Technological Innovations for Heating and Process Control of Glass Melting Furnaces

glasstec 2010

DeNOx Technology Energy savings and NOx reduction

STG Oxygen Sensor

STG Optical Melting Control

STG Process Control System

STG DeNOx Gas/Oil Burner

STG Air Curtain Bafe

STG DeNOx Technology helps industry to meet governmental requirements for NOx reduction as well as CO2 reduction and emission trading. STG DeNOx Technology combines the primary goal of NOx reduction with energy savings. STG DeNOx Technology is based on two main principles: A remarkably increased energy transfer from ame to glass and batch decreases NOx and furnace and ue gas temperatures. Control of combustion air with Lambda Control reduces and compensates inltration of excess air which will decrease NOx formation as well as the amount of ue gas. By the combination of STG DeNOx burners, Process Control Systems using Lambda Control based on STG Oxygen Sensors as well as an optimized port design and ame adjustment, we are able to offer a STG DeNOx technology that achieves very low NOx target values of 400 1,000 mg/Nm3. Parallel side effects are: Saving energy input, Increase of melting capacity, Improvement of overall technological process control STG DeNOx Technology is a reasonable and efcient alternative to process-external DeNOx-methods and can even be combined with signicantly smaller sized lter facilities.

STG DeNOx Technology

Results

FLOAT GLASS 6 8% Energy savings 35% NOx-reduction 30 t/d increased melting capacity 25 K Temperature reduction

Port 1-4 low-turbulence DeNOx burners Initial situation

Example: 6-Port Float glass furnace

Port 1-4 with STG DeNOx Technology

Energy saving DeNOx gas and oil burners

DeNOx FreeJet Gas injector STG Gas injectors ame design follows precisely the ow characteristics of a free gas jet, resulting in a low turbulence combustion with low ame temperatures and low tail re. The unique installation of the injector inside of the furnace wall, burner head ush with the furnace inside, eliminates negative inuence of known burner blocks and results in excellent service characteristics. With a controlled delay of combustion reaction high temperature peaks of the ame will be avoided and emissivity increases signicantly. Self carburization intensies energy transfer onto glass and batch, which reduces ame and crown temperatures by up to 50 K , lowers NOx formation - and lower ue gas temperatures reduce ue gas energy losses. Two separate gas inputs allow stageless control of ring parameters as ame length and combustion speed. Injector can be easily adapted to different furnace constructions. Taking in account different air ows and port geometries STG denes the best position to install, in order to achieve optimum ring performance. There are available eight injector sizes, covering a range from 50-1100 Nm3/h. Complementary STG also provides Dual-injectors for combined usage of gas and oil for underport installation. Describing the DeNOx Gas injector in short terms: Energy savings and low emissions are ideally combined.
Cooling Improved radiation Gas

DeNOx gas injector in underport position

Improve radiation transfer ame to Glass/Batch

Lower ame temperature by 50 K

Reduce NOx

+
DeNOx gas injector Self carburisation Controlled mixing delay Low turbulent combustion Lower crown temperature Lower ue gas temperature by 50 K Save Energy

+
Longer service life

Working principle: Low turbulent Gas injector

FLAMMATEC - A Joint Venture of STG and GLASS SERVICE FLAMMATEC as a producer of energy efcient, low NOx burners relies on the same principles of low turbulent combustion as originally developed by STG: The resulting low turbulence provides improved emissivity of the gas ame, which results in lower ame temperature, lower NOx-emission and lower energy consumption. The FLAMMATEC Flex Burner will be installed in the traditional burner position, using a sealing plate and injector block. Operating experience of the FLAMMATEC Flex Burner has shown improvements in energy transfer of low turbulence gas ames, compared to other common designs with sealing plate. Two separate gas inputs control the ame characteristics and qualify the FLAMMATEC Flex Burner to be used as dual injector for combined usage of gas and oil for underport installation.

