Method and system for operating and / or decarbonizing a more particularly industrial production process

Description

1 / 35 METHOD AND SYSTEM FOR OPERATING AND / OR DECARBONIZING A MORE PARTICULARLY INDUSTRIAL PRODUCTION PROCESS

[0001] The invention relates to a method and a system for operating and / or decarbonizing a particularly industrial production process, preferably a coating process such as galvanizing, in which a heated molten material is supplied and / or stored. Additionally, the invention also relates to uses of the system in question in heat-consuming processes, preferably in coating processes such as galvanizing.

[0002] The present invention relates to the field of operational industrial processes in the context of which the production, treatment and / or processing of actual goods or products are carried out on a commercial scale. For the purposes of the present invention, an industrial process should thus be understood as mass production and / or mass manufacturing process or the commercial processing of actual goods or components, in particular for coating workpieces.

[0003] Industrial production processes inevitably require a high level of process heat, especially during heat treatment or process steps intended to alter the properties and / or characteristics of the material. Due to the industrial scale of the production processes in question, it is natural that the supply of heat or energy required for this is guaranteed continuously and / or throughout the entire production process and thus permanently.

[0004] In this context, the present invention specifically targets heat-consuming production processes that are carried out using a heated molten material or in which a heated molten material is supplied and / or stored. Heated molten materials are preferably understood to be liquid metal of any type and alloy, which is used in industrial production processes in a variety of ways, for example, in casting. Petition 870250087389, dated 09 / 26 / 2025, page 53 / 231 2 / 35 or in the coating of workpieces.

[0005] However, the main starting point of the invention is coating processes in which a firmly adherent layer of shapeless material is applied to the surface of a workpiece. For this purpose, a heated molten material that acts as a coating mass is then kept in reserve or supplied accordingly.

[0006] A coating process frequently used in industry is galvanizing, especially hot-dip galvanizing, whereby a coating of molten metallic zinc is applied to protect against rust or corrosion by immersing the workpieces to be coated in the zinc-containing coating compound.

[0007] In galvanizing, in particular, it is fundamental that the molten zinc supplied for the coating be maintained at a permanently defined process temperature or with a constant supply of heat. This is the only way to guarantee targeted process control due to the dependence between the quality of the coating to be obtained, on the one hand, and the temperature of the molten material or coating mass, on the other.

[0008] In practice, the process heat required in production processes of the type mentioned above, particularly in coating or galvanizing processes, is covered by burning fossil fuels, usually gas, such as natural gas. In practice, for example, a galvanizing furnace with the coating or galvanizing paste inside is heated using gas burners operated with natural gas.

[0009] However, the use of natural gas in industrial processes is problematic due to the associated emissions of climate-damaging substances such as carbon dioxide. In addition to the lack of sustainability and the associated climate impact, there are also a number of geopolitical aspects that argue against the use of natural gas as an energy source, especially in industrial processes.

[0010] The disadvantages described above are particularly significant in Petition 870250087389, dated 09 / 26 / 2025, page 54 / 231 3 / 35 industrial processes in question that involve the use of a molten material, since continuous heating or heating the molten material to a comparatively high process temperature requires a particularly high energy input and, ultimately, a high consumption of the fossil fuels or natural gas needed for that purpose.

[0011] Despite the disadvantages described above, the implementation of natural gas for process heat generation in industrial production processes is essentially suitable for complex process control for the permanent and defined heating of molten materials, since the combustion of natural gas, which is usually carried out via a large number of gas burners, basically guarantees sufficient heat coupling and thus reliable heating of the molten material. In this respect, and in view of the high costs associated with any conversions in plant technology, natural gas fuel has not been used as an energy source in coating processes, particularly in galvanizing.

[0012] Now, the objective of the present invention is to avoid or at least substantially reduce the aforementioned disadvantages of the prior art.

[0013] According to the invention, a method and a system for operating and / or decarbonizing an industrial production process are proposed to solve the aforementioned objective, wherein the heating of the molten material is carried out by means of at least one electric heating device and / or at least one non-electric heating device. This means that the heating can be operated only electrically, only non-electrically, or in a hybrid combination – electric and non-electric at the same time.

[0014] In the development of the present invention, it was recognized that there are a number of advantages in no longer heating the molten material using exclusively a non-electric or gas-based energy source, but rather optionally using an electric heating device. The molten material can be heated by means of electrical heat storage in addition to the non-electric heating device or as a replacement. Petition 870250087389, dated 09 / 26 / 2025, page 55 / 231 4 / 35 complete non-electric or gas-based heating device.

[0015] In this respect, the term optionally or or ultimately encompasses three different methods or process modes for supplying all the energy required for the industrial process or for heating the molten material. Thus, depending on the process, the molten material can be heated exclusively by means of the non-electric heating device (first process mode). Furthermore, it is possible to couple the heat by means of a combined heat input using the non-electric heating device and the electric heating device (second process mode). Finally, it is also possible to heat the molten material using exclusively the electric heating device (third process mode).

[0016] Due to the optional use of the electric heating device, the disadvantages associated with non-electric or gas-based heating devices are avoided or mitigated, particularly with regard to avoiding climate-damaging emissions such as carbon dioxide. This creates the basis for the decarbonization foreseen in the process, since the replacement of an electric heating device, as provided by the invention, allows the heat required for heating the molten material to be associated with a significant reduction and, in some cases, the complete elimination of climate-damaging emissions such as carbon dioxide emissions.

[0017] In this respect, the term decarbonization, as used in the context of the present invention, should be understood as a way of avoiding or at least reducing emissions that cause damage to the climate, such as those produced in conventional industrial processes, in particular in the combustion of fossil fuels, such as natural gas. The term emissions that cause damage to the climate should be understood broadly and ultimately includes all gaseous emissions that have a negative impact on the climate. The present invention has as its main objective to avoid or reduce carbon dioxide (CO2), but is not limited to this. For example, other gases, such as Petition 870250087389, dated 09 / 26 / 2025, page 56 / 231 5 / 35 Carbon monoxide, methane, nitrous oxide, or other greenhouse gases (GHGs) with a negative impact on the climate may also be emissions that cause climate damage according to the teachings of the invention.

[0018] In other words, a hybrid heating concept is proposed according to the invention, whereby an electric heating device is used optionally or at least proportionally for the permanent heating of the molten material, accompanied by the desired decarbonization of the industrial process to be operated.

[0019] The term permanent supply or availability of molten material preferably refers to a period of at least one hour, preferably at least 5 hours, in particular at least 10 hours, whereby, depending on the scope of process control, this may also include a day or 24 hours up to several days. In this respect, the term permanent should preferably be understood in a broad sense.

[0020] In particular, with reference to a coating or galvanizing process, the term permanent defines the operating time during which a molten material held in a container can be used in a stationary and / or functional manner to coat workpieces as part of a coating process without drainage or preparations.

