OPTIBAT® for Batch Furnaces

The metal industry makes use of batch furnaces to apply different heat treatments to the product, which give to it the intended metallurgical properties. Examples are furnaces for tempering and annealing, which normally make use of gas or fuel. The gas is burnt in several burners that inject their flames towards the interior of the oven, where the pieces lie. In these furnaces, the pieces that have to be treated stay at high temperatures that can exceed 1,000°C for long periods of time, sometimes more than one day, consuming large amounts of energy. The differences between pieces, variations in the quality of the gas and in the intake air conditions, make the parameters of the oven to be away from the optimum point of operation, increasing heat losses in the exhaust gases, for example. With OPTIBAT® BF is easy to specify operation parameters of the oven that will be adjusted in Real time by the system, as well as their room for maneuver. In this way, you get the same curve of temperature (characteristic of the treatment) with lower gas consumption, helping to obtain savings additional to any other Energy Efficiency measure.

OPTIBAT® for Continuous Furnaces

Continuous furnaces for heat treatment, especially those used in metallurgy, require the attention of operators in order to adjust the temperature setpoints to the type of product, oversee the functioning of the burners, the correct entry and exit of the product and the compliance with production targets. Different levels of qualification and experience among shifts make of this a highly dependent task on the human factor. However, a correct operation of the furnace has an influence not only in their energy consumption, but also in the quality of the treatment. OPTIBAT® CF is able of learning automatically from historical data of the furnace PLC, what are the best practices in terms of operation. I.e., those involving a better quality of treatments with lower energy consumption. Depending on the type of product and other contextual conditions (gas, air features) OPTIBAT® will always recommend best practices learned over time even for new types of product, thus compensating the differences between operation shifts and homogenizing operational practices.

OPTIBAT® for Induction Furnaces

Numerous foundries use induction furnaces for melting loads of several tons of iron or steel up to temperatures of 1,500°C or more. These furnaces are big electricity consumers, which have to meet production demands with the metal ready to be poured into the molds at the time and in the amount required. The irregularities in the scrap that they melt, as well as the different production needs, may cause peaks in the electrical power that penalize the electrical costs, while electrical and thermal losses take place, caused by a changing energy absorption capacity of the metal which depends on the conditions of production, the time between castings, warm-ups, and so on. OPTIBAT® induct allows to minimize electrical and thermal losses in this type of installation, integrating perfectly with existing control systems and effectively making use of information from the ERP manufacturing orders. Electricity bills are substantially reduced, providing savings from the first month of use and net improvements in the company accounts.

OPTIBAT® Electric Arc Furnaces

The regulation of an Electric Arc Furnace is a key topic in the steel industry. This type of furnace consumes large amounts of electric energy and provides the steel melted for the rest of the production process. OPTIBAT® EAF adds one step forward to the system of regulation of the electrodes, which is its optimization. It perfectly complements with the techniques of advanced control of the electrodes, whose purpose is to maintaining stable the furnace variables. The contribution of OPTIBAT® focuses on adjusting setpoints, within safe ranges, and communicate them to the advanced control system.

OPTIBAT® for regenerative furnaces

Regenerative kilns alternately use the heat of exhaust gases from a group of burners to heat the chamber through which intake air of another symmetrical group of burners will pass, in order to preheat the intake air. They are used in very different processes, from glass furnaces to forge or calcinations furnaces. In this alternating process, every change of cycle implies a greater or lesser effectiveness of the preheating. OPTIBAT® RF is able to determine and implement automatically the most appropriate time to make a change of cycle and thus to maximize the heat transfer from flue gases, maintaining all the properties of the treatment.

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