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Equipment for the Glass Industry Perfect Solutions for the Glass Industry

KomE/10.12.V2.2 _KomE/10.08/V2.2

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Page 1: KomE/10.12.V2.2 _KomE/10.08/V2.2

Equipment for the Glass Industry

Perfect Solutions for the Glass Industry

Page 2: KomE/10.12.V2.2 _KomE/10.08/V2.2

2KomE/10.12.V2.2

Page 3: KomE/10.12.V2.2 _KomE/10.08/V2.2

Contents

Oil Supply Equipment page 5

Oil Control Stations for Recuperative and Regenerative Furnaces page 6

Gas Control Stations for Recuperative and Regenerative Furnaces page 7

Gas Burners for Regenerative Furnaces page 8

Oil Burners for Regenerative Furnaces page 10

Gas and Oil Burners for Recuperative Furnaces page 11

Furnace Reversal Systems page 12

Waste Gas System Equipment page 14

Metallic Recuperators page 16

TV Equipment page 18

Furnace Transformers page 19

Electrode Holders and Electrodes for Furnaces page 20

Water Cooling Systems page 22

Bubbler Systems page 24

Glass Level Measurement page 26

Batch Chargers for Conventional Furnaces page 28

Batch Chargers for Electric Furnaces page 31

Air Supply Equipment page 32

Temperature Measurement page 34

Oxygen Measurement page 36

Control Equipment page 38

Alarm Warning System page 41

Drain System Equipment page 42

Gas and Air Stations for Working Ends, Forehearthsand Gathering Bays page 44

Burners for Working Ends and Forehearths page 46

Electrical Heating Equipment for Forehearths page 48

Stirrers page 50

Metering Equipment for Colouring Forehearths page 52

3KomE/10.12.V2.2

Page 4: KomE/10.12.V2.2 _KomE/10.08/V2.2

Why components from SORG®?

Although SORG® is primarilyknown as a successful furnaceengineering company, it alsolays great importance on thedesign and specification of peri-pheral equipment. The key toSORG® success in this field isthe fact that the furnace, work -ing end and forehearths are viewed as a complete unit, sothe equipment can be designedspecifically to meet the variousrequire ments. This is backed bya detailed know ledge of the difficult conditions under whichthe equipment must operate, 24hours a day, 7 days a week, yearin and year out.

This high level of reliability andquality was not achieved over-night. Many years of experience,both positive and negative, liebehind the development ofalmost every item of equipmentdescribed in this handbook.

Detailed descriptions

As the range of components iswide, not all details could beincluded here. However, webelieve that the descriptionsgive a good general picture ofthe equipment we supply. Thefrequent heading “our standardequipment” refers to standarditems that are supplied regularly.However, this does not meanthat other sizes, capacities, shapes etc. are not available,and specials are almost alwayspossible.

4KomE/10.12.V2.2

Regulations and standards

In some cases reference ismade to certi fication standards,in particular to DIN-EN stan-dards. Even where this is notspeci fically mentioned in thishand book, all equipment sup-plied by SORG® corres ponds toeither the relevant harmon isedEuropean Standards or, if thesehave not yet been agreed, tothe relevant German Standards.

Finally, the equipment shown inthis handbook is not limited touse on SORG® furnaces, work -ing ends or forehearths. Manyitems can be, and are in fact,used on other installations.

Foreword

There are many reasons why glass melt ing and conditioninginstallations per form well, producing good glass quality, withlow energy consumption, and operating reliably throughout along campaign. One reason is definitely related to the qualityof the equipment used on and around the furnace, workingend and forehearths.

Many such components are essential for the correct operationof the plant, and it is a testimony to their high quality if product ionis not frequently interrupted as a result of faulty equipment.

Page 5: KomE/10.12.V2.2 _KomE/10.08/V2.2

SORG® hot oil tracer heating system

Oil Supply Equipment

The viscosity of heavy fuel oil is extremely temperature depen-dent, and two requirements must be met before the oil can besupplied to the furnace burners. The viscosity must be reducedto an acceptable level by increasing the temperature, and itmust also be held constant, so that the control equipment andthe furnace burners operate correctly.

Components

An immersion heater in the oiltank ensures that the oil temp -erature is at the correct levelbefore the oil is fed to the system,where it is first passed throughthe electrically heated oil filterand then to the double pumpunit (pump station). There the oilis heated to a suitable tempera-ture by an electric flow heater(with a second as stand-by).

