Melting furnaces to help improve energy efficiency

Melting scrap iron and additives into new castings is a very energy-intensive process, with temperatures reaching over 1,500 degrees Celsius. It is therefore an area where even minor adjustments can have a big impact on reducing energy consumption.

Foundries within the BIRN Group are continually seeking to optimise the melting processes, and BIRN in Holstebro has increased the digitalisation of operator functions in recent years. With a digital tool in the form of tablets that use data and advanced algorithms to calculate the current temperature in the melting furnaces, the operators of the melting furnaces in the iron foundry can see exactly when to add new materials in order to maintain a stable furnace temperature.

Dashboard solution highlights energy consumption

“During 2024, we continued to develop even better data insight and the ability to react immediately to any changes or fluctuations. Using a dashboard solution that is visible at both management and operator level, and for the melting and holding furnaces, we can continuously monitor operation of the furnaces. We can also use it for maintenance by seeing exactly where, for example, a mistake has been made and what has to be done to fix it,” explains Emil Husted Brodersen, Group Sustainability Manager at BIRN Group.

BIRN’s annual energy consumption is over 100 GWh, 53 per cent of which goes to the melting furnaces alone, and the company is constantly striving to achieve the most energy-efficient production possible.

“Our greater focus on automation and digitalisation is a crucial factor in this. The more data we have, the better informed our response is,” says Emil Husted Brodersen.