Furnace Solutions 13 at Lucideon on 7 June 2018

All presenters, who are not part of the Melting Technical Committee [MTC], will be eligible for ‘The Michael Garvey Award’ - for the day's best presentation. The recipient of the award is decided by members of the MTC present on the day.  The 2017 - FS12 - year Garvey Award went to Tunc Goruney, Sisecam for his presentation titled "Pushing the Envelope of Waste Heat Recovery in Oxy-fuel Tableware Furnaces”

 

SEFPRO Abstract
Corrosion process and glass defect formation  in Glass furnace Feeder  are critical issues because this area is the last conditioning area before the machine. We propose an overview of corrosion mechanism in this particular area and will discuss refractory optimized solution adapted to glass quality constrain and feeder lifetime  

LTB ( Luft- und Thermotechnik Bayreuth GmbH) Abstract
Energy efficiency is an important issue not just for the glass furnace but for the whole glass melting system. Part of this system is the flue gas cleaning. For this two questions arise. First, which type of system to install to cope with environmental limits and second, where and how to implement any heat recovery.
Classic systems for dedusting are electrostatic precipitators or the more modern bag filters. Both are not the best solution if you want to recover energy in a heat exchanger downstream the system. The ESP keeps the high input temperature and requires no cooling in advance, but reaches only poor emission values, which reduce the efficiency of any heat exchanger downstream the ESP. A fabric filter requires a cooling to stay below the temperature limits of the fabric, which reduces the available energy downstream.
So the best solution is to keep the temperature of the gases high and achieve lowest dust emissions. This could be achieved by using a ceramic candle filter, suitable for high temperatures. As these are also coated with a catalyst, it is also possible to reduce NOx emissions without adding a separate SCR for DeNOx.
In the presentation the technology will be shown in detail as well as examples of realized systems at Unifrax, Libbey and Wiegand Glas.
For the energy recovery various solutions will be considered, even ORC solutions to create electricity.

Sorg Abstract
This paper will present and highlight recent improvements made to the SORG 340S forehearth. This is a system that has been successfully implemented 270 times to date and is a standard for mass produced glass containers around the globe.
The new 340S+ is a further development to meet even more stringent customer glass conditioning demands.
Improvements are not limited to operations. The system has been redesigned for easier construction and heatup. This is made possible through modifications to the superstructure and steel bracing that allow for installation savings.
A new cooling design allows us to reduce the number of fans thus lowering operating and investment costs.
In addition to the currently available options, the 340S+ superstructure allows for optional top electrodes in the equalizing section which can be installed and removed on the fly. This offers more flexibility and higher homogeneity when melting colored glass. This also eliminates the need for having sidewall electrodes in the glass during the entire campaign when they are only needed occasionally.
The most recent operational results will be presented as well.

Air Products Abstract

Oxy-fuel glass melting has steadily gained traction over the past 25 years due to increasing pressure on manufacturers to reduce both fuel consumption and NOx emissions.  While there have been concurrent advancements in oxy-fuel combustion technology, challenges have remained, particularly in the area of foam formation and optimal control of flame properties.  One key development in the evolution of oxy-fuel burners was oxygen staging, or delayed oxygen-fuel mixing, which allowed for increased flame radiation and even deeper reductions in NOx emissions.  That said, the historic use of staging has been limited due to loss of flame momentum and inefficiencies in fuel / oxygen mixing.  Recent progress in control of fuel and oxygen by Air Products’ combustion engineers has, however, led to the development of a new burner technology, Cleanfire® HRx,™ capable of staging nearly 100% of the burner oxygen while maintaining flame momentum and preserving optimal fuel / oxygen mixing.  Results of several recent commercial installations of the HRx burner have verified the ability to attain higher melting efficiency, lower NOx emissions, and improved flame length control / stability than past designs.  Moreover, additional HRx burner functionality enables substantial control of the gas atmosphere in contact with the glass surface, which has proven to be effective in reducing foam formation in the refining section of the melter.  This, in turn, leads to higher melt temperatures and more efficient removal of glass defects in the refining section.  Operational properties of the HRx burner are introduced, and results of both lab tests and commercial demonstrations are presented.


Glass Service Abstract

Industry 4.0 is the current trend of automation and data exchange in manufacturing technologies. It includes cyber-physical systems, the internet of things and cloud computing. Industry 4.0 creates what has been called a “smart factory”. Several parts of the glass making progress already have been converted, especially in the cold end, but overall integration has not been done. In this paper we want to explain what this means specifically for the glass industry and how Glass Service with our Expert System advanced software and hardware toolbox can be part of filling in this puzzle.
Is this the end of the “glass melting expert”? Similar as before the glass blower already vanished for container glass, flat glass and majority of table ware production.

STARA Glass S.p.a.

Glass industry is nowadays facing the problem of nitrogen oxides that come from its typical very high-temperature diffusive combustion systems. The first step to contain NOx pollution is to proceed at the level of the combustion chamber employing primary containment measures, which are techniques for the non-generation of nitrogen oxides.
Within the Prime Glass project (www.primeglass.it), Stara Glass, together with the University of Genova and Stazione Sperimentale del Vetro, developed and patented two techniques for the primary containment of NOx in regenerative end-port glass furnaces that gave excellent field results thanks to the percentages of NOx abatement of the order of 30/40 %.
One of the direct consequences has been the optimisation of the furnace design because to have a better impact of the new glass furnaces on the environment it is necessary to start with a different design: this means couple the well-based experience with the new criteria and the new geometries.

Simpson Combustion & Energy with AMETEK Land

Following on from the 2017 presentation on the use of the near infrared thermal imaging borescope to profile furnace and increase capacity, this year's presentation will discuss the use of special filters that can make NOx “visible" and therefore manageable. Whereas last year the focus was on the superstructure with no flames present this year we are looking during the flames firing. By highlighting and identifying areas of peak flame intensity it is possible to identify which firing side has higher NOx and which port/burner is impacting the most.  The presentation will show an example where the image was used to help optimise combustion for stack emission test.

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