The energy consumption of glass melting furnaces accounts for more than 70% of the total energy consumption of glass plants. In the past ten years, many energy-saving measures have been taken, involving glass frit formulation, heating system, combustion system, kiln body insulation, waste heat utilization, operation control, etc., and energy consumption has been significantly reduced.
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1) Kiln body insulation
The heat dissipation area of the glass melting furnace is large, the outer surface temperature becomes higher, and the heat dissipation is about 10-50% of the total heat, especially when heavy oil is used as fuel and fused zirconium corundum bricks are used, the heat dissipation is more prominent. After the kiln body is insulated, the fuel is saved by 15-20%, and the flame greenhouse is increased by 20-20 °C.
The thermal insulation part should be expanded as much as possible based on the principle of "guaranteed if it can be guaranteed": the thermal insulation surface. But the kiln body insulation should pay attention to the following issues:
①The pool wall 200-300mm below the liquid surface line cannot be insulated, and cooling needs to be strengthened.
② In order to prevent leakage of materials, the brick joints should be allowed when the pool wall is insulated;
⑧ When the bottom of the pool is insulated, the quality of the furnace should be guaranteed, and the floating bricks and leakage of materials should be strictly prevented;
④The steel structure should be exposed when the breast wall is insulated to avoid affecting the strength.
⑤Insulation of arch and breast wall can only be carried out when the temperature of the kiln is higher than 700°C. Before 700°C, a layer of light refractory bricks can be temporarily laid, so that both ends of the silica bricks can be expanded evenly.
2) Enlarge the regenerator
The temperature of the flue gas leaving the flame space of the glass melting furnace can reach more than 1400 ℃, and the heat energy taken away generally accounts for 50-70% of the heat supplied by the furnace. The waste heat recovery is of special significance in the glass furnace. In the past 10 years, the heating area of the regenerator lattice bricks occupied by the glass pool furnace has reached 20m2/m2, and the individual melting furnaces are as high as 47m2/m2. The air preheating temperature is also increased from 1000 ℃ to 1200-1300 ℃.
The overall thermal insulation of the melting furnace and the expansion of the regenerator are the main technical measures for energy saving of the glass melting furnace at present.
3) Use heavy oil as fuel
Glass melting mainly relies on radiation heating, and heavy oil flame has strong heat radiation, which is very suitable for melting process requirements. As the country has increased the supply of fuel oil for glass melting furnaces, oil burning furnaces have developed rapidly in the past 10 years, and have achieved remarkable results in reducing fuel consumption and pollution.
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4) Use high-quality refractory materials and rationalize matching
The melting pool is built with fused zirconium corundum bricks, and attention is paid to the matching of the overall materials of the melting furnace, and the furnace age can be extended by more than one year.
5) Improve and develop automatic control of kiln thermal process
The automatic control of thermal parameters of the melting furnace has developed rapidly in the past 10 years, which has improved the operation level of the melting furnace.
6) Auxiliary electrofusion
For melting furnaces with variable products and unstable fuel quality, the auxiliary electric melting method is used to adjust the production capacity of the melting furnace, so that the production capacity of the melting furnace is often at full load.
7) Strengthen pre-melting and strengthen homogenization
Strengthen the pre-melting of batch materials, control the distribution position and shape of batch materials in the melting zone, and strengthen the sealing of the feeding port. Enhanced homogenization, such as bottom bubbling, stirring, overflow, discharge, etc.
But to further save energy, we must start from improving the melting efficiency.
There are two major problems in glass pool furnaces today: one is that the flame coverage area is not large; the other is that the flame temperature is not low, and the average temperature of the molten pool glass is not high, which brings difficulties to improving the melting rate.
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If it is not desired to increase the flame temperature, but also to improve the melting efficiency, the best method is to increase the average temperature of the glass. The furnace type structure can be changed, that is, a new type of kiln can be designed to explore ways to save energy.
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