Hybrid Furnace Technology for Intelligent Energy Use

Abstract Rising energy costs and stricter CO2 emission regulations are putting increasing pressure on the heat treatment industry. Overcoming these challenges requires technically advanced systems. Hybrid heating systems offer the flexibility to select and use multiple energy sources simultaneously, optimizing costs and emissions. Ipsen’s hybrid radiant tube burners can operate with natural gas, propane, and hydrogen. When combined with electric heating elements, these systems provide maximum adaptability in energy sourcing. This allows not only the selection of heating gas but also the integration of costeffective renewable electricity whenever available. To fully capitalize on the advantages of hybrid heating, additional technical solutions are necessary. These include tracking real-time CO2 emissions based on the carbon footprints of the energy sources used and forecasting power demands for upcoming treatment processes to optimize process planning. This forecasting is achieved using a digital twin, which simulates the power demand of a heat-treated batch, ensuring high time resolution for better energy management and planning. Furthermore, advanced gas analytics are employed to minimize the use of endogas and reduce energy consumption through active endogas control.