What equipment is available for glass furnaces?

Regenerators in glass furnaces enable the recovery of exhaust gas heat for preheating combustion air. The heat is stored in a refractory grid structure and released back to the incoming air in alternating operation.

The regenerator includes several components, which are listed in detail in the datasheet. These components together form the system for heat storage and recovery and are structurally and functionally coordinated. These include in particular:

• Regenerator
• Regenerator flap

The regenerator itself comprises the storage mass and the associated chamber structure, in which the exhaust gas heat is absorbed and released again with a time delay. The regenerator flap takes over the targeted switching of the flow direction between exhaust gas and air operation and is thus crucial for cyclic operation and the continuous use of stored heat.

Recuperators in glass furnaces enable continuous heat recovery, where exhaust gas heat is directly transferred to the combustion air. In contrast to the regenerator, this process occurs without cyclic changes, leading to a uniform and stable mode of operation.

The recuperator includes several components, which are listed in detail in the datasheet. These components together 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, in which the exhaust gas heat is directly transferred to the combustion air. The fan ensures the controlled guidance and conveyance of airflows through the system, thereby ensuring continuous operation and stable and efficient heat recovery.

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

IWG develops coordinated burner systems for various energy sources and operating modes. The focus is on optimized air-fuel ratios and adapted flame geometries – for high energy efficiency with simultaneously reduced $\\text{NO}_x$ emissions. The fuel technology is specifically combined with electric boosting, charging strategy, and furnace geometry.

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

• Gas safety line
• Distribution station
• Fans
• Burners

Precise control enables 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 melt. They stabilize the process, improve homogeneity, and increase energy efficiency. IWG develops coordinated systems that are optimally integrated into the furnace design and allow for targeted adjustment of temperature profiles.

E-boosting and electric heating technology include several component parts, which are listed in detail in the datasheets. Together, these form the system for energy 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 the targeted dissipation of heat and the protection of highly stressed furnace areas. It stabilizes thermal conditions and contributes to the safe and durable operation of the plant. IWG develops coordinated cooling systems that are directly integrated into the furnace design and allow for precise adaptation to the respective process conditions.

Air cooling includes several component parts, which are listed in detail in the datasheets. Together, these form the system for heat dissipation and flow guidance in the furnace. These include, in particular:

• Fans
• Palisade / Passage 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 melt surface. The challenge lies in homogeneous distribution with minimal dust generation and the least possible thermal disturbance to the melt.

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

Precise positioning prevents local cooling zones, accelerates the melting kinetics, and creates the basis for stable refining. Thus, the chosen charging strategy directly influences the energy demand and the service life of the refractory lining. IWG considers the entire process dynamics during design – from mechanical loads to thermal interactions with flame guidance, electric heating, and exhaust gas flow.

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

• Charger

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

Continuous and highly precise control of the glass level is the basic prerequisite for constant drawing conditions, stable temperature profiles, and uniform throughput rates. Our level control systems utilize state-of-the-art, non-contact measurement methods and are seamlessly integrated into the overarching 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, where measurement accuracy, reaction time, and process dynamics are precisely matched 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 even the smallest process deviations before they affect quality.

Bubbling systems are essential for the efficient homogenization and refining of the glass melt. Through the defined injection of gases, controlled convection currents are generated, which effectively equalize temperature gradients and concentration differences in the melt bath.

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

At IWG, we design the gas flow to avoid unwanted turbulence and minimize the thermal impact on the furnace hydraulics. This allows us to specifically enhance the refining effect and ensure a smooth, quality-optimized process.

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

The excellence of measurement data directly defines the control quality and thus directly influences energy consumption, plant service life, and final product quality. IWG relies on a combination of robust industrial sensors, 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 proactive process control minimizes unplanned interventions and guarantees maximum plant availability.