Objective

Fluorescent substances are able to convert ultraviolet radiation into visible light. The plant in Schwabm�nchen manufactures calcium phosphate fluorescents for standard fluorescent lamps and LUMILUX fluorescents for DULUX and LUMILUX lamps. Almost any color of light can be produced by mixing various fluorescent components. Manufacturing fluorescent substances is an extremely energy-intensive process that involves heating the individual components at temperatures of over 1500� C, periodically in a nitrogen atmosphere.

The goal during the expansion in production of our calcium phosphate phosphor was to reduce the environment interferences and resource usage lastingly

Solution

An innovative furnace design boosts energy efficiency. It features significantly reduced heating and cooling zones and overall less surface area. This made it possible to reduce the energy required per tonne of product by 50%, benefiting the environment and the company's cost-effectiveness.

In addition, water consumption was reduced by using an air cooling system instead of water to cool the furnace shell. As a result, the company saves 5 cubic meters of cooling water an hour.

The fluorescent substances are blown through pipes to other parts of the plant. Via the textile filters of this transport system, a certain amount of fluorescent particles are carried into the main ventilation system. At this point they mix with other substances on their way to the exhaust cleaning facility, making them unsuitable for use in manufacturing.

Today thanks to the use of specially coated foam rubber filters that remove 15 times as many particles from the air, the plant annually recovers 11 tonnes of calcium phosphate that would have otherwise ended up as refuse.