[0021] Furthermore, the term molten material, as preferably used in the context of the present invention, should be understood as a mass of non-ferrous metallic coating that is supplied and / or maintained in a container or other retention medium and that is used in a stationary manner or as an immersion bath with at least substantially constant volume or mass throughout the process, i.e., without draining the container. In this respect, a molten material within the meaning of the present invention should preferably not be understood as a molten casting material for primary casting or molding of corresponding cast products. However, the use of the method according to the invention may also be convenient in casting processes and is therefore Petition 870250087389, dated 09 / 26 / 2025, page 57 / 231 6 / 35 expressly covered by the teaching in accordance with the invention.

[0022] In developing the invention with the described hybrid heating strategy in an industrial process, several technical preconceptions had to be overcome. Depending on the application or specific requirements, industrial processes have hitherto used burners that are heated with natural gas or other fossil gaseous energy sources. Alternatively, processes are known that consume heat using only electricity, either by inductive or resistance heating. Due to the complex process control involved in heat-consuming processes, the hybrid use combining electrical and non-electrical energy sources has not been considered until now. In particular, it has also been considered disadvantageous and disproportionate in other technical fields to provide hybrid systems, as the change of energy sources or the associated energy input involves complicated conversion measures and a corresponding interruption of the heat supply.This interruption can last from a few minutes to hours, accompanied by corresponding production interruptions and technical precautions to prevent a drop in process temperature. As a result, the use of hybrid systems or the parallel operation of electric and non-electric heating in heat-consuming processes has not been considered in practice to date.

[0023] Contrary to this prevailing opinion, it has now been recognized, in the context of the solution according to the invention, that a hybrid heating system, consisting of an electric heating device and a non-electric heating device, is very well suited in industrial production processes, specifically for heating a molten material held or supplied, in particular, for a coating process.

[0024] In the context of the invention, it has been determined that molten materials requiring continuous heating, preferably metal molten materials and / or non-ferrous molten materials, in particular zinc-containing metal molten materials, are therefore suitable for heat supply. Petition 870250087389, dated 09 / 26 / 2025, page 58 / 231 7 / 35 hybrid heating systems have a comparatively high thermal inertia, or their temperature changes relatively slowly during heat supply and / or heat removal due to a relatively high mass and heat capacity. This results in a comparatively large time window or reduced sensitivity for implementing the process modes described above, or for selecting a heating device, or for switching from one heating device to another, and for the hybrid heating system.

[0025] As a result, the present invention proposes, for the first time and in the form of a single-piece concept, that, in order to decarbonize a heat-consuming process, the heating of a molten material used in that process should not be implemented exclusively by means of gas-based or non-electric heating, but at least partially or optionally also by means of an electric heating device, whereby parallel or simultaneous heating by means of non-electric and electric heating devices is also possible.

[0026] Due to the inertia of the molten material, heating optionally by means of the electric heating device and / or the non-electric heating device provided by the process ensures that, even in the event of a brief interruption of the heat input to the molten material to be heated, there is no loss of process performance compared with known non-electric or gas-based heating of the prior art.

[0027] As a specific supplement to the hybrid heating described above, the invention also provides that, in order to operate the electric heating device, an excess current occurring in a power network, in particular in the public power network, is at least partially extracted and used to operate the electric heating device.

[0028] In this context, excess electricity is electricity that is only available with fluctuating output over time and can therefore lead to an oversupply of electricity or overcapacity in the power network. Petition 870250087389, dated 09 / 26 / 2025, page 59 / 231 8 / 35 In this regard, situations are increasingly occurring where electrical energy or electricity cannot be fully consumed due to an oversupply of electricity in the power grid.

[0029] Surplus electricity, that is, electricity with fluctuating production over time, is due in particular to the participation of renewable energies, whose share of electricity is increasingly fed and prioritized in the power grid. As the underlying energy sources, namely sun, wind and water, are not constantly available over time and their availability is also difficult to predict, fluctuating production and excess capacity or periods of surplus electricity are inevitable. For example, a high level of short-term wind can lead to an oversupply of electricity or power spikes in the power grid, accompanied by the problem that the resulting excess electricity must be diverted or consumed to avoid overloading the power grid and the associated damage.

[0030] The term power network, as used in the context of the present invention, is preferably understood broadly and in electrical power engineering refers to a network for the transmission and distribution of electrical energy. It consists of electrical lines, such as overhead lines and underground cables, as well as associated equipment such as switching stations and substations. Large, spatially adjacent, and electrically connected power networks are called interconnected networks, while small, spatially separated power networks are called isolated networks. The method according to the invention is particularly used in power networks that obtain at least a portion of their electrical energy from renewable sources.

[0031] In the near future, the introduction of proportionally larger renewable energies, from the sun, wind and water, into the power grid will increasingly lead to electricity peaks and / or surplus electricity, which can only be purchased incompletely by electricity consumers and is therefore offered on the electricity market as such. Petition 870250087389, dated 09 / 26 / 2025, page 60 / 231 9 / 35 called surplus electricity, well below its production costs or at prices lower in relation to its energy content than a fossil fuel with the same calorific value, or free of charge, that is, without compensation, or even at negative prices.

[0032] To date, overload current has not been used to reduce energy spikes related to metal smelting. Instead, in practice, attempts have been made to store excess energy or energy spikes in storage systems such as batteries and pumped-storage power plants, and feed them back into the grid later. However, the use of battery systems is problematic in terms of associated costs and resource requirements. From an ecological point of view, in particular, the use of batteries with limited lifespan and decreasing performance in the long term or with increased use is counterproductive and therefore not convenient from a sustainability perspective. Recycling and disposing of batteries on the necessary scale is also known to be problematic.

[0033] With regard to the buffers and storage systems in question, it should also be noted that the construction of such systems is very expensive and, depending on geographical conditions and the high losses associated with energy conversion, is not a viable solution.

[0034] In this regard, no satisfactory concept has been developed in practice for making targeted use of surplus electricity. However, at the same time, handling surplus electricity is an important aspect with regard to the energy transition, since the surplus electricity in question is generated mainly from renewable energies.

[0035] The invention now makes it possible to use the electrical energy generated by excess current specifically to operate an electric heating device or to heat a molten material.

[0036] This requirement is based on the aforementioned finding that heating the molten material using an electric heating device Petition 870250087389, dated 09 / 26 / 2025, page 61 / 231 10 / 35 on an industrial scale in combination with a non-electric heating device is entirely feasible.

[0037] In contrast to this precedent, the solution according to the invention also contributes to avoiding overloading the power grid and to the efficient use of surplus electricity, which comes mainly from renewable energy sources, such as solar, wind and hydroelectric power.

[0038] As a result, the solution according to the invention therefore provides a specifically coordinated concept whereby two findings are combined for a specific purpose, which are already advantageous in themselves with regard to decarbonisation and / or the prevention of emissions that cause climate damage, such as carbon dioxide.

[0039] Therefore, decarbonization is already achieved through the use of electric heating systems. This basic idea is then completed or supplemented by the additional requirement that surplus electricity be used specifically to operate electric heating systems. This surplus electricity comes primarily from renewable energy sources, meaning that the surplus electricity itself also comes from an emission-free source. This enables the achievement of an emission-free process chain, completely avoiding the formation of emissions that cause climate damage, such as carbon oxides.

[0040] In this regard, the solution according to the invention contributes to the decarbonization of an industrial production process using a molten material, while simultaneously providing the integration of surplus electricity or electricity generated from renewable energies, thus also addressing aspects of grid service capacity and grid relief.

