Regenerator Repair without production loss, possible ? HOTWORK
What if an unexpected, but major regenerator problem occurs? Which options are available, allowing to repair the regenerator and return to full production as soon as possible? How can you avoid losing month of production if there is no refractory available? Often regenerator problems can occur unexpected, thus a fast and reliable emergency solution is required, is it at all possible?
Various options are being discussed within this talk, giving end users an overview of proven technologies for the repair of regenerators (partial and full) with and without production loss. Besides the technology we focus also on the economics and feasibility of the repair method.
Optimelt process LIBBEY
Praxair’s OPTIMELT™ regenerative Thermo-Chemical Regenerator (TCR) system has been in commercial operation on an oxy-fuel fired tableware glass furnace at Libbey Leerdam in The Netherlands since November 2017. The TCR stores waste heat from the hot oxy-fuel flue gas in regenerator beds and uses this energy to reform a mixture of natural gas and recirculated flue gas to hot syngas which is combusted with oxygen in the furnace. This presentation will briefly introduce the implementation of the TCR heat recovery system at Libbey Leerdam and review operational experience, performance, and glass quality results from the TCR operation.
Batch plant upgrades- Challenges for a batch plant supplier EME
EME often performs audits in order to determine opportunities to update, upgrade or modernize existing batch plants. This is often rather challenging since there is only limited project information, technical documentation or drawings for the existing batch plants available. Measurements on site have to be performed, available technical data collected and system parameters and timing has to be determined for dosing, weighing, mixing and batch transport. The identification of bottle necks in the cycle times and the creation of solutions to reduce them, is the main task. Additionally, often a batch plant feeds several furnaces and must remain in operation during upgrades. Consequently, secure uninterrupted batch delivery is critical at all times during the upgrade. In order to achieve solutions that will meet these customer needs, EME has developed special tools for the modification of batch plants.
Electric Melting: Refractory corrosion, prediction and prevention FIVES
Electric melting (and the application of high levels of electric boosting in fuel-fired furnaces) is invariably perceived as being associated with higher rates of refractory corrosion and shortened furnace campaigns. Why should use of electric heat input necessarily impact furnace life? Are shorter campaigns inevitable for furnace with high electrical heat input? How can the ‘problem’ be addressed through design and adjustment of operational modes?
Although the chemical nature of corrosion is well understood for most glass types; the precise role played by the main process drivers, and their relative impact the local corrosion rate, is less well understood. This presentation aims to provide an overview of corrosion processes in the context of electrical heating systems and how corrosion rates can be predicted and reduced during the design phase. We consider also how the change in tank profile caused by corrosion can impact performance during the campaign; and importantly, what can be done to mitigate the effect. The presentation is founded on extensive work conducted by Fives to extend campaign lives of all-electric and highly boosted ‘hybrid’ furnaces; in conclusion however, we will also challenge the philosophy that long campaigns are always the best solution.
HSE manufacturing sector plan and 2019/20 operational guidance HSE
My 30 minute presentation would cover the HSE manufacturing sector plan and 2019/20 operational guidance. The talk will cover the background and current health and safety position within the manufacturing sector, our priorities and planned outcomes and our delivery strategy. This will include an overview of our operation inspection programme for 2019/20 and our work to engage with others to improve health and safety. HSE is focussed on raising the profile of health issues and has identified 3 key occupational health priorities : occupational lung disease, musculoskeletal disorders and stress. Key industry sectors have been identified and proactive inspection work and operational resource is directed towards those particular industries and their particular risks. For example with the Stone industry our occupational lung disease focus is on control of respirable crystalline silica dust. I will also outline the work we do with relevant trade associations and others to increase broader understanding of these issues and to facilitate the development of relevant industry produced health and safety guidance and plans. Reducing serious and fatal accidents and catastrophic events remains a plan priority and I will outline the key areas of focus.
Improving Furnace Performance by Design and Operation SISECAM
One of the efforts to strengthen the competitive power in challenging glass market conditions is to cut the cost of production by efficient use of energy. Since the melting process consumes substantial amounts of energy, specific fuel consumption reduction through improving furnace design is high priority need. Proper furnace design with fine operational tuning can reduce energy consumption in a cost-effective way while maintaining quality performance. All of this will create a positive impact on competitiveness performance in rapidly changing environment.
This study investigated role of each design parameters in combustion space on energy consumption and better management of the temperature profile in glass container furnaces. In order to have a better understanding on the combustion behaviour and hence furnace performance, effect of crown height, port design, burner type and gas velocity, distance between burner and glass surface on flame form, temperature and velocity distributions was first evaluated individually for a container furnace. Interaction of the design parameter with others was examined by applying stepwise approach. After conducting extensive computations by Şişecam Furnace Model and obtaining feedback from operational sites, it was well understood that what role design parameter plays in in flame formation and the amount and distribution of energy transferred to the glass. More importantly, these parameters need to be optimized specifically for different furnace sizes, specific melting rates and for different production types. In recently commissioned Şişecam container furnaces, an additional % 7 of energy reduction has been realized, % 4 resulting from combustion space design improvements.