DeNOx oil injector in underport position

FLAMMATEC Sideport and Flex Burner

DeNOx oil injector

STG Oxygen Sensors and Lambda Control

STG Zirconium Oxide Oxygen Sensors Lambda Control In-situ measurement of residual Oxygen content in the waste gas ow is the basis for an energy efcient and NOx reducing operation of glass melting furnaces. Being installed in more than 200 furnaces worldwide, STG Oxygen sensors have become an essential tool for combustion analysis and set a new standard. Their longevity and reliability allows it to use O2 signals as the basis for a permanent measurement and sophisticated control algorithms. The more exact and the more reliable the measurement of residual oxygen in the ue gas, the closer the furnace may be operated to the low stoichiometric optimum without safety margin of excess air, which wastes energy and causes NOx . A simple ratio control is limited to adjustment of air and fuel without any feedback of the actual results of the combustion. Only STG Lambda Control allows it to control and to compensate the input of ingressed air (about 2 10% of total air) and thus really decides the efciency and NOx emission. Process value Lambda will be derived directly from the measuring result of the Oxygen sensor. Unlike the measuring value O2%, the calculated value Lambda will be made available in the technological interesting range 0,96 < < 1,5 , linear dependent to excess or missing combustion air.
U (mV) TC/B

Using our rent-and-service system for Oxygen sensors, the customer only buys what he really needs the reliable O2% measurement signal and he leaves installation, maintenance and predictive replacements of sensors to experienced STG service personnel.

Signal processing of Oxygen Sensors

Protection tube Carrier tube Signal cable to inner electrode Signal cable to outside electrode Zirconium oxide tube Reference air Inner electrode Outside electrode Inner tube with reference air Integrated thermocouple

STG Air Curtain System to Control Combustion Air Flow without regenerator section walls STG Air Curtain System allows to control combustion air distribution even for furnace constructions without regenerator section walls, by utilizing a controllable compressed air barrier, that forces unwanted excess of preheated combustion air to distribute to where it is needed. Through this, Lambda Control can be used efciently even without section chambers.
Distribution of combustion air
O2 (%) 6,0 5,5 5,0 4,5 4,0 3,5 3,0 2,5 2,0

Port 6

Port 5

Zirconium oxide Oxygen probe

Zirconium oxide Oxygen probe - The Sensor

1,5 1,0 0,5 0,0

Port 1 4 without ... ... with air curtain

Oxygen probes installed

Air curtain bafe, installed in the port bottom

Process Control System and Optical Melting Control

Intelligent solutions for process control for glass melting and industrial furnaces There is no other European company having more experience in Process Automation of Float line or in ber glass facilities than STG Cottbus. The reference list of STG includes more than 45 oat lines and more than 30 ber glass and container glass lines. Based on many years of cooperation with SIEMENS Automation, and years of work on glass and industrial furnaces, STG has the experience to execute complex automation projects in PCS7, Teleperm M DCS systems, or SIMATIC PLCs. In addition, STG has expertise with WinCC, WinTM or Intellution FixDmacs and IFix. The scope of STG project capabilities includes CAD design, mounting and testing of control panels, eld installation, industry specic process expertise, and the programming and commissioning of DCS, PLC and Visualisation systems. Detailed system testing at STG, training of customers staff on site or at STG, and even jointly working with customers engineers on programming at STG facilities, is a common practice. STG has at its disposal a library of proven advanced process control software solutions especially for glass and industrial furnace applications. For example: BTR (Fuel-Temperature) control for regenerative furnaces Flexible energy control for gas and oil simultaneously ring Lambda Control taking control and compensating any ingressed air Redundant solutions with CPUs or backup controllers Electrical power management controlling power limits Providing long-time Excel data bases to acquire average data per each shift Special reversal program module for exible handling of error situations, real time recording of reversal actuators, and coordinating control actions with a user friendly manual operator layer.

OMC Optical Melting Control While STG DeNOx Technology remarkably decreases NOx emissions, reduces energy consumption and furnace crown temperatures, there is available a new reliable reference for stable melting conditions and glass quality. Optical Melting Control (OMC) is an instrument developed for continuous monitoring and control of the real energy input into the melting zone and it goes beyond what can be done with a glass bath probe (punctual measuring the temperature of the melting glass). The digital analysis of a standard furnace TV camera signal provides batch pattern scum line, exact unmolten batch covered area and gradient of melting speed. Also OMC provides control of ame length, position of temperature maximum and of bubbling spots. Using the OMC video server as an intelligent transmitter these data will be sent to the PCS7 control system that combines it with energy inputs and temperatures to form a basis for a technologically oriented control strategy.

OMC-Picture analysis for an endport furnace

By using a) redundant PLC b) backup controllers or c) distributed redundancy STG has designed system architectures that provide sophisticated control functions and robust performance for the rigorous requirements of the Glass industry. These control systems are specically designed to avoid any losses of production in case of breakdowns or restarts of the control system.

