FEATURE ADVANCED MATERIALS & PROCESSES | NOVEMBER 2026 22 T he transition toward sustainable industrial pro- duction coincides with a shift in energy markets driven by the increasing share of renewable energy sources. Heat treatment technologies must provide greater flexibility in energy use while simultaneously reducing costs and emissions. Hybrid radiant tube burners combined with electric heating elements represent a key enabling technology, allowing dynamic adaptation to changing energy availability and market conditions. When supplemented by predictive energy demand models for optimized process planning, real-time CO2 footprint assessment, and measures to minimize process gas consumption, a future-proof heat treatment concept emerges. As an energy-intensive manufacturing process, heat treatment is particularly affected by rising environmental requirements, increasing energy costs, and changing energy supply structures. In addition to growing public awareness of climate change, regulatory developments such as the EU target to reduce greenhouse gas emissions by 55% by 2030 and the introduction of the Carbon Border Adjustment Mechanism (CBAM) are increasing pressure on manufacturers. Future CO2-related costs further strengthen the need for more energy-efficient production processes. At the same time, renewable electricity and green hydrogen create new opportunities for sustainable heat treatment technologies. To address these challenges, Ipsen has developed three key approaches to improve the sustainability of heat treatment systems: • Hybrid heating systems with intelligent control: Predictive energy demand simulations enable dynamic selection of the most suitable energy source and process scheduling. • Carbon footprint transparency: The carbon footprint of each batch is calculated from measured energy and process media consumption, including timedependent grid carbon intensity, providing customers with transparent sustainability data. • Reduction of process gas consumption: Active furnace atmosphere control reduces endogas consumption during carburizing, lowering costs and improving overall energy efficiency. HYBRID FURNACE TECHNOLOGY FOR INTELLIGENT ENERGY USE Hybrid heating systems, CO2 forecasting, and advanced atmosphere control can contribute to more sustainable and efficient heat treating. Bora Özkan and Martin Hellwig Ipsen International GmbH, Kleve, Germany HYBRID HEATING SYSTEMS WITH INTELLIGENT CONTROL Flexibility in choosing an energy source provides independence of single sources and the opportunity to actively take advantage of fluctuations in production and pricing. Given the long service life of heat treatment furnaces, it is essential to implement forward-looking solutions that allow for adaptation to political and energy market developments in the long run. Hybrid heating system. To support the transition toward sustainable heat treatment, Ipsen introduced hydrogen-ready Recon IV radiant tube burners to be combined with electric heating elements, enabling flexible use of natural gas or propane, hydrogen, and electricity. Depending on process requirements, both heating technologies can be used independently or in combination. Standardized mechanical integration enables retro- fitting while the configuration of burners and electric heaters can be configured to the customers’ preferences. Fig. 1 — Hybrid heating system of the ATLAS Green furnace with hybrid radiant tube burners (blue) and electric heaters (green).
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