light sources. With product revenues of € 2.6 billion and precious metal trading revenues of € 13.6 billion, as well as more than 12,300 employees in over 110 subsidiaries worldwide, Heraeus holds a leading position in its global markets.

Further Information:

Readers:
Heraeus Noblelight GmbH
Reinhard-Heraeus-Ring 7
D-63801 Kleinostheim
Phone +49 6181/35-8545, Fax +49 6181/35-16 8545
E-Mail hng-infrared@heraeus.com
Press:
Dr. Marie-Luise Bopp
Heraeus Noblelight GmbH,
Abteilung Marketing/Werbung
Phone +49 6181/35-8547, Fax +49 6181/35-16 8547
E-Mail marie-luise.bopp@heraeus.com

Dr. Marie-Luise Bopp | Heraeus Noblelight GmbH
Further information:
http://www.heraeus-noblelight.com

More articles from Power and Electrical Engineering:

nachricht How protons move through a fuel cell
22.06.2017 | Empa - Eidgenössische Materialprüfungs- und Forschungsanstalt

nachricht Fraunhofer IZFP acquires lucrative EU project for increasing nuclear power plant safety
21.06.2017 | Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP

All articles from Power and Electrical Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Can we see monkeys from space? Emerging technologies to map biodiversity

An international team of scientists has proposed a new multi-disciplinary approach in which an array of new technologies will allow us to map biodiversity and the risks that wildlife is facing at the scale of whole landscapes. The findings are published in Nature Ecology and Evolution. This international research is led by the Kunming Institute of Zoology from China, University of East Anglia, University of Leicester and the Leibniz Institute for Zoo and Wildlife Research.

Using a combination of satellite and ground data, the team proposes that it is now possible to map biodiversity with an accuracy that has not been previously...

Im Focus: Climate satellite: Tracking methane with robust laser technology

Heatwaves in the Arctic, longer periods of vegetation in Europe, severe floods in West Africa – starting in 2021, scientists want to explore the emissions of the greenhouse gas methane with the German-French satellite MERLIN. This is made possible by a new robust laser system of the Fraunhofer Institute for Laser Technology ILT in Aachen, which achieves unprecedented measurement accuracy.

Methane is primarily the result of the decomposition of organic matter. The gas has a 25 times greater warming potential than carbon dioxide, but is not as...

Im Focus: How protons move through a fuel cell

Hydrogen is regarded as the energy source of the future: It is produced with solar power and can be used to generate heat and electricity in fuel cells. Empa researchers have now succeeded in decoding the movement of hydrogen ions in crystals – a key step towards more efficient energy conversion in the hydrogen industry of tomorrow.

As charge carriers, electrons and ions play the leading role in electrochemical energy storage devices and converters such as batteries and fuel cells. Proton...

Im Focus: A unique data centre for cosmological simulations

Scientists from the Excellence Cluster Universe at the Ludwig-Maximilians-Universität Munich have establised "Cosmowebportal", a unique data centre for cosmological simulations located at the Leibniz Supercomputing Centre (LRZ) of the Bavarian Academy of Sciences. The complete results of a series of large hydrodynamical cosmological simulations are available, with data volumes typically exceeding several hundred terabytes. Scientists worldwide can interactively explore these complex simulations via a web interface and directly access the results.

With current telescopes, scientists can observe our Universe’s galaxies and galaxy clusters and their distribution along an invisible cosmic web. From the...

Im Focus: Scientists develop molecular thermometer for contactless measurement using infrared light

Temperature measurements possible even on the smallest scale / Molecular ruby for use in material sciences, biology, and medicine

Chemists at Johannes Gutenberg University Mainz (JGU) in cooperation with researchers of the German Federal Institute for Materials Research and Testing (BAM)...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Plants are networkers

19.06.2017 | Event News

Digital Survival Training for Executives

13.06.2017 | Event News

Global Learning Council Summit 2017

13.06.2017 | Event News

 
Latest News

Quantum thermometer or optical refrigerator?

23.06.2017 | Physics and Astronomy

A 100-year-old physics problem has been solved at EPFL

23.06.2017 | Physics and Astronomy

Equipping form with function

23.06.2017 | Information Technology

VideoLinks
B2B-VideoLinks
More VideoLinks >>>