The overflow valve for the returnflow is installed immediatelybefore the oil control station.Another flow heater can beinstalled after the station (with a second as stand-by) beforethe branches to the individual burners. The viscosity on theburners should be 2 °E at apressure of about 6 bar.

All components described abovecan be supplied separately.

Our standard equipment

Immersion heater:Various standard units, up to apower of 120 kW

Double pump unit:Units up to 4000 l/h, pressure 800 kPa

Electric flow heater(preheater or reheater):Various standard sizes, 18 – 48 kW

Overflow control valve:Two sizes available - DN 15/25

Options

• pipe insulation

• tracer heating for pipework

• hot oil tracer heating system

5

Advantages

■ more constant viscosity inthe total circulation system(overflow control valve – return flow)

■ optimum oil temperature before the station and at the burner

■ oil “freezing“ unlikely (this depends on the distancesbetween the components)

■ fewer deposits in pipes orfittings (less cleaning required)

■ increased flame stability due to less pressurefluctuation

KomE/10.12.V2.2

SORG® heavy oil pump unit

Page 6: KomE/10.12.V2.2 _KomE/10.08/V2.2

Oil Control Stations for Recuperative and Regenerative Furnaces

The oil control station on afurnace is designed to carryout 4 functions:

• preparation of the oil sup-ply for the heating system

• regulation of the oil volumeaccording to the automaticcontrol system requirements

• preparation of atomising air

• safety related functions

The open station design is flex ibleand can be adapted to suit siteconditions. The stations aresupplied completely piped andcabled. They are checked be foredelivery and are ready forconnection.

Our standard equipment

Standard oil control stations canbe supplied for capacities of400, 700, 900, 1000 and 2000litres/hour.

Options

• stations for single burner control, with metering and control equipment provided for each burner

• electrically operated control valves

• enclosed station, installed in a sheet steel casing

The atomising air and oil pres-sures are maintained at a con-stant level in the station, whilstthe oil quantity is meas ured andthen regulated by the controlsystem. The safety functionsinterrupt the oil flow if a fault,such as a combustion air failure,should occur. The oil pipes areinsulated in order to reduceheat losses.

SORG® oil stations are fitted withatom ising air pressure control,oil pressure control, filters,safety equipment and meteringand control equipment. Thecontrol valve is provided with anelectro-pneumatic actuator, andthe oil quantity is measuredusing an oval gear meter.

In the case of regenerative fur-naces the oil and atomising airreversal equipment is also inte-grated in the station. All com -ponents which are needed tomaintain operational security arefitted with by-passes.

6

Advantages

■ short installation time

■ high quality and certified components ensure high operational security

KomE/10.12.V2.2

SORG® oil station for a regenerative furnace

Page 7: KomE/10.12.V2.2 _KomE/10.08/V2.2

Gas Control Stations for Recuperative and Regenerative Furnaces

The gas control station on afurnace is designed to carryout 3 functions:

• preparation of the gas supply for the heating system

• gas quantity regulation according to the require-ments of the automatic control system

• safety related functions

In the station the gas pressure isreduced to a suitable level andmaintained at a constant value. Ifthe pressure rises or falls too muchthe safety shut-off valve, integra-ted in the gas pressure regulator,closes the gas supply. The gasquantity is measured by means ofa turbine meter and then regula-ted by the control valve. Thesafety functions interrupt the gasflow if a fault, such as a combus -tion air failure, should occur.

In the case of stations for regener -ative furnaces the gas reversalfunction is also included in thestation.

SORG® gas control stations areprovided with filters, a gas con-trol valve with electro-pneumaticdrive, rapid-action safety valvesand operating to normal cubicmeter con ver sion of the gasquantity measurement. Stationsfor regenerative furnaces alsohave gas reversing valves. Toensure optimum operationalsecurity all parts are providedwith a by-pass.

7

Advantages

■ reserve pressure controllerfor optimum operational security

■ short installation time

■ high level of operational security as a result of the use of DIN-EN certified equipment

KomE/10.12.V2.2

SORG® gas station for a regenerative furnace

The open station design is flex -ible and can be adapted to suitsite conditions. The stations aresupplied completely piped, cab-led, ready for connection, andhave been checked before deli-very.

Our standard equipment

The following standard stationsare available:

throughput:150 – 3000 Nm3/h natural gas or equivalent

pipe size:DN 25 – 250

Options

• stations for single burner control with metering and control equipment for each burner

• enclosed station, installed in a sheet steel casing

• electric actuator for control valve

Page 8: KomE/10.12.V2.2 _KomE/10.08/V2.2

Gas Burnersfor Regenerative Furnaces

Gas burners form an impor-tant part of the regenerativeheating system. They areused to influence flame sizeand shape, both of which canaffect the melting processand the fuel efficiency of thefurnace.

