Flow monitoring of the natural gas consumption of melting furnaces

We are delighted to present an application in the field of process optimisation, in which CS INSTRUMENTS has made a significant contribution to improving efficiency. In collaboration with a renowned foundry, we had the opportunity to deploy our VA 570 thermal mass flow meters to monitor natural gas consumption in the melting furnaces.

Prior to the implementation of our technology, the furnaces were operated without flow monitoring, which meant that natural gas consumption was based on empirical values and the individual gut feelings of staff members. After some burners were replaced due to age, the foundry identified quality issues and unexplained fluctuations. This is where we recognised the potential of our technology.

The findings were extremely revealing. Through accurate measurements, we established that identical annealing furnaces with the same burner types consumed different amounts of natural gas because they had been manually adjusted differently. Furthermore, we observed fluctuations of up to 10 per cent in consumption between day and night operations.

By precisely adjusting the burners using our VA 570 mass flow meters, we were able to reduce the annealing furnaces’ natural gas consumption by an impressive 25 per cent.

Our technology enables the efficient monitoring and optimisation of processes, leading to significant cost savings.

This success story highlights the capabilities of our broad product portfolio and demonstrates how CS INSTRUMENTS helps to improve processes in order to significantly reduce industrial energy consumption.