Efficient cooling of industrial furnaces

A well-known industrial company in China specializes in the research, development and production of high-tech materials and specialized industrial furnaces for a wide range of applications. These include, among others, the production of ceramic composite materials, the heat treatment and densification of workpieces under vacuum, and waste incineration and disposal. Materials such as metals, ceramics, plastics and minerals are processed in high-temperature and high-pressure furnaces under extreme conditions of up to 2600 °C and pressures of up to 25 MPa.

Compared to open furnaces, sealed industrial furnaces are more energy efficient and environmentally friendly. However, cooling a sealed high-temperature, high-pressure furnace is highly demanding due to the higher combustion temperatures. To ensure safe and efficient furnace operation, the flow and temperature of the cooling water as well as energy consumption must be continuously monitored and controlled. TURCK's FS+ flow sensors are ideally suited for this application because they monitor not only flow, but also the temperature of the cooling medium.

FS+ all-in-one solution

To ensure the cooling performance of the system and reduce energy consumption, it is first essential to have a precise understanding of energy usage. This requires monitoring both the flow and the temperature of the cooling system. Because FS+ product series flow sensors monitor liquid media using the calorimetric principle, they can continuously measure the medium temperature in addition to flow. Measurement and process data as well as relevant diagnostic information are transmitted from the sensor to the control system via IO-Link. To verify cooling circuit performance, FS+ flow sensors were installed on both the inlet and outlet side of each line.

With a temperature measuring range of up to 85 °C, pressure resistance of up to 300 bar and the ability to measure flow velocities of up to 3 m/s, the FS+ flow sensors meet all customer requirements for this application. In addition, with high protection ratings of IP6K7 and IP69K, the devices can be reliably used in harsh environments with high temperatures and dust. Another advantage is that the FS+ sensor housing can be rotated by 340 °, allowing optimal alignment of the display and the electrical interface during installation. This ensures that, regardless of the mounting situation, users always have a clear view of the on-site display.

Easy commissioning and operation

With Quick Teach and Delta Flow, the FS+ offers two functions that simplify commissioning. Delta Flow ensures that the teach process is only started once the warmup phase of the temperature peak has ended and a stable flow condition is present. The sensor also provides a range of practical features, such as a locking mechanism that prevents the user from inadvertently operating the sensor incorrectly. In addition, users benefit from an M18 × 1.5 adapter on the sensor body, which allows the sensor to be adapted to different process connections with varying thread types. A wide selection of probe lengths is also available depending on the pipe diameter.

Predictive maintenance via IO-Link

By processing process and diagnostic information directly in the field, the higher-level control system is relieved, improving overall system efficiency and reducing costs. The acquisition and analysis of process and diagnostic data provide the basis for predictive maintenance of the overall system, enabling potential issues to be identified at an early stage.

Summary

Effective cooling and predictive maintenance of sealed industrial furnaces require continuous monitoring of the cooling water including temperature and energy consumption. The FS+ flow sensor is the right solution for these tasks, as it enables simultaneous monitoring of flow and temperature and transparently transmits process data and other relevant information to the control system via IO-Link. With these advantages and their user-friendly operating and installation concept, the FS+ sensors also impressed the Chinese industrial furnace manufacturer.