In the glass production process, the size of the melting capacity is directly related to production efficiency and product quality. So, in the face of this challenge, how should we deal with it? Don't worry, I will introduce some practical measures to improve the melting capacity of float glass kilns, hoping to help your production.
PART 01 Reasonable main process dimensions of the kiln shape
When discussing the process dimensions of the float glass kiln, we have to mention its harmonious symbiotic relationship with the melting capacity. An efficient and stable glass melting process must have a design that perfectly matches the main process dimensions of the kiln shape. Especially when we focus on the key dimensions of the melting part and the melting zone, the pool width, pool length and the proportional relationship between the two are of utmost importance.
The setting of the pool width and pool length must accurately reflect the melting capacity we expect to achieve. If the size is too small, it will lead to insufficient melting efficiency, which will in turn affect the overall production capacity and economic benefits. On the contrary, if the size is too large, it will not only cause a waste of resources, but also have an adverse effect on the melting quality, and may even increase energy consumption, which runs counter to our pursuit of high efficiency and energy saving goals.
Therefore, when planning the kiln shape and process size of the float glass kiln, we must not only fully consider the requirements of the melting capacity, but also have an in-depth understanding of the melting process to ensure that each dimension setting can perfectly match the melting requirements, so as to create an efficient and energy-saving glass melting environment. Such a design concept will undoubtedly bring more possibilities and advantages to our glass production.
PART 02 High calorific value fuel and efficient high-energy spray gun
When talking about improving the melting capacity of the float glass kiln, we have to mention the importance of high calorific value fuel and efficient high-energy spray gun. The combination of these two can create an ideal high-temperature environment in the melting zone, thereby ensuring that the glass melting achieves the best effect.
Melting temperature, this core parameter, has a decisive influence on the melting capacity of the glass melting furnace. In order to ensure sufficient melting temperature, we need to choose high calorific value fuels, such as heavy oil, liquefied petroleum gas (LPG) and natural gas. These fuels can not only provide a stable heat source for the melting process, but also effectively improve the melting efficiency.
And in the selection of spray guns, we also need to consider carefully. At present, there are two main types of spray gun installation for glass melting furnaces: spray guns ignited in a small furnace and spray guns ignited outside a small furnace. Spray guns ignited in a small furnace, such as top-inserted, side-inserted and bottom-inserted, usually have higher combustion efficiency due to their structural characteristics. The under-furnace spray gun, as a representative of small furnace ignition, has been widely used in most domestic glass melting furnaces. Its maintenance and replacement are relatively convenient and it is the first choice for many companies.
However, although the spray guns ignited outside the small furnace have an advantage in convenience, the spray guns ignited in the small furnace are more efficient. These efficient spray guns can make more full use of fuel, increase the temperature of the melting zone, and thus enhance the melting capacity. However, this also means that they may require higher costs in initial investment and later maintenance. Therefore, when choosing a spray gun, we need to comprehensively consider factors such as melting efficiency, cost investment, and maintenance convenience to ensure that the final choice can meet production needs to the greatest extent.
PART 03 Full kiln width feeding technology
In the production of float glass kilns, full kiln width feeding technology is gradually replacing the traditional narrow feeding method to achieve a more efficient and higher quality glass melting process. The traditional narrow feeding port usually only accounts for about 80% of the width of the melting tank, and the width of the feeding machine's distribution hopper (what we often call "winnowing basket") is even narrower. Therefore, the distribution width of the batch in the kiln can often only reach about 70% of the kiln width. This feeding method obviously cannot fully utilize the heating area of the batch by the flame in the kiln, thus affecting the melting efficiency and the quality of the glass liquid.
In order to overcome this limitation, we introduced the full kiln width feeding technology. By adopting the full kiln width feeding pool, the distribution width of the batch in the kiln can reach about 90% of the width of the melting tank. This means that the flame in the kiln can heat the batch more evenly, realizing the full utilization of the heating area. This not only helps to improve the melting capacity of the melting furnace, but also ensures that the quality of the melted glass liquid is better. Practice has shown that the full-kiln-width charging pool can increase the melting capacity by about 8-10% compared with the traditional narrow charging pool, which undoubtedly brings significant economic benefits and competitive advantages to glass manufacturers.
When implementing the full-kiln-width charging technology, we need to ensure that the design and operation of the charging machine match the full-kiln-width charging pool to ensure that the batch can enter the kiln evenly and stably. At the same time, we also need to pay attention to the temperature control and material flow stability during the charging process to ensure the smooth progress of the melting process and the stable improvement of the glass liquid quality.
PART 04 Increase the length of the pre-melting zone
In the design of float glass kilns, the pre-melting zone is a crucial part. When we mention increasing the length of the pre-melting zone, we are actually considering how to use heat more effectively to promote the melting process of the glass batch. Usually, the length of the pre-melting zone we refer to refers to the size from the center line of the small furnace to the front end of the melting part. However, the actual pre-melting area also covers the area below the L-shaped hanging wall nose area, which is also a detail worthy of our attention.
