Characterisation of industrial thermoprocessing plants

In industrial thermoprocessing plants, energy losses are caused by thermal insulation, by exhaust gases or cooling air, by heat radiation losses as well as by the residual heat of the material to be heated and the auxiliary materials. The energy efficiency deteriorates during operation due to ageing of components, e.g. the furnace insulation. Countermeasures can be taken if the energy balance is measured regularly. This is very costly.
For the user many industrial furnaces are a black box on the inside.
The temperature distribution as well as the composition and flow velocity of the furnace atmosphere can only be determined insufficiently. However, these parameters have a great impact on the product quality after heat treatment.

The material and energy balance on the outer shell of industrial thermoprocessing plants are to be established using efficient methods. Furthermore, temperature fields, gas flows and gas composition inside the furnaces are to be determined as precisely as possible. For this purpose, existing methods are to be tested and, if necessary, new methods are to be developed. The characterisation of the thermoprocessing plants is offered as a service for furnace operators and manufacturers.

The material and energy flows of a kiln must be completely recorded. It is important that the technology used does not interfere or disturb the process. For this reason, non-contact methods are applied as far as possible for measurement.

The following measuring methods or measurements are necessary:

• Quantitative 3D Thermography
• Flow measurement for water and gases
• Power measurement of electrical consumers
  
• Measurement of the temperature distribution within the furnace
  
• Measurement of the furnace atmosphere
  
• Measurement of exhaust gases

A mobile analysis system is being set up to measure thermoprocess plants in the industry.