[0041] Based on the fundamental considerations above regarding the solution according to the invention, the advantageous procedural aspects of the present invention are discussed below.

[0042] The occurrence of overcurrent in the power network can be detected by a detection device. This can preferably be done Petition 870250087389, dated 09 / 26 / 2025, page 62 / 231 11 / 35 automatically, in particular by frequency control and / or internet. A detection device is also understood as a device for receiving a signal or similar that is emitted manually or automatically by the network operator and received by the receiving device. After the overcurrent is detected, the electric heating device and the non-electric heating device are controlled by means of a control and / or regulation device. Consequently, in the method for operating the production process, a distinction is made between a period of time before the occurrence of the overcurrent and a period of time after the occurrence of the overcurrent, in which, after the occurrence of the overcurrent, the control / regulation of the electric and non-electric heating device occurs preferentially, where the overcurrent is used to operate the electric heating device.Excess current is preferably used in such a way that the heated molten material is supplied and / or maintained within a defined process temperature range, in particular permanently or throughout the entire production cycle.

[0043] The use of surplus electricity to operate the electric heating system and the shutdown of the non-electric heating system, as needed, is preferably carried out in such a way that the production process runs continuously during electric heating. Consequently, the use of surplus electricity to operate the electric heating system is not associated with any disadvantage compared to conventional non-electric or gas-based heating, so that the use of hybrid heating using the electric heating system does not lead to any restriction in the production process during the change from one process to another, gas-based heating, so that the use of hybrid heating using the electric heating device does not lead to any restriction in the production process, which continues continuously during the change from one process mode to another.

[0044] With regard to a specific process control, it is preferably Petition 870250087389, dated 09 / 26 / 2025, page 63 / 231 12 / 35 provided that, when overcurrent occurs and / or is detected, the heating power of the non-electric heating device is reduced and the operation of the electric heating device is initiated, preferably whereby the operation of the non-electric heating device is terminated and the heating of the molten material is performed exclusively by the electric heating device using overcurrent.

[0045] This type of process is particularly advantageous when surplus electricity is expected to be available for a longer period of time. In this case, the process can be explicitly designed so that the production process runs continuously using only electric heating or surplus electricity for this purpose. The non-electric heating system can then be permanently deactivated, resulting in maximum decarbonization and / or avoiding climate-damaging emissions such as carbon oxides, since the use of fossil fuels is completely eliminated. However, it cannot be ruled out that, starting from purely electric heating, the non-electric heating system could be switched on again. It is also possible to completely switch off the electric heating system or heat exclusively with the non-electric heating system.This always happens when it is foreseeable that the surplus electricity will no longer be available.

[0046] The reduction or switching off of the non-electric heating device and / or the starting or activation of the electric heating device may occur continuously or discontinuously. Preferably, the switching off or starting is adjusted automatically as if the reduction of the non-electric heating device were compensated by a corresponding starting of the electric heating device, and the total thermal energy and / or process temperature introduced into the molten material were kept at least essentially constant throughout the production process. This avoids undesirable temperature fluctuations. Petition 870250087389, dated 09 / 26 / 2025, page 64 / 231 13 / 35 processing of the molten material. Ultimately, this is possible by controlling / regulating the temperature of the molten material, which is measured continuously.

[0047] In this context, it is possible to define a transition time, the start of which is defined by the detection of excess current and / or by the start of the shutdown of the non-electric heating device and / or by the start of the initialization of the electric heating device. The end of the transition time is defined by the complete shutdown of the non-electric heating device and / or by the complete initialization of the electric heating device.

[0048] The transition time in question is preferably freely selectable, whereby flexibly adaptable transition times are possible, in principle, due to the comparatively high heat capacity of the molten material. However, these times also depend on the total volume of the molten material aggregation.

[0049] A transition time may be provided in the range of a few seconds, for example, a maximum of 45 or a maximum of 30 seconds, to several minutes, for example, 5 to 10 minutes, preferably 5 to 30 minutes, within which the non-electric heating device has been completely switched off and the electric heating device has been completely initialized. However, shorter or longer transition times are also possible, particularly depending on the excess current available and the amount of molten bath.

[0050] Preferably, the molten material can be heated exclusively by the non-electric heating device before the occurrence and / or detection of overcurrent, and the electric heating device can be added to the non-electric heating device when overcurrent occurs and / or is detected. In this regard, it is preferable that the switching on or activation of the electric heating device be specifically coupled to the occurrence of overcurrent, whereby, at times when there is no overcurrent in the power network, the Petition 870250087389, dated 09 / 26 / 2025, page 65 / 231 14 / 35 Heating is provided exclusively by the non-electric heating device. However, it is understood that it is also possible to operate the electric heating device without excess current, for example, by connecting it directly to any electrical power source, which is preferably powered at least partially, in particular completely, by renewable energy sources.

[0051] With regard to the operation of the non-electric heating device, a preferred method provides that the non-electric heating device is operated with a CO2-free fuel gas or at least with natural gas and / or CO2-reduced fuel gas, in particular pure hydrogen or a hydrogen-containing fuel gas, for example, a fuel gas in the form of a natural gas-hydrogen mixture.

[0052] According to this particularly preferred method, decarbonization is achieved not only by using an electric heating device, but also by modifying the non-electric heating device, whereby hydrogen is used or mixed in instead of a pure fossil fuel gas or natural gas. The combustion products of hydrogen are mainly water vapor, which is beneficial in terms of avoiding the formation of climate-damaging emissions, such as carbon oxidants, which are produced during the combustion of natural gas.

[0053] Preferably, while pure hydrogen is not yet available on a large industrial and economical scale, it is particularly convenient for hydrogen to be mixed with a carrier gas, preferably natural gas, to obtain hydrogen-containing fuel gas. The carrier gas or natural gas in question is preferably at least partly a process gas produced in an industrial process, such as mine gas and / or coke oven gas.

[0054] The hydrogen content in the mixed gas, in particular consisting of or containing natural gas and hydrogen, is preferably at least 20%, preferably at least 40%, particularly, preferably at least Petition 870250087389, dated 09 / 26 / 2025, page 66 / 231 15 / 35 60%, very particularly, preferably at least 80% or 90%.

[0055] In particular, a combustible gas containing hydrogen is used to operate non-electric heating devices, wherein the combustible gas contains at least 1 to 100% by volume, preferably 25 to 100% by volume, and preferably 50 to 100% by volume, of hydrogen.

[0056] In particular, preferably, the non-electric heating device is operated exclusively and / or 100% with hydrogen, preferably pure and / or green hydrogen.

[0057] In particular, so-called green hydrogen is used exclusively to operate non-electric heating devices and / or as a pure fuel gas or proportionally in a mixed gas, for example, with natural gas. Green hydrogen is produced by electrolysis of water, for which the electricity required is, in turn, obtained from renewable energy sources.

[0058] According to the invention, it is also possible to operate the non-electric heating device at least partially from renewable energies, namely, hydrogen obtained from renewable energy sources.