Example: PCS7-System architecture with redundant PLC

References in more than 35 countries worldwide

NORTH & CENTRAL AMERICA

CANADA RHI Becancour MEXICO Saint Gobain Vetrotex America USA Cardinal Float Menomonie /WI Cardinal Float Winlock/WA O-I Winston Salem

EUROPE
BELGIUM AGC Mol AGC Moustier AGC Momignies EMGO Lommel Saint-Gobain Glass Auvelais BULGARIA New Glass Novi Pazar DENMARK Ardagh Holmegard GERMANY Arcelor Mittal Stahl Eisenhttenstadt Ardagh Bad Mnder Ardagh Drebkau Ardagh Lnen Bentrup Cognis Dsseldorf DESAG Grnenplanen Euroglas Haldensleben Euroglas Osterweddingen f | glass Osterweddingen Gerresheimer Essen Gerresheimer Lohr Glasmanufaktur Brandenburg Tschernitz Glastechnik Piesau Glaswerk Ernstthal

Glaswerk Freital Grob Gemnden Guardian Thalheim HORN Plberg Hydro Alu Rackwitz ISOVER Lbz Jasper Kristallglas AG Zwiesel Lamberts Wunsiedel Lausitzer Glashtte Dbern Nachtmann Amberg Narva Brand-Erbisdorf Noelle & van Campe Boffzen O-I Achern O-I Bernsdorf O-I Holzminden O-I Rinteln OWA Amorbach Pilkington Gladbeck PQ Wurzen RHI Didier Niederdollendorf Saint Gobain Glass Herzogenrath Saint Gobain Glass Kipfenberg Saint Gobain Glass Kln-Porz Saint Gobain Glass Mannheim Saint Gobain Glass Stolberg Saint Gobain Glass Torgau Saint-Gobain Oberland Bad Wurzach Saint-Gobain Oberland Essen Saint-Gobain Oberland Neuburg Saint-Gobain Oberland Wirges Schott Jena Schott Mainz Schott Mitterteich SORG Lohr Spiegelau GmbH Werk Frauenau Stlzle Glas Weiwasser Thringer Behlterglas Schleusingen TU Freiberg Woltz Wertheim Yara Rostock

FRANCE AGC Boussois O-I Gironcourt O-I Puy Guillaume (Villeurbanne) O-I Reims O-I Vayres PQ La Motte Saint Gobain Glass Lagnieu Cedex Saint-Gobain Glass Aniche Saint-Gobain Glass Chantereine Saint-Gobain Glass Salaise sur Sanne UNITED KINGDOM Allied Glass Leeds Ardagh Doncaster Ardagh Irvine Ardagh Knottingley Guardian Goole Saint-Gobain Glass Eggborough Stlze Knottingley Teco Glass ITALY AGC Cuneo AGC Salerno Ardagh Montorio O-I Aprilia O-I Marsala O-I Origgio O-I San Gemini O-I VEME Stara Genua CROATIA Vetropack Hum na Sutli LUXEMBOURG Guardian Luxguard I Guardian Luxguard II

THE NETHERLANDS Ardagh Dongen O-I Leerdam O-I Maastricht O-I Schiedam PQ Winschoten Royal Libbey Leerdam AUSTRIA Vetropack Kremsmnster Vetropack Pchlarn POLAND Euroglas Ujazd Guardian Czestochowa Gulber Gliwice Pilkington Sandoglass Saint Gobain Glass Dabrowo Gornicza PORTUGAL BA Sotancro Venda Nova Gallo Vidro Marinha Grande RUSSIA AGC Float Klin I / II Guardian Ryazan ISOVER Yegoriewsk Veda Pack Kingisepp Salavatsteklo Bashkortostan I/ II SWEDEN Ardagh Limmared SWITZERLAND Vetropack St. Prex SPAIN BA Vidrio Leon BA Vidros Villa Franca Guardian Llodio O-I Barcelona (Rovira) O-I Sevilla Saint-Gobain Glass Arboc Vidrala Llodio

CZECH REPUBLIC AGC Teplice O-I Dubi O-I Nove Sedlo UKRAINE Vetropack Gostomel HUNGARY Guardian Hunguard Oroshaza BELARUS Gomel Steklo

