What equipment is available for glass tanks?

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 then released back to the incoming air in alternating operation.

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

• Regenerator
• Regenerator Damper

The regenerator itself comprises the storage mass and the associated chamber structure, where the exhaust gas heat is absorbed and released again with a time delay. The regenerator damper 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. Unlike regenerators, 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 data sheet. 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 air flows 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 control 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 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 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 data sheets. 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 long-lasting 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 plant.

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 lowest possible thermal disturbance to the melt.

Our chargers enable precise, cycle-accurate feeding, which is exactly matched to the melting capacity, furnace geometry, and specific batch properties. Depending on 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. Furthermore, depending on customer requirements, other charger types 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 datasheets. These include, in particular:

• Chargers (e.g., piston or X-Y chargers, as well as other process-dependent variants)
• Mechanical and control technology 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 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 use 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 fining 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 influence on the furnace hydraulics. In this way, we specifically enhance the fining 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 management minimizes unplanned interventions and guarantees maximum plant availability.

Furnace pressure measurement is a central component of modern glass furnace technology, ensuring 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 affect flame guidance, cause false air, or lead to energy losses. Precise regulation prevents over- or underpressure and ensures uniform 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 control
• Air supply
• Burner adjustment

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

A drainage system in a glass furnace serves for the targeted removal of zirconium-containing or streaky bottom glass from the lower areas of the glass melt.

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

Controlled discharge 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 melt management.

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