Energy Balance Model (EBM) Software
Reveal energy flows. Identify losses. Improve efficiency.
What is EBM software?
Imagine having a virtual copy of your furnace, from the melting tank to the combustion space, and from regenerators to batch pre-heaters. The Energy Balance Model software maps every heat flow across your furnace. It pinpoints sources of energy loss and inefficiency with precision. With these insights, you can then figure out which solutions to implement to enhance your furnace's efficiency, thereby reducing its energy consumption and associated costs without extensive modeling.
Using EBM has the following benefits:
- Easy and fast calculation times.
- One executable file for everyone in your organization.
- One language, one philosophy.
- A proven way of calculating energy costs.
- Easy link to process control.
EBM in action
With the goal to reduce energy consumption in a container glass plant, CelSian performed on-site support combined with EBM modelling.
Results:
- Identified major heat-loss sources (air leakage, insulation gaps)
- Improved furnace sealing and insulation
- Optimised combustion settings
- Achieved measurable reductions in energy demand
To reduce energy consumption in a flat glass furnace, the customer integrated an energy audit with EBM modeling.
Results:
- Identified sealing leaks and insulation losses
- Provided a clear optimization plan
- Implemented improved sealing and insulation
- Achieved ~1% energy savings and enhanced thermal efficiency
An extra-clear glass bottle manufacturer was experiencing foam formation in the melting tank and rejects due to blisters. We performed melting trials in our lab to optimize the batch formulation, including raw materials and refining agents, by evaluating foaming, melting, and refining behavior.
Impact:
- Improved glass surface in the melting tank
- Reduced foam formation
- Enhanced heat transfer
- Lower furnace temperatures
- Reduced blister-related rejects
- 16% lower batch formulation costs without compromising glass color or product properties
Our Energy Balanced Model (EBM) supports process control by providing a clear understanding of furnace heat distribution and temperature balance. By modeling thermal flows across the melting tank and combustion space with minimal data, EBM enables more accurate temperature management and improved operational stability.
This structured thermal insight enables controlled adjustments, reduces temperature fluctuations, and contributes to more stable, consistent furnace operation.