[0059] The preferred process control described above with respect to the use of hydrogen, preferably green hydrogen, enhances the decarbonization of the process according to the invention and further optimizes the sustainability of the process according to the invention, in particular, in addition to hybrid heating by means of electric heating energy.

[0060] Heat coupling in the molten material or heating of the molten material may preferably occur at least partially indirectly via a vessel receiving the molten material, preferably with a furnace chamber surrounding the vessel being heated by means of an electric and / or non-electric heating device. In particular, the furnace chamber is heated by means of a non-electric heating device and the molten material is additionally heated directly by means of a Petition 870250087389, dated 09 / 26 / 2025, page 67 / 231 16 / 35 electric heating device, preferably placed in the molten material.

[0061] Consequently, the non-electric heating device, on the one hand, and the electric heating device, on the other, are preferably spatially separated. Preferably, the non-electric heating device can be used in the furnace chamber to heat the vessel wall, while the electric heating device can be accommodated in the vessel for direct contact with the molten material. In particular, this prevents the electric heating device from coming into contact with potentially harmful exhaust gases during the use of the non-electric heating device or the combustion of the fuel gas. However, it is also possible to arrange the non-electric heating device and the electric heating device together in the furnace chamber.For this purpose, the electric heating device, preferably in rod form, may be provided with a protective layer to provide protection against exhaust gases emitted by the non-electric or gas-based heating device.

[0062] The molten material is preferably heated in such a way that the molten material is maintained at a process temperature that is at least 10 °C, preferably at least 20 °C, in particular at least 30 °C, above the melting temperature of the molten material.

[0063] It is preferable that the molten material be maintained at a process temperature in the range of 200 °C to 1200 °C, preferably in the range of 350 °C to 470 °C or preferably in the range of 510 °C to 610 °C.

[0064] Particularly preferably, the molten material may be held at a process temperature in the range of 400 °C to 600 °C, preferably in the range of 415 °C to 470 °C, or preferably in the range of 510 °C to 610 °C, in particular 520 °C to 600 °C. The temperature ranges in question are preferred for galvanizing processes, whereby the increased temperature range of 510 °C to 610 °C or 520 °C to 600 °C is provided for galvanizing. Petition 870250087389, dated 09 / 26 / 2025, page 68 / 231 17 / 35 high temperature.

[0065] In particular, the molten material is supplied and / or stored as an immersion bath, especially a galvanizing bath, in a metal coating process, whereby at least one component to be coated with the molten material is immersed in the molten material and emerged from the molten material.

[0066] It is particularly preferred that the molten material or immersion bath be supplied as a molten metal alloy. Preferably, a molten zinc alloy is supplied or used as the molten material.

[0067] The process according to the invention has proved to be particularly useful for hot-dip galvanizing or hot-dip galvanizing, in particular batch galvanizing, whereby a material or component to be coated, preferably steel or a steel component, is continuously (e.g., strip and wire) or in pieces (e.g., components) immersed in a boiler heated with liquid zinc alloy at temperatures of approximately 400 °C to 600 °C, so that the zinc alloy is applied to the material or component, a steel component is continuously immersed (e.g., strips and wires) or in pieces (e.g., components) at temperatures of approximately 400 °C to 600 °C in a boiler heated with liquid zinc alloy, so that it forms a resistant layer of iron and zinc alloy on the surface of the steel or on the surface of the material and a very firmly adherent layer of zinc or zinc alloy on top.

[0068] The method according to the invention enables a continuous production process, in particular a hot-dip galvanizing process, whereby, compared with the heating of molten material known from the prior art based solely on non-electric or gas-based heating, no loss can be determined with respect to the temperature and / or quality of the molten material to be maintained. Currently, as described in detail above, the process control according to the invention makes it possible to achieve significantly network sustainability or utility. Petition 870250087389, dated 09 / 26 / 2025, page 69 / 231 18 / 35 improved due to associated decarbonization.

[0069] Accordingly, the process control according to the invention makes it possible to supply and / or maintain the molten material at the process temperature permanently and / or over a period of at least 1 hour, preferably at least 5 hours, particularly, preferably at least 10 hours.

[0070] Alternatively or additionally, the molten material is also supplied in a mass or dimension typical for hot-dip galvanizing or industrial galvanizing, preferably with a mass of 200 to 800 t (tonnes), preferably 250 to 750 t, in particular 300 to 700 t, in particular in a container intended for the industrial coating process or for industrial galvanizing.

[0071] However, it should be noted that the process according to the invention is not limited to galvanizing or coating processes. Ultimately, the teaching according to the invention can be transferred to all known coating processes of the prior art, provided that a heated molten material is used or supplied as the relevant coating composition.

[0072] According to a further aspect of the present invention, the system according to the invention for operating and / or decarbonizing an industrial process, preferably an industrial production process, is described below.

[0073] More specifically, the present invention also relates to a system for operating and / or decarbonizing an industrial production process, preferably a coating process, such as galvanizing, in which a vessel is provided for a molten material to be received and heated. The system according to the invention has at least one electric heating device and at least one non-electric heating device.

[0074] According to the invention, the system has at least one control and / or regulation device for selectively heating the molten material by means of the electric heating device and / or the non-electric heating device. Petition 870250087389, dated 09 / 26 / 2025, page 70 / 231 19 / 35 non-electric, wherein the control and / or regulation device is additionally designed to at least partially extract excess current occurring in a power network and to operate the electric heating device with the extracted excess current. In this way, the advantages or special features of the present invention, discussed above, can be implemented according to the device.

[0075] Consequently, the system according to the invention is designed or conceived in particular for the implementation of the method discussed above. The advantages mentioned above for the method also apply to the system in the same way.

[0076] In another preferred embodiment of the invention, the control and / or regulation device has a detection device to detect the occurrence of overcurrent and a control and / or regulation device to operate the electric heating device and the non-electric heating device after the overcurrent has been detected. The detection device may also be designed as a receiving device to receive signals or similar sent by the network operator or third parties when overcurrent occurs. The control and / or regulation device may comprise the detection device and the control and / or regulation device as a higher-level assembly. It is understood that, in principle, it is also possible to design the detection device and the control and / or regulation device as modules or units separate from each other according to the device and connected to each other by means of signal technology.The control and / or regulation device should therefore be understood abstractly or as a superordinate designation, unrelated to the device itself, of the structural units in question.

[0077] In another preferred embodiment of the invention, a furnace chamber is provided that at least partially surrounds the vessel, preferably in which the electric heating device and / or the non-electric heating device is / are designed to heat the Petition 870250087389, dated 09 / 26 / 2025, page 71 / 231 20 / 35 furnace chamber and / or is / are arranged on or within the furnace chamber, in particular, wherein the non-electric heating device is / are arranged on or within the furnace chamber and the electric heating device is / are designed to come into contact with the molten material and / or is / are arranged to directly heat the molten material within the vessel, in particular, wherein the non-electric heating device is arranged on or within the furnace chamber and the electric heating device to come into contact with the molten material and / or to directly heat the molten material is arranged inside the vessel and / or the electric heating device is arranged on or within the outer wall region outside the vessel.The physically separate arrangement of the electric heating device from the non-electric heating device prevents the electric heating device from coming into contact with the combustion gases emitted by the non-electric heating device. In this way, the electric heating device is protected from the harmful exhaust gases of the non-electric heating device, enabling the reliable long-term operation of the hybrid heating system.

