Run industrial furnaces more intelligently.
Backes combines multidimensional data analysis, control engineering and process models into coordinated furnace operation. Dynamic loss windows can be reduced, existing control loops can be tuned more precisely, and energy efficiency as well as process stability can be improved – without fundamentally rebuilding the plant.
Patent application filed
Dynamic operating phases cause the largest losses.
Many furnaces appear stable on average yet lose disproportionate energy during short events. Classical averages hide precisely those windows in which gas, air, pressure and cycle control interact unfavorably.
Gas peaks, pressure dips, O₂ peaks and increased exhaust losses often occur as a connected chain of events. The decisive factor is therefore not only the held temperature, but the quality of the entire dynamic process control.
Identify and deliberately control dynamic event chains.
The analysis places events in their time context, evaluates interactions and shows which short operating windows consume disproportionate fuel or burden process stability.
Start with existing sensors. Optimize step by step.
The entry point uses existing measurement values, actuators and automation structures. Parameters and operating states are systematically analyzed, purposefully developed and assessed via load-adjusted KPIs.
Focused data analysis and classification of relevant operating states.
Identify key loss windows from O₂, gas/air ratio, pressure, exhaust gas and cycle timing.
Develop minimum times, actuator limits, dead bands and state-dependent strategies.
Implement measures in a controlled and reversible manner and evaluate them using robust KPI comparisons.
Keep existing controllers. Coordinate at a higher level.
A higher-level model-based layer takes process dynamics, interactions and operating limits into account. Proven local controllers remain in place and are coordinated via predictively calculated setpoints.
Local stabilization
Temperature, gas/air, furnace pressure, dampers, fans and cycle timing secure immediate process stability.
Predictive coordination
Evaluates expected process trajectories and calculates suitable setpoints within defined technical limits.
Robust overall operation
Fewer peaks, calmer combustion and more reproducible process conditions across changing operating states.
* Target corridor from the optimization concept; the achievable effect depends on the plant and operation.
Stabilize the overall process – not just individual actuators.
- Synchronize gas and air side and safely limit excess air
- Calm burner cycling through minimum times and actuator limits
- Operate damper and VFD exhaust fan with clear task allocation
- Treat holding, startup, ramps, empty positions and standby as separate control cases
- Evaluate product quality together with energy and emission KPIs
Optimization does not replace protective and safety functions. Burner controls, limit monitoring, shutdowns and plant-specific safety chains remain independent and leading.
Patent application filed: hierarchical control for industrial furnaces.
A patent application has been filed with the German Patent and Trade Mark Office for the method and system for controlling gas-fired industrial furnaces. The approach combines local stabilization, model-based coordination and consideration of operational and safety-related limits.
Where does your furnace lose energy, stability or throughput today?
We review data availability, dynamic loss windows, existing control loops and a sensible pilot scope – without replacing protective and safety functions.