When the glass batch enters the kiln, it needs to pass through a relatively long pre-melting zone. During this process, the batch is subjected to continuous thermal action and gradually heats up. This design not only helps the batch to be heated more evenly, but also ensures that it gradually adapts to the melting environment, thereby more effectively improving the melting capacity. Therefore, by reasonably increasing the length of the pre-melting zone, we can provide a more ideal melting condition for the glass batch, thereby improving the overall melting efficiency and quality. This improvement is of great significance to improving the efficiency of the float glass production process and product quality.
PART 05 Increase flame coverage
Increasing the flame coverage of the float glass kiln is one of the important measures to improve the melting capacity. Here are some methods and related explanations on how to increase the flame coverage:
① What is flame coverage: Flame coverage refers to the percentage of the total width of the small furnace nozzle of the whole kiln to the length of the melting zone. This indicator reflects the uniformity of the flame distribution in the kiln.
② Importance of flame coverage:
The larger the flame coverage, the more uniform the flame distribution in the kiln, which is more beneficial to the melting effect. Uniform flame distribution can improve the melting capacity of the melting furnace and reduce energy waste. By adjusting the flame coverage, the temperature and heat distribution in the glass melting process can be effectively controlled to improve product quality.
③ Methods to increase flame coverage:
a. Optimize the design of the spray gun: select a spray gun with high efficiency and wide spray range to ensure that the flame can evenly cover the melting area.
b. Adjust the fuel supply: According to the temperature in the kiln and the melting demand, adjust the fuel supply in time to maintain the stability and uniformity of the flame.
c. Improve combustion conditions: Optimize the combustion chamber structure, improve the mixing conditions of fuel and air, and improve the combustion efficiency, thereby increasing the flame coverage.
d. Adopt full kiln width feeding technology: By adopting the full kiln width feeding pool, the distribution width of the batch material in the kiln is increased, which is conducive to the uniform coverage of the flame.
e. Reasonable setting of the kiln chamber structure: Optimize the size, shape and material of the kiln chamber, improve the heat transfer efficiency, reduce heat loss, and help maintain the intensity and uniformity of the flame.
④ Precautions:
In the process of increasing the flame coverage, be careful not to excessively increase the flame temperature to avoid damage to the kiln body or affect the product quality. According to the kiln type and melting requirements, reasonable adjustment methods and ranges should be selected to ensure the stability and economy of the melting process.
PART 06 Increase the number of spray guns
Increasing the number of spray guns is a strategy worth exploring when optimizing the melting efficiency of float glass kilns. From the actual operation data of many domestic melting furnaces, it is not difficult to find that the layout of the spray guns has a significant impact on the distribution of flames in the kiln.
Specifically, when only two spray guns are used in each small furnace, although the basic melting requirements can be met, the flame distribution in the kiln is often not uniform enough. This may lead to blind spots in the melting process, thereby affecting the melting efficiency and the quality of glass products.
However, when we choose to arrange 3 or more spray guns in the small furnace, the situation is greatly improved. This multi-gun arrangement can not only effectively improve the uniformity of the flame distribution in the kiln, but also in a sense is equivalent to increasing the flame coverage rate. The increase in flame coverage means that the melting area is heated more evenly and the melting effect is more sufficient, which is undoubtedly beneficial to improving the melting capacity of the melting furnace.
Therefore, we recommend that the layout and number of spray guns be fully considered when designing a float glass furnace. Through reasonable spray gun configuration, we can significantly improve the melting efficiency and provide a strong guarantee for the production of higher quality glass products.
PART 07 Increase the melting temperature
In the process of optimizing the melting efficiency of the float glass furnace, increasing the melting temperature has become a key strategy. To achieve efficient high-temperature melting, we need to adopt a higher temperature curve before the hot spot in the melting zone to ensure that the hot spot temperature can reach or exceed 1590℃. The realization of this goal is inseparable from the improvement and coordination of the structural conditions of the melting furnace.
First, the reasonable design of the kiln size is the basis. Only a kiln with a reasonable size can ensure the uniform distribution of heat in the kiln and provide a stable environment for high-temperature melting.
Secondly, the application of high calorific value fuels and high-efficiency spray guns is crucial. High calorific value fuels can provide sufficient heat for the melting process, while high-efficiency spray guns can ensure that this heat is fully utilized, thereby further increasing the melting temperature.
In addition, the pros and cons of refractory performance cannot be ignored. High-quality refractory materials can withstand continuous work in high-temperature environments, ensure the stable operation of the melting furnace, and provide solid support for high-temperature melting.
When the structural conditions of the melting furnace are met, increasing the melting temperature can not only improve the melting capacity, but also optimize the melting quality. Higher melting temperatures help to fully melt the glass raw materials, reduce unmelted impurities, and improve the purity and transparency of the glass liquid.
Therefore, in actual operation, we need to comprehensively consider multiple factors such as melting furnace structure, fuel selection, spray gun design, and refractory material performance to achieve efficient high-temperature melting and bring greater benefits to float glass production.
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