Controller helps manufacturers cut energy usage.September 1, 2006 -
Suitable for batch processes in manufacturing plants, Furnace Energy Optimization solution is based on independently validated algorithm within LIN control environment, which calculates derivative of power required to heat furnace. When derivative is 0, steady state has been reached where power input is equal to furnace losses. Ability to pinpoint exact moment when center of load and piece parts reach required temperature allows cycle time to be optimized.
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Original Press release
Eurotherm Controls
741-F Miller Dr.
Leesburg, VA, 20175
USA
Significant Energy Savings and Improved Productivity with Latest Eurotherm Technology: 'Furnace Energy Optimization'
LEESBURG, VA, USA, 1 August 2006 - Manufacturers of metallurgical products are continually seeking new methods of reducing energy usage due to the increasing cost of energy and growing industry legislation to conserve valuable resources. The latest control technology developed by Eurotherm specifically addresses this need. Customer installations at foundries are demonstrating annual energy savings of up to 9%, resulting in a payback of 18 months or less. Additionally, the process time required is shown to be greatly reduced, resulting in improved productivity of up to 20%.
This latest innovation, known as the Eurotherm "Furnace Energy Optimization" solution is appropriate for batch processes within foundries, forges, billet and ingot manufacturing plants. The technology is based around an independently validated algorithm within Eurotherm's LIN control environment, which calculates the derivative of the power required to heat the furnace. When this derivative is zero, a "steady state" has been reached where power input is equal to furnaces losses and no further energy is being absorbed by the load. This demonstrates that temperature uniformity has been reached for an entire load, both at the center and within all of the homogeneous piece parts. This ability to pinpoint the exact moment when the center of the load and the piece parts reach the required temperature allows the cycle time, regardless of load, to be optimized.
Traditionally, methods of ensuring a stable and homogeneous load temperature have depended either on manual intervention or standard automatic control. Manual intervention has the dual disadvantages that it is dependent on accurate interpretation by the operator, and interrupts the furnace operation, slowing the overall process. Using the standard automatic control solution, the dwell temperature heating process parameters need to be over-specified to allow for a margin of variance and ensure that the piece part temperature is uniform. This inevitably leads to energy wastage.
Successful references of Eurotherm's "Furnace Energy Optimization" solution with existing customers, including one of Europe's largest energy suppliers, continue to show dramatic savings and it is likely that this application will be widely adopted to demonstrate a commitment to energy saving.
About Eurotherm
Eurotherm is a leading global supplier of control, measurement and data recording solutions and services to industrial and process customers. The company's international reputation as a provider of innovative solutions across a broad spectrum of vertical markets is supported by engineering services designed to realize greater benefits to customers' plant-wide assets. Eurotherm's product range includes distributed process automation systems and machine control incorporating single and multi loop control, operator displays, data management and graphic recorders, power control and signal conditioning. It is an ISO9000 approved Company, and operates TickIT protocols for software management.
Eurotherm is a key business within Invensys, the global automation, controls and process solutions Group. Invensys products, service expertise and ongoing support enable intelligent systems to monitor and control processes in many different environments. Leading companies in a wide range of industries rely on Invensys to help them perform with greater efficiency, safety and cost-effectiveness.
Headquartered in London and listed on the London Stock Exchange, the Invensys Group is made up of five businesses: Process Systems, APV, Eurotherm, Rail Systems and Controls. Overall The Group has over 30,000 employees working in 60 countries. For additional information visit: www.eurotherm.com .
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