[0078] The present invention also relates, in view of the above features or advantages, to the use of the system according to the invention to reduce and / or avoid the formation of emissions that cause damage to the climate, such as carbon oxides, in the generation of process heat in the operation of a heat-consuming process, preferably a coating process, such as galvanizing, in particular hot-dip galvanizing.

[0079] Consequently, the present invention also relates to the use of the system according to the invention to extract excess current when current peaks occur and / or to increase the utility of the network in a heat-consuming process, preferably a coating process such as galvanizing, in particular hot-dip galvanizing.

[0080] It is understood that it is also possible to use the system according to the invention both to reduce and / or avoid the formation of emissions that cause Petition 870250087389, dated 09 / 26 / 2025, p. 72 / 231 21 / 35 damage to the climate, such as carbon dioxide, as well as extracting excess electricity when electricity peaks occur and / or increasing grid utility, i.e., a combination of the above uses. As described above, the uses in question are related to coordinated or mutually reinforcing aspects of decarbonization, since it is precisely the operation of the electric heating device using excess electricity that initially reduces the proportion of non-electric heating devices, whereby the use of excess electricity, which comes mainly or exclusively from renewable energy sources, brings with it an additional increase in decarbonization or enhanced sustainability.

[0081] Consequently, the uses or aspects in question should preferably be understood in their purposeful combination.

[0082] Other features, advantages and possible applications of the present invention are evident from the description of the embodiments of the present invention with reference to the drawing and the drawing itself. All features described and / or illustrated constitute the object of the present invention, individually or in any combination, regardless of their summary in the claims or their relationship to each other.

[0083] It is shown in: Fig. 1 a schematic representation of a system according to the invention and the sequence of the method according to the invention and Fig. 2 a perspective view of a molten material received in a container for the schematic representation of the hybrid heating process in the sense of the method or system according to the invention.

[0084] Fig. 1 schematically illustrates a system 1 according to the invention for operating and / or decarbonizing an industrial production process using a molten material 2.

[0085] As follows, the components or devices of system 1 according to the invention are first described, followed by a discussion of the course. Petition 870250087389, dated 09 / 26 / 2025, page 73 / 231 22 / 35 of the method according to the invention, using system 1 according to the invention on that basis.

[0086] In this context, it should be noted that the following explanations regarding system 1 according to the invention do not represent the only possibility for implementing the method according to the invention. Instead, a basic concept or a possible implementation is described here in order to practically implement the method according to the invention to operate and / or decarbonize an industrial production process using a heated molten material 2. Based on this, a large number of modifications and / or technical specifications are possible, in principle, compared to system 1 described according to the invention.

[0087] As system 1 according to the invention is designed to operate an industrial production process using molten material 2, system 1 according to the invention has a container 3 in which the molten material 2 to be heated can be accommodated or is accommodated.

[0088] The molten material 2 is preferably designed as a dipping bath, in particular a galvanizing bath, or is used in a metal coating process, such as galvanizing, in particular hot-dip galvanizing. Consequently, the heated molten material 2 is supplied and / or stored as a coating mass.

[0089] To heat the molten material 2, the system 1 has at least one non-electric heating device 4, preferably a plurality of non-electric heating devices 4 is provided. The non-electric heating device 4 is preferably designed to burn a combustible gas or as a gas burner to enable the introduction of heat into the molten material 2 to be heated.

[0090] Consequently, the non-electric heating device 4 is connected to a power source 5, preferably a gas source. Through the power source 5, the fuel gas, for example, natural gas, in particular natural gas mixed with hydrogen or pure hydrogen, can be Petition 870250087389, dated 09 / 26 / 2025, page 74 / 231 23 / 35 available to operate the non-electric heating device 4.

[0091] If a mixed gas is used, an additional upstream hydrogen source may be provided to mix the gas from energy source 5, preferably natural gas, with hydrogen as an additional gaseous component or vice versa. The hydrogen is preferably generated from renewable energy sources, produced by the electrolysis of water, in which water is split into hydrogen and oxygen using renewable electricity. In this respect, it is preferably referred to as green hydrogen.

[0092] For additional or optional heating of the molten material 2, the system 1 has at least one electric heating device 6, preferably a plurality of electric heating devices 6.

[0093] Consequently, the electric heating device 6 can be connected to a power grid 7. The power grid 7 is preferably a public power grid. Preferably, the power grid 7 or the electrical power source contains electricity produced at least in part from renewable energy sources, which is fed into the power grid 7 as needed.

[0094] System 1 according to the invention has a control and / or regulation device 8 for selectively heating the molten material 2 by means of the non-electric heating device 4 and / or the electric heating device 6.

[0095] The control and / or regulation device 8 was designed to extract at least some of the excess current in the power network 7 and to operate the electric heating device 6 with the extracted excess current.

[0096] For preferably automatic and / or frequency-controlled or Internet-controlled detection of overcurrent, the control and / or regulation device 8 has a detection device 9 to detect the occurrence of overcurrent and a control and / or regulation device 10 to operate the electric heating device 6 and the non-electric heating device 4 after the overcurrent has been detected. A device of Petition 870250087389, dated 09 / 26 / 2025, page 75 / 231 24 / 35 detection 9 is also understood to be a device used to receive signals transmitted by the network operator or a third party, whereby the transmission of a signal occurs automatically when current spikes or overcurrent are present in the network or when this is announced. Signals of this type are generated and transmitted automatically by the network operator or a third party.

[0097] The detection device 9 and the control and / or regulation device 10 are preferably connected to each other by means of signals.

[0098] This signaling connection is preferably made in such a way that, when excess current from the detection device 9 occurs and / or is detected, the control and / or regulation device 10 is activated to remove the excess current from the power network 7.

[0099] The control and / or regulation device 10 is designed to control or regulate the non-electric heating device 4 and the electric heating device 6. For this purpose, the control and / or regulation device 10 is connected to the non-electric heating device 4 and the electric heating device 6 by means of signals.

[0100] The control and / or regulation device 10 is designed to regulate the thermal energy introduced into the molten material 2 by the non-electric heating device 4 and the electric heating device 6 as a function of the excess current occurring in the power network 7 and / or the temperature of the molten material 2. Preferably, the regulation or control is performed in such a way that a constant heat input occurs into the molten material 2 throughout the occurrence of the excess current and / or a defined constant process temperature of the molten material 2 is ensured.

[0101] For this purpose, the control and / or regulation device 10 is designed to increase the power of the electric heating device 6 when excess current occurs and / or is detected and, preferably simultaneously, to reduce the power of the non-electric heating device. Petition 870250087389, dated 09 / 26 / 2025, page 76 / 231 25 / 35 electric 4, preferably in such a way that the total heat input coupled to the molten material 2 by the combination of the non-electric heating device 4 and the electric heating device 6 or the associated process temperature remains constant. If the excess flow fluctuates, the control and / or regulation device 10 is also designed to adjust the heat input introduced into the molten material 2 by the heating devices 4, 6 consequently, in order to ensure a constant heat input or a constant process temperature, even if the excess flow fluctuates.

