Process analysis and optimisation

In most cases, a com­ple­te ana­ly­sis of a ther­mal or metall­ur­gi­cal pro­cess chain first requi­res an ener­gy and mass balan­ce of indi­vi­du­al pro­ces­ses. From this, ener­gy effi­ci­en­ci­es and other balan­ces such as life cycle assess­ments or even a pro­fi­ta­bi­li­ty ana­ly­sis can be deri­ved. From the­se, various opti­mi­sa­ti­on poten­ti­als or stra­te­gic issues (e.g. for a tech­no­lo­gy chan­ge) can then be developed.

In addi­ti­on to the recor­ding and ana­ly­sis of the cur­rent sta­tus and the balan­cing, we also sup­port you in the deve­lo­p­ment of case stu­dies that eva­lua­te the influence of con­ver­si­on mea­su­res or chan­ges in pro­cess ope­ra­ti­on on effi­ci­en­cy fac­tors agreed with you.

Thus, we offer you com­pre­hen­si­ve sup­port and advice in opti­mi­sing your processes.

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Process gas analysis

In addi­ti­on to mea­su­re­ments accor­ding to cur­rent stan­dards, we also deve­lop indi­vi­du­al solu­ti­ons for our cus­to­mers based on our many years of expe­ri­ence. Our sam­pling sys­tems are spe­ci­al­ly adapt­ed for the high-tem­pe­ra­tu­re ran­ge and the harsh envi­ron­ment at metall­ur­gi­cal reac­tors and indus­tri­al fur­naces. We determine:

  • Gas com­po­si­ti­on (CO, CO2, H2, O2, …)
  • Air pol­lut­ants (CO, NOx, SOx, …)
  • Dust mea­su­re­ment accor­ding to VDI 2066
  • Volu­me flow, velocity
  • Tem­pe­ra­tu­re (con­ven­tio­nal or with suc­tion pyrometer)
  • Humi­di­ty

In addi­ti­on, other pro­cess data such as flows, tem­pe­ra­tures or pres­su­res can be mea­su­red continuously

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Numerical simulation and process modeling

We simu­la­te sin­gle and mul­ti-pha­se, ther­mal, reac­ti­ve flows in indus­tri­al fur­naces, metall­ur­gi­cal reac­tors and elec­tric arc fur­naces and have many years of exper­ti­se in the fol­lo­wing areas:

  • Flow and mixing phe­no­me­na in ther­mopro­ces­sing plants (sin­gle as well as multiphase)
  • Mel­ting and soli­di­fi­ca­ti­on processes
  • Magne­to­hy­dro­dy­na­mic flows in melts
  • Com­bus­ti­on and heat trans­fer phenomena
  • Flu­id-struc­tu­re inter­ac­tion, effect of flui­dic and ther­mal phe­no­me­na on load and fur­nace casing
  • Deve­lo­p­ment of fast online/offline models for ther­mal processes

In addi­ti­on, we offer sup­port in the flui­dic design of ther­mopro­ces­sing plants, draw up ener­gy and mass balan­ces or car­ry out heat flow cal­cu­la­ti­ons for you.

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Experimental investigations

In addi­ti­on to theo­re­ti­cal cal­cu­la­ti­ons, we can car­ry out expe­ri­men­tal inves­ti­ga­ti­ons on test ben­ches or water models, which we can also set up on your behalf. The sca­les of exis­ting plants are in the ran­ge of 1:5 to 1:1, depen­ding on the appli­ca­ti­on. Our 495 m² tech­ni­cal cent­re has a ther­mal con­nec­ted load of approx. 3 MW (natu­ral gas) and an elec­tri­cal con­nec­ted load of 600 kW. In addi­ti­on, we also accom­pa­ny tests direct­ly in indus­try with mea­su­re­ment tech­no­lo­gy and pro­vi­de sup­port in eva­lua­ti­on and assessment.

Our equip­ment allows us to deter­mi­ne heat trans­fer and emis­si­on coef­fi­ci­ents, the qua­li­ta­ti­ve and quan­ti­ta­ti­ve descrip­ti­on of gas and water flows with con­ven­tio­nal and laser mea­su­re­ment tech­no­lo­gy, and the deter­mi­na­ti­on of many other rele­vant pro­cess varia­bles such as tem­pe­ra­tu­re and pressure.

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Heat treatments

We can tre­at samples or com­pon­ents in small quan­ti­ties in our heat tre­at­ment fur­naces. Tests on heat tre­at­ment and sin­te­ring can be car­ri­ed out in a wide tem­pe­ra­tu­re ran­ge (up to max. 1600°C) and under a wide varie­ty of atmospheres.

In our anne­al­ing simu­la­tor we run high hea­ting and coo­ling rates (gas) for your sheet metal samples.


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