What equipment is available for glass tanks?

Regenerators in a glass furnace enable the recovery of waste gas heat to preheat the combustion air. The heat is stored in a refractory checkerwork structure and is released back to the incoming air in alternating operation.

The regenerator consists of several components, which are listed in detail in the data sheet. Together, these components form the system for heat storage and recovery and are structurally and functionally coordinated. These include in particular:

• Regenerator
• Regenerator valve

The regenerator itself comprises the storage mass and the associated chamber structure, where the waste gas heat is absorbed and released with a time delay. The regenerator valve handles the targeted switching of the flow direction between exhaust gas and air operation, making it crucial for cyclical operation and the continuous use of the stored heat.

Recuperators in a glass furnace enable continuous heat recovery, where the waste gas heat is transferred directly to the combustion air. Unlike a regenerator, this process occurs without cyclical switching, leading to uniform and stable operation.

The recuperator consists of several components, which are listed in detail in the data sheet. Together, these components form the heat recovery system and are structurally and functionally coordinated. These include in particular:

• Recuperator
• Fan

The recuperator itself comprises the heat exchanger structure, where the waste gas heat is transferred directly to the combustion air. The fan ensures the controlled guidance and conveyance of the airflows through the system, thereby ensuring continuous operation as well as stable and efficient heat recovery.

Fuel-based heating is the central element for heat transfer and flow control in the furnace chamber. The design and positioning of the burners are crucial for melting performance, refining efficiency, and temperature distribution.

IWG develops tailored burner systems for different energy sources and operating modes. The focus is on optimized air-fuel ratios and adapted flame geometries – for high energy efficiency with simultaneously reduced emissions. The fuel technology is specifically combined with electric boosting, batch charging strategy, and furnace geometry.

Fuel heating technology includes several components, which are listed in detail in the data sheets. These include in particular:

• Gas safety train
• Distribution station
• Fans
• Burners

Precise control allows for adaptation to variable operating conditions, stabilizes the process, and increases the energy efficiency of the system.

Electric heating and e-boosting enable precise, locally controllable energy input into the glass bath. They stabilize the process, improve homogeneity, and increase energy efficiency. IWG develops tailored systems that are optimally integrated into the furnace concept and allow for targeted adjustment of temperature profiles.

E-boosting and electric heating technology include several components, which are listed in detail in the data sheets. Together, these form the system for power supply, control, and cooling. These include in particular:

• Control cabinets
• Transformers
• Thyristors
• Electrodes
• Cooling water distribution station
• Cooling water treatment station

The coordinated design ensures stable operation and high efficiency of the melting process.

Air cooling in the glass furnace serves to specifically dissipate heat and protect highly stressed furnace areas. It stabilizes the thermal conditions and contributes to the safe and long-lasting operation of the system. IWG develops coordinated cooling systems that are directly integrated into the furnace structure and allow for precise adaptation to the respective process conditions.

Air cooling includes several components, which are listed in detail in the data sheets. Together, they form the system for heat dissipation and flow control in the furnace. These include in particular:

• Fans
• Palisade / Port cooling

The coordinated design reduces thermal loads, protects critical areas, and increases the service life of the furnace system.

State-of-the-art batch charging systems ensure a uniform and process-stable batch feed onto the surface of the molten bath. The challenge lies in achieving homogeneous distribution with minimal dust generation and the least possible thermal disturbance of the bath.

Our batch chargers enable precisely timed feeding, which is exactly matched to the melting capacity, furnace geometry, and specific batch properties. Depending on the requirements, different types of chargers are used, which are individually designed for the respective process.

Charging machines are always adapted to the respective furnace type and specific process requirements. IWG develops and manufactures its own systems such as piston chargers and X-Y chargers. In addition, depending on customer requirements, other types of chargers such as screw chargers can also be integrated into the overall concept and supplied. The goal is always an optimally coordinated solution from a single source.

The charging system includes several components, which are listed in detail in the data sheets. These include in particular:

• Chargers (e.g., piston or X-Y chargers, as well as other process-dependent variants)
• Mechanical and control components for precise feeding

For operation, a cooling water supply and a control cabinet for control and connection to the plant technology are also required.

Continuous and high-precision control of the glass level is the basic prerequisite for constant drawing conditions, stable temperature profiles, and uniform throughput rates. Our level control systems use state-of-the-art, non-contact measurement methods and are seamlessly integrated into the higher-level furnace control system.

Precise control eliminates fluctuations in hydrostatic pressure, which would directly affect gob weight, viscosity, and the stability of the forming process. Furthermore, a constant glass level protects the refractory lining from premature thermal overload. IWG develops customized control concepts for this purpose, in which measurement accuracy, response time, and process dynamics are precisely tailored to the characteristics of your plant.

For maximum operational reliability, we implement supplementary limit value monitoring and intelligent trend analyses. This allows you to react proactively to the smallest process deviations before they affect quality.