[0102] To control or regulate the heating devices 4, 6, a process temperature in the molten material 2 is preferably measured continuously as a controlled variable and compared with a reference variable or with the desired process temperature of the molten material 2. Based on any control deviation that may occur, the power input of the heating devices 4, 6 is then adjusted by means of the control and / or regulation device 10. In principle, it is also possible to superheat the molten material 2 by the electric heating device 6 in a temperature range up to 20 °C above the usual process temperature and then adjust the electric heating for some time until the temperature of the molten material 2 drops back to the usual process temperature.The control and / or regulation device 10 is also designed to completely switch off the non-electric heating device 4 or to cause the molten material 2 to be heated exclusively by the electric heating device 6. The molten material 2 is then preferably heated exclusively by means of the electric heating device 6 or exclusively using excess current.

[0103] However, the molten material 2 can also be heated by means of the control and / or regulation device 10 with exclusive operation of the non-electric heating device 4, whereby the control and / or regulation device 10 is consequently designed to switch off the device of Petition 870250087389, dated 09 / 26 / 2025, page 77 / 231 26 / 35 electric heating 6 completely.

[0104] It should be noted that system 1 may also have a second control and / or regulation device (not shown), which may be provided in addition to the control and / or regulation device 8 described or shown. This additional or second control and / or regulation device may be provided, in particular, for process operation if there is no overcurrent and / or is designed to operate the process or the non-electric heating device 4 and / or the electric heating device 6 independently of the power network 7. Consequently, the described or first control and / or regulation device 8 is used only when overcurrent is present or detected in the power network 7.

[0105] Similarly, at least one switching device may be provided to switch between the non-electric heating device 4 and the electric heating device 6. This switching device is preferably also connected to the control and / or regulation device 8 or to the control and / or regulation device 10 by means of signals.

[0106] Thus, the molten material 2 is optionally heated by means of the electric heating device 6 and / or the non-electric heating device 4.

[0107] The optional term ultimately defines three different process modes, according to which heating is carried out exclusively by the non-electric heating device 4 (first process mode), by the non-electric heating device 4 and the electric heating device 6 (second process mode) or exclusively by the electric heating device 4 (third process mode).

[0108] To control and / or regulate heating devices 4, 6 and / or to change the process modes in question, heating devices 4, 6 are connected to the control and / or regulation device 8 of system 1 by means of signals.

[0109] Heating devices 4, 6 are controlled by means of Petition 870250087389, dated 09 / 26 / 2025, page 78 / 231 27 / 35 control and / or regulation device 8, in particular, such that a defined process temperature or a predetermined temperature range of the molten material 2 is specified as a target or controlled variable. For this purpose, the control and / or regulation device 8 is preferably supplied continuously or at intervals with the actual temperatures of the molten material 2, based on which the heating devices 4, 6 are then selectively controlled to supply the molten material 2 continuously at the defined process temperature.

[0110] It is understood that system 1 according to the invention may have temperature sensors or thermocouples, not shown, in the area of ​​the container 3 and / or the molten material 2 to determine the actual temperature of the molten material 2.

[0111] Due to the combined heating by means of the non-electric heating device 4 and the electric heating device 6, decarbonization can occur compared to processes operated only with a non-electric heating device 4.

[0112] With this in mind, the method according to the invention, using system 1 according to the invention, is described below.

[0113] According to the method, it is expected that if there is excess current in power network 7, this is at least partially extracted from power network 7 and used to operate the electric heating device 6.

[0114] The presence of excess current is detected, preferably automatically, by the detection device 9, with the result that the regulation or control of the heating devices 4, 6 takes into account the excess current extracted.

[0115] Specifically, the control and / or regulation device 10 of the control and / or regulation device 8 is initially designed to operate the electric heating device 6 using excess current drawn from the power grid 7.

[0116] Simultaneously or alternatively, the control device and / or Petition 870250087389, dated 09 / 26 / 2025, page 79 / 231 28 / 35 regulation 10 is also designed to reduce or turn off the heating output of the non-electric heating device 4 as a result of the occurrence of overcurrent and heating operation assumed by the electric heating device 6.

[0117] The control of heating devices 4, 6, in particular the initialization of the electric heating device 6 and the shutdown of the non-electric heating device 4, continues to occur under the condition that a defined process temperature of the molten material 2 is maintained, which continues to be processed as a reference variable or target variable in the control and / or regulation device 8 or in the control and / or regulation device 10.

[0118] It has been proven that it is convenient for the molten material 2 to be initially heated exclusively by the non-electric heating device 4, which is operated or supplied by the power source 6, before excess current is detected. When excess current from the power source 7 is detected, the electric heating device 6 is then switched on, with the result that the heat input previously supplied exclusively by the non-electric heating device 4 is now initially taken up proportionally or completely by the electric heating device 6.

[0119] As a result, the exhaust gas pollution emitted by the non-electric heating device 4 is reduced, along with the decarbonization of the industrial production process achieved by the process.

[0120] At the same time, the use of surplus electricity is associated with an improvement in the efficiency of the power grid 7, since the overload of the power grid 7 that would occur if the surplus electricity were not used is avoided or compensated for.

[0121] Particularly in the case of prolonged or excessive overflow, it has been found that it is advisable to completely switch off the heating using the non-electric heating device 4 and heat the molten material. Petition 870250087389, dated 09 / 26 / 2025, page 80 / 231 29 / 35 exclusively by means of the electric heating device 6.

[0122] A possible embodiment of arrangements and / or designs of heating devices 4, 6 for heating the molten material 2 held in the container 3 is described below with reference to Fig. 2.

[0123] In this context, it should be noted that the arrangement shown is a possible technical variant according to the invention for carrying out the method according to the invention, which, however, should not be understood necessarily as the only technical possibility. In this respect, teaching according to the invention is not limited to the arrangement illustrated below and a large number of other embodiments are possible or conceivable.

[0124] The connection and / or design of the heating devices 4, 6 for heating the molten material 2 is preferably carried out in such a way that process control can be performed throughout the process independently of each other or with the exclusive use of the non-electric heating devices 4 or the electric heating devices 6, whereby the combined use of the heating devices 4, 6 is also possible with any proportion of heat coupling introduced by the heating devices 4, 6.

[0125] In particular, the electric heating devices 6 are designed and / or arranged in such a way that the molten material 2 can be heated in the range of a defined process temperature exclusively by electric heating, preferably using only the excess current from the power grid 7.

[0126] In the embodiment shown in Fig. 2, a furnace chamber 11 is provided that at least partially surrounds the vessel 3, which is preferably designed as an annular chamber and / or surrounds the vessel 3 on all sides.

[0127] The furnace chamber 11 is bounded internally by the wall of the vessel 3 and externally by a furnace housing 12, through which the vessel 3 is accommodated in the furnace housing 12. Petition 870250087389, dated 09 / 26 / 2025, page 81 / 231 30 / 35

[0128] In the exemplary embodiment illustrated and preferred, a plurality of rod-shaped electric heating devices 6 are provided, which are inserted or immersed in the molten material 2 for direct contact or heating. The electric heating devices 6 may be arranged within the molten material 2, preferably in pairs at opposite ends of the container 3, in particular in a vertical orientation when in use.