ASIA

STG agencies and representatives worldwide

CHINA Luoyang Float O-I Shanghai Samsung Shenzhen Shenzhen Float INDIA AGC Roorkee HNG Bahadurgarh HNG Float Glass Halol HNG Nashik HNG Neemrana HNG Pondicherry HNG Rishikesh HNG Rishra JAPAN AGC Kashima Hakuyo Glass Fukushima Nihon-Yamamura Harima Toyo Glass Chiba Toyo Glass Shiga MALAYSIA Samsung Seremban PAKISTAN Khawaja Float SOUTH KOREA Samsung Gumi Samsung Suwon THAILAND Ocean Glass

ASIA
INDIA Ceracon Engineers Pvt Ltd. B-1/75, Janak Puri New Delhi - 110058 Phone: +91 11 2559 8468 Fax: +91 11 2552 5397 ceracon@vsnl.com Mr. Jay Sarin JAPAN Ceramic Forum Co., Ltd. First Komoda Bldg. 5 F 1-6-6, Taito, Taito-ku, Tokyo Phone: +81 3 5812 3351 Fax: +81 3 5812 3352 kato-iwa@ceramicforum.co.jp Mr. Iwao Kato

EUROPE
PORTUGAL TecInde Equipamentos Produtos e Servios Industriais, Lda. Av. Almirante Gago Coutinho 132/134, Edifcio 2, Portela de Sintra 2710 - 418 Sintra Phone: +35 1 21 9248020 Fax: +35 1 21 9248022 info@tecinde.com Mr. Paulo de Botton SPAIN Technalloy S.A. C/Amposta, 14-18 1 3a 08174 Sant Cugat del Valls Phone: +34 93 586 28 10 glf@technalloy.es Mr. Guillermo Leopold Fernndez

AFRICA / MIDDLE EAST

EGYPT Egyptian Glass Company (Guardian) IRAN Iran Float Saveh Kaveh Float Saveh Kaveh Soda Marraghe Liya Glass Qazvin ISRAEL Phoenicia America Israel Flat Glass (Guardian) SAUDI ARABIA Guardian Gulfguard Al Jubail SOUTH AFRICA PQ Durban UNITED ARAB EMIRATES Guardian Ras Al Kaimah

NORTH AMERICA
Service point USA STG Cottbus at INP North America, Inc. 11390 Old Roswell Road Suite 126 Alpharetta, GA 30009 Phone: +1 678 527 1400 Fax: +1 678 527 1410 us@inp-e.com Mr. Rolf Krey Mr. Andreas Droege

AUSTRALIA
O-I Adelaide

LEGEND Process Automation Zirconium Oxide Oxygen Sensors Gas- /Oil Burners Reseller

Company, Team and Production in Cottbus Partner of the Glass Industry since more than 20 years
Introducing STG Company STG was founded on the 18th of April 1990 by three chemical engineers who had known each other since college. By now this innovative and technology-oriented engineering company has more than 50 employees who have already realized solutions for energy savings, NOx reduction, optimized process control systems, sensors and heating for industrial furnaces in more than 35 countries throughout the world. Traditionally STG nds its customers mainly in the glass industry. However, we also provide solutions for ceramic and metallurgic production. STG production facilities at the Great Mill Madlow offer more than 3.000 m of space for efcient engineering and production; manufacturing of sensors and burners, software development, test and training area for furnace control systems.

STG Combustion Control GmbH & Co KG Kiekebuscher Weg 14 03050 Cottbus/Germany phone: +49 (0) 355-5 90 20-0 fax: +49 (0) 355-54 11 24 e-mail: stg@stg-cottbus.de web: www.stg-cottbus.de

STG production facilities since 2003: Great Mill Madlow in Cottbus

Spreeaue
(Pcklerpark, BUGA, Tierpark) Cottbus

Kiekebusch (Kibus)

B 97

Facilities Great Mill Madlow

Main building production

Old Main Ofce

Manufacturing of burners

... endangered avenue

Cottbus-Sd

A 15

E 36

Berlin 120 km Dresden 120 km

Manufacturing of O2 sensors

PCS7 test eld and training area

Harnischdorf 8,1 km

Dipl. - Ing. Frank Hegewald Frank Hegewald was one of the three partners who established STG. He added a lot of his ideas and visions to form STGs character and face as we know it today. He died on the 18th of August 2003, a week before turning age 55. We will keep him in our hearts and minds forever and will do our best to continue his work.

STG Foundation Partners (from left): Dipl.-Ing. Helmut Heelemann and Dr.-Ing. Peter Hemmann