Bubbling systems are essential for the efficient homogenization and fining of the glass melt. The defined injection of gases creates controlled convection currents that effectively balance temperature gradients and concentration differences in the molten bath.

The precise coordination of positioning, gas volume, and bubble characteristics optimizes bubble rise and residence time. A correctly designed system significantly increases glass quality, minimizes the formation of striae, and guarantees a stable viscosity distribution in the transition to conditioning.

At IWG, we design the gas routing to avoid unwanted turbulence and minimize the thermal influence on the furnace hydraulics. In this way, we specifically enhance the fining effect and ensure a smooth, quality-optimized process flow.

The efficient operation of modern glass furnaces is based on high-resolution measurement and control technology. All parameters – from temperature and pressure to the glass level, energy input, and exhaust gas values – are continuously recorded and processed in intelligent process control systems.

The excellence of the measurement data directly defines the control quality and thus directly influences energy consumption, the service life of the system, and the final product quality. IWG relies on a combination of robust industrial sensor technology, redundant measurement concepts, and adaptive control algorithms that react precisely to dynamic operating conditions.

By intelligently linking real-time data with historical process values, we make trends visible and sustainably optimize your operating strategies. This predictive process management minimizes unplanned interventions and guarantees maximum plant availability.

Furnace pressure measurement is a central component of modern glass furnace technology and ensures a stable and controlled furnace atmosphere. The goal is to continuously monitor and precisely regulate the pressure in the furnace chamber.

Even minor pressure deviations can influence flame guidance, cause false air, or lead to energy losses. Precise control prevents overpressure or underpressure and ensures even heat distribution in the furnace.

Robust sensor systems are used in combination with intelligent control. This actively controls the furnace pressure – for example, via:

• Exhaust gas guidance
• Air supply
• Burner setting

Furnace pressure measurement thus contributes significantly to process stability, energy efficiency, and operational safety and is individually adapted by IWG to the furnace type and plant concept.

A drainage system in the glass furnace is used for the targeted removal of zircon-containing or cordy bottom glass from the lower areas of the glass melt.

In the melting tank, the clear focus is on influencing the flow behavior and the early removal of heavy, inhomogeneous glass components. These preferably accumulate in deeper zones and can negatively affect the melting process and homogenization.

Controlled drainage prevents these impurities from entering the further process and continuing into the forehearth. At the same time, the system contributes to a more stable and uniform melting process.

Operation is continuous or in defined intervals and is adapted to the respective melting conditions.

IWG develops individual overall cooling water concepts for external parts and connected components in the plant environment. The focus is not on cooling the glass furnace itself, but on the reliable temperature control and protection of components that are subject to thermal stress during operation.

The cooling water system is considered a complete technical unit – from the design of the cooling circuits and the routing of the pipes to integration into existing supply systems. Depending on the requirements, flow rates, pressure conditions, temperature ranges, connection points, and customer-specific interfaces are taken into account.

The goal is a stable, maintenance-friendly solution tailored to the respective plant operation. Thus, the overall cooling water concept supports the safe operation of external components and contributes to the reliable functioning of the entire plant.

Transformers and thyristors are central components for the reliable energy supply and precise power control of electrically heated glass tanks. They transfer the required electrical energy to the heating circuits in a controlled manner and support a stable, efficient, and uniform melting process.

IWG plans and integrates transformers and thyristor controllers to match the respective glass tank, the existing infrastructure, and the process engineering requirements of the plant. A precisely coordinated design supports constant temperature control, improves process reliability, and contributes to a consistently high glass quality.

For new constructions, modernizations, and expansions of existing plants, IWG develops robust solutions for transformers and thyristors in industrial glass furnace construction – durable, operationally reliable, and designed for long-term use on glass tanks.

Oxy-fuel burners as complete systems enable efficient and powerful heating of glass tanks and industrial melting plants. By using oxygen instead of combustion air, the combustion process can be specifically optimized, and energy can be introduced into the melting chamber particularly effectively.

IWG plans and integrates oxy-fuel burner systems tailored to the respective glass tank, the required power, and the process engineering requirements of the plant. In addition to the burners, the complete system includes the appropriate media supply, control technology, and integration into the plant concept. A well-thought-out design supports stable temperature control, uniform heat distribution, and reliable operation in industrial glass furnace construction.

For new constructions, modernizations, and expansions of existing plants, IWG develops robust oxy-fuel solutions designed for efficiency, operational reliability, and long-term usability.

Electrical control cabinets are an important component of electrically heated glass tanks and melting plants. They combine the central control, protection, and distribution of electrical energy, thereby creating the foundation for reliable plant operation.

IWG plans and integrates transformers and thyristor controllers to match the respective glass tank, the existing infrastructure, and the process engineering requirements of the plant. A precisely coordinated design supports constant temperature control, improves process reliability, and contributes to consistently high glass quality.

For new constructions, modernizations, and expansions of existing plants, IWG develops robust solutions for transformers and thyristors in industrial glass furnace construction – durable, reliable, and designed for continuous use on glass tanks.