[0129] Additionally, a plurality of non-electric heating devices 4 are provided, which are designed as gas burners. The non-electric heating devices 4 are designed to heat the furnace chamber 11 and / or are arranged in the furnace chamber 11, preferably in the region of at least one side wall, in particular the longitudinal side wall, of the vessel 3. However, the non-electric heating devices 4 and / or electric heating devices 6 may also be arranged on opposite side walls, in particular longitudinal side walls, of the vessel 3.

[0130] It may be provided that the non-electric heating devices 4 are arranged and / or accommodated in the furnace housing 12, preferably in the region of at least one side wall, in particular the longitudinal side wall, of the furnace housing 12.

[0131] Additionally or as an alternative to the electric heating devices 6 disposed in the molten material 2, at least one electric heating device 6 may also be disposed in the furnace chamber 11. The electric heating device 6 may preferably be designed as an electric and / or flexible heating conductor, wherein the length of the electric conductor exceeds the length of the container 3 by a multiple.

[0132] The electric heating device 6 is preferably designed for the same side wall, in particular the longitudinal side wall, of the container 3 as the non-electric heating devices 4. Petition 870250087389, dated 09 / 26 / 2025, page 82 / 231 31 / 35

[0133] In the example illustrated and in the preferred embodiment, the electric heating device 6 is arranged in a loop or meander shape around the non-electric heating devices 4, preferably in such a way that the non-electric heating devices 4 are surrounded by the electric heating device 6.

[0134] It is understood that other provisions for non-electric heating devices 4 or electric heating device 6 may also be provided.

[0135] According to an embodiment not shown, it may also be provided that all or at least some of the non-electric heating devices 4 or heating burners are decoupled from the vessel 3 or furnace chamber 11 and / or arranged in a heating chamber upstream of the vessel 3. This heating chamber then functions as an upstream heating chamber, into which heating air or pre-heated heating gas is supplied. On the other hand, the electric heating devices 6 are decoupled from the non-electric heating devices 4 and are directly immersed in the molten material 2 and / or arranged in the furnace chamber 11.

[0136] Alternatively or additionally, it may also be provided that all or at least some of the electric heating devices 6 are decoupled from the vessel 3 or the furnace chamber 11 and / or arranged in an additional heating chamber or in the heating chamber upstream of the vessel 3. This one or additional heating chamber then functions as an upstream heating chamber, into which heating air or preheated heating gas is supplied. In contrast, the non-electric heating devices 4 are designed and / or arranged separately from the electric heating devices 6 for heating the furnace chamber 11.

[0137] By storing heated air in the upstream heating chamber, this heated air can be fed into furnace chamber 11 with a time Petition 870250087389, dated 09 / 26 / 2025, p. 83 / 231 32 / 35 fast response, provided that, preferably starting from the electric heating of the molten material 2, the heating of the molten material 2 is switched back to the non-electric heating device 4. For this purpose, the furnace chamber 11 may be flooded with already heated heating air to ensure that production continues or that the defined process temperature of the molten material 2 is maintained. For this purpose, the furnace housing 12 may have a corresponding inlet and / or outlet line 13 to feed a heated heat stream or heated heating air into the furnace chamber 11 as required, and / or to discharge the spent process air from the furnace chamber 11.

[0138] Indirect heat coupling by means of at least one electric heating device 6 and / or at least one non-electric heating device 4 disposed in the furnace chamber 11 occurs, in particular, in such a way that the air in the furnace chamber 11 is heated via a side wall, in particular a longitudinal side wall, and the wall of the vessel 3 is heated above it. This initially heats the molten material 2 on the side of the wall. Due to the associated heat convection, a flow or circulation of the wall-heated molten material 2 occurs into the interior of the vessel 3, so that the heated molten material 2, starting from the wall sections, also reaches the interior of the vessel 3 and the heated molten material 2 is therefore mixed within the vessel 3.

[0139] The electric heating devices 6 are preferably isolated or specially protected from the aggressive exhaust air of the non-electric heating devices 4, in particular if the heating devices 4, 6 are arranged or accommodated together in the furnace chamber 11.

[0140] Inlet and / or outlet 13 may preferably be closed as needed and / or fitted with a corresponding exhaust gas flap.

[0141] Additionally, several thermocouples or sensors attached to container 3 are provided to, preferably, continuously monitor and / or record. Petition 870250087389, dated 09 / 26 / 2025, p. 84 / 231 33 / 35 the temperature of the molten material 2 and / or the heating temperature in the furnace chamber 11.

[0142] The temperature in vessel 3 and / or furnace chamber 11 thus functions preferentially as a control variable, which is fed to the control and / or regulation device 8 or to the control and / or regulation device 10 for the purpose of regulating the non-electric heating device 4 and the electric heating device 6, consequently. As a result, the heat input of the electric heating device 6 and / or the non-electric heating device 4 is regulated or adjusted as necessary to avoid critical temperatures for the system and / or to maintain the molten material 2 at a permanently defined process temperature.

[0143] The control and / or regulation device 8 may have a switching device to implement on-demand switching of the heating mode between the electric heating device 4 and the non-electric heating device 6. The switching device may have the corresponding switching and / or line components for this purpose.

[0144] The non-electric heating devices 4 are preferably arranged as a matrix and / or in a fixed group pattern in the furnace chamber 11. Preferably, the non-electric heating devices 4 are associated with a side wall, in particular a longitudinal side wall, of the vessel 3.

[0145] Alternatively or additionally, non-electric heating devices 4 and / or electric heating devices 6 may be assigned to opposite side walls, in particular longitudinal side walls, of the container 3.

[0146] For a defined heat coupling, the non-electric heating devices 4 and / or the electric heating devices 6 can be controlled or regulated individually or in defined zones or groups, in particular by means of the control and / or regulation device 8 and / or the control and / or regulation device 10. Petition 870250087389, dated 09 / 26 / 2025, page 85 / 231 34 / 35

[0147] If the control and / or regulation device 8, in particular the detection device 9, receives a pulse from the power grid 7, in particular frequency-controlled or Internet-controlled, indicating that there is excess current in the power grid 7, the heat output or the firing output of the non-electric heating devices 4 is reduced by switching off one or more non-electric heating devices 4 and / or reducing the heat output or firing output of one or more non-electric heating devices 4. At the same time, the electric heating drive is initiated via the electric heating devices 6, using the excess current removed from the power grid 7.

[0148] For this purpose, the non-electric heating mode can be completely switched off after a defined transition period, if necessary, so that no heat is coupled via the non-electric heating devices 4. The molten material 2 is then preferably heated exclusively via the electric heating devices 6, which are accommodated in the molten material 2. Through convection and mixing in the container 3, all the molten material 2 is then heated or uniformly heated by means of the electric heating devices 6.

