Researching Energy Optimization in Aluminum Melting

From the simulation to the optimized furnace: up to 15% energy savings as a result of process optimization on an aluminum melting furnace.

To determine the energy-savings potential for aluminum melting processes, minimize melting loss, and create the basis for a heat recovery system, researchers have developed a system for monitoring and controlling the melting process. Furnace builder ZPF GmbH led a four-year R&D program funded by Germany’s Federal Ministry of Economics and Technology (BMWi). At the conclusion in 2016, the researchers reported a significant reduction in melting downtime, and the possibility for a 15% improvement in energy efficiency.

"The entire furnace system needs to be optimized in order to achieve sustainable improvements. This was the main finding from the previous project concluded in 2011, which was mainly concerned with new burner arrangements and alternative refractory material,” reported Sven-Olaf Sauke, of ZPF.

Read a full summary of the EDUSAL II project, which focused 1) on developing measuring technology to detect the furnace chamber by sensors; and 2) on determining how a dynamic furnace system can be aligned with the melting charge, on the basis of the measured data and whether the efficiency of the overall system can be increased as a result.
Sensor-Based Optimization Saves Energy in Aluminum Melting