Energy optimization of thermochemical vacuum processes and equipment in large-scale production

The energy optimization of thermoprocessing equipment is of great ecological and economical importance. Thermoprocessing equipment consumes up to 40 % of the energy used in industrial applications. Therefore it is necessary to increase the energy efficiency of thermoprocessing equipment in order to meet the EU's targets to reduce greenhouse gas emissions. To exploit the potential for energy savings, it is essential to analyze and optimize processes and plants as well as operating methods of electrically heated vacuum plants used in large scale production. The process can be improved by accelerated heating through the application of convective heating. In addition higher process temperatures can be applied in diffusion-controlled thermochemical processes to accelerate the process significantly. Modular vacuum systems prove to be very energy-efficient because they adapt to the changing production requirements step-by-step. An optimized insulation structure reduces thermal losses considerably. Energy management systems installed in the plant-control optimally manage the energy used for start-up and shutdown of the plants while preventing energy peak loads. The use of new CFC-fixtures also contributes to reduce the energy demand.