[0149] The molten material 2 can be heated via the electric heating devices 6 in such a way that the molten material 2 is heated above the process temperature or within a defined process temperature range, preferably by at least 20 °C, preferably by at least 40 °C above the process temperature. After this overheating, the heating can then be reduced or completely stopped by means of the non-electric heating devices 4 and / or the electric heating devices 6, so that the molten material 2 cools again from the overheating above the process temperature. If the molten material 2 reaches or falls below the process temperature again, the molten material 2 can be reheated by means of the non-electric heating devices 4 and / or the heating devices Petition 870250087389, dated 09 / 26 / 2025, page 86 / 231 35 / 35 electric 6, preferably exclusively by means of electric heating devices 6, preferably with the molten material 2 being reheated above the process temperature, as described above.

[0150] In this regard, heating intervals can be defined between which the molten material 2 is not heated. Within the heating intervals, the molten material 2 is reheated, preferably exclusively by means of the electric heating device 6.

[0151] The duration of the heating intervals can be defined flexibly and is preferably implemented in such a way that continuous operation of the coating process is possible both within the heating intervals and between heating intervals.

[0152] Reference signs: System Molten material Container Non-electric heating device Power source Electric heating device Power grid Control and / or regulation device Detection device Control and / or regulation device Furnace chamber Furnace housing Entry and / or exit Petition 870250087389, dated 09 / 26 / 2025, page 87 / 231

Claims

1 / 5 CLAIMS 1. Method for operating and / or decarbonizing an industrial production process characterized in that the industrial production process is galvanizing, wherein a heated molten material (2) is supplied and / or maintained as a zinc alloy, wherein the molten material (2) is maintained within a defined process temperature range comprising a temperature range of 200 °C to 1200 °C, wherein the heating of the molten material (2) is effected selectively, by control and / or by choice, by means of at least one electric heating device (6) and / or by means of at least one non-electric heating device (4), wherein, in the event of an excess current in an electrical power network (7), said excess current is at least partially removed from the electrical power network (7) and is used to operate the electric heating device (6),wherein an occurrence of said overcurrent is detected by a detection device (9) and wherein the electric heating device (6) and the non-electric heating device (4) are operated, upon detection of said overcurrent, by means of a control and / or regulation device (10), so that the molten material (2) is supplied and / or maintained within said defined process temperature range using said overcurrent.

2. Method according to claim 1, characterized in that the production process is carried out continuously during electric heating (6) and, in particular, within said defined temperature range.

3. Method according to claim 1 or 2, Petition 870250087389, dated 09 / 26 / 2025, page 88 / 231 2 / 5 characterized in that, after the occurrence and / or detection of said overcurrent, the heating power of the non-electric heating device (4) is reduced and the operation of the electric heating device (6) is initiated, preferably in which the operation or heating by means of the non-electric heating device (4) is terminated and the heating of the molten material (2) is performed exclusively by means of the electric heating device (6) using said overcurrent.

4. Method, according to any of the preceding claims, characterized in that the heating of the molten material (2), before the occurrence and / or detection of excess current, is carried out exclusively by the non-electric heating device (4) and the electric heating device (6) is switched on, in addition to the non-electric heating device (4), after the occurrence and / or detection of said excess current.

5. Method, according to any of the preceding claims, characterized in that the non-electric heating device (4) is operated, preferably exclusively, with hydrogen as fuel gas or a fuel gas and / or mixed gas containing hydrogen, in particular a hydrogen-natural gas mixed gas, preferably wherein the fuel gas and / or mixed gas contains at least 1 to 80% by vol., preferably 25 to 90% by vol., preferably 50 to 100% by vol., of hydrogen.

6. Method, according to any of the preceding claims, characterized in that the molten material (2) is heated at least partially indirectly via a vessel (3) containing the molten material (2), preferably wherein a furnace chamber (11) surrounding the vessel (3) is heated by means of an electric and / or non-electric heating device (4, 6), in particular wherein the furnace chamber (11) is heated by means of a non-electric heating device (4) and the molten material (2) is additionally heated directly and / or connected by contact by means of an electric heating device (6), preferably disposed in the molten material (2).

7. Method, according to any of the preceding claims, characterized in that the molten material (2) is maintained at a process temperature that is at least 10 °C, preferably at least 20 °C, in particular at least 30 °C, above the melting temperature of the molten material (2).

8. Method, according to any of the preceding claims, characterized in that the molten material (2) is maintained at a process temperature in the range of 350 °C to 470 °C or in the range of 510 °C to 610 °C.

9. A method, according to any of the preceding claims, characterized in that the production process is carried out as hot-dip galvanizing, in particular galvanizing of parts or in batches.

10. System (1) for operating and / or decarbonizing an industrial production process using a molten material (2), wherein the industrial production process is galvanizing, in particular a system (1) for performing the method as defined in one of claims 1 to 9, wherein the system (1) is characterized by comprising: - a container (3) for a molten material (2) to be heated, - at least one electric heating device (6) and at least one non-electric heating device (4), and - at least one control and / or regulation device (8) for selectively heating the molten material (2), by means of control and / or by means of selection, by means of the electric heating device (6) and / or by means of the non-electric heating device (4), wherein the control and / or regulation device (8) is further configured to at least partially remove any Petition 870250087389, dated 09 / 26 / 2025, page.90 / 231 4 / 5 excess current occurring in an electrical power network (7) and to operate the electric heating device (6) with said excess current removed, and wherein the control and / or regulation device (8) comprises a detection device (9) to detect any occurrence of said excess current and a control and / or regulation device (10) to operate the electric heating device (6) and the non-electric heating device (4) by detecting the excess current, such that the molten material (2) is supplied and / or maintained within a defined process temperature range.

11. System according to claim 10, wherein the system (1) is further characterized by comprising a furnace chamber (11) that at least partially surrounds the vessel (3), preferably wherein the electric heating device (6) and / or the non-electric heating device (4) is / are disposed in the furnace chamber (11), in particular wherein the non-electric heating device (4) is disposed in the furnace chamber (11) and the electric heating device (6) is disposed to come into contact with the molten material (2) and / or to directly heat the molten material (2) within the vessel (3).

12. Use of a system (1) as defined in one of claims 10 or 11 characterized in being for decarbonization, in particular for reducing and / or preventing the formation of emissions that cause damage to the climate, particularly carbon oxides, when operating a heat-consuming process, wherein the heat-consuming process is galvanizing.

13. Use of a system (1) according to one of claims 10 or 11 characterized in that it is for removing excess current from an electrical power network when electrical current peaks occur in said electrical power network and / or for increasing the service capacity for an electrical power network when operating a heat-consuming process, wherein the heat-consuming process is galvanizing.

14. A method for decarbonization, in particular for reducing and / or avoiding the formation of emissions that cause damage to the climate, particularly carbon oxides, when operating a heat-consuming process, wherein the heat-consuming process is galvanizing, in which the method is characterized by comprising the step of using a system as defined in one of claims 10 or 11 to operate the heat-consuming process.

15. Method for removing excess current from an electrical power network when current peaks occur in said electrical power network and / or for increasing the service capacity for an electrical power network when operating a heat-consuming process, wherein the heat-consuming process is galvanizing, wherein the method is characterized by comprising the step of using a system as defined in one of claims 10 or 11 to operate the heat-consuming process. Petition 870250087389, dated 09 / 26 / 2025, pp. 92 / 231

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