Our standard equipment

SJG 221: 0 – 300 Nm3/h natural gas

SJG 231: 0 – 700 Nm3/h natural gas

SJG Series

In the SORG® SJG series ofburners the gas quantity isregulated by a perforated drumwithin the burner body. Thedrum can be adjusted bymeans of a hand wheel. Theflame shape can be varied byadjusting the drum.

A compressed air connection isprovided to cool the burnerduring the exhaust phase of theregenerative heating cycle.

Burners of the SJG series areideally suited for standard appli-cations as they have a simpleconstruction and are easy tooperate. The burners are sup-plied complete with holderswhich have height and angleadjustment, flexible gas hose,gas non-return valve, shut-offvalve and cast iron sealingplate.

The burners operate with a gaspressure of 50 – 200 mbar atthe burner.

8

Advantages

■ low maintenance

■ simple operation

■ cast iron sealing plate produces an efficient and permanent seal at the connection between fur-nace wall and burner, to prevent the infiltration of

KomE/10.12.V2.2

SORG® SJG gas burner installed on an end-fired regenerative furnace

Page 9: KomE/10.12.V2.2 _KomE/10.08/V2.2

SGB200 Series

The SORG® SGB200 series ofgas burners offer two adjust-ments to vary the flame shape.Both adjustments are made atthe rear of the burner.

By adjusting the position of aninner tube with respect to theburner body the actual crosssection of the outlet nozzle canbe varied to suit the gas flow.

In addition, the gas flow is div -ided into two streams by anadjustable perforated drum withinthe burner body. Most of thegas flows at a lower velocitythrough the main body, whilst asmaller amount flows at a highervelocity through an inner tube.The flame is produced when thetwo gas streams meet again atthe exit nozzle. Increasing theamount of gas passing throughthe inner tube shortens andsharpens the flame, and viceversa.

Other features of the design,such as a rounded outsideedge to the nozzle and a castiron sealing plate, ensure opti-mum sealing between the bur-ner nozzle and burner block,and eliminate cold air infiltrationaround the burner.

During the waste gas phase,the burner nozzles are protec-ted against over-heating by aseparate air supply. Anotherexternal cooling air supply pro-tects the cast iron sealing plateand the outside of the burnertip.

The two adjustments for varyingthe flame shape ensure that theburner can be set to give opti-

9

Advantages

■ adjustable outlet nozzle improves combustion adjustment (flame length and sharpness)

■ NOx reduction is achievedby the combination of adjustable outlet nozzleand variable gas stream separation

■ cast iron sealing plate produces an efficient and permanent seal at the connection between fur-nace wall and burner, to prevent the infiltration of cold air

KomE/10.12.V2.2

mum operation at all times. Thismeans that SGB200 burnersare particularly suitable for appli-cations where NOx emissionsmust be reduced.

The burners require a pressureof 50 – 200 mbar at the burner.

The burners are supplied com-plete with holders with heightand angle adjustment, flexiblegas hose, gas non-return valve,shut-off valve and sealing plate.

Our standard equipment

SGB 221: 0 – 300 Nm3/h natural gas

SGB 231: 0 – 700 Nm3/h natural gas

SORG® SGB200 series gas burner installed on an end-fired regenerative furnace

Options

• rotameter flow meter, so thatgas distribution betweenburners can be observed

• individual control valves on each burner, for regulation of gas distribution

• flow meter with electrical out-put, for registration of gas distribution

Gas Burners for Regenerative Furnaces

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Oil Burners for Regenerative Furnaces

Oil burners form an importantpart of the regenerative heat -ing system. They are used toinfluence flame size andshape, both of which canaffect the melting processand the fuel efficiency of thefurnace.

The oil exits the SORG® NL4burner as a central streamenveloped in a peripheral streamof compressed air. The highvelo city differential between theoil and com pressed air streamspulls the oil stream apart andatomises the oil.

The correct combination ofoil/air nozzle and adjustment ofthe oil and atomising air gives aradiating flame with minimumNOx production.

The burner is supplied completewith adjustable holder, flexibleoil and air hoses and shut-offvalve.

Our standard equipment

Burner type NL43 sizes of oil nozzle

size 1:max. throughput ca. 150 l/h

size 2:max. throughput ca. 300 l/h

size 3:max. throughput ca. 600 l/h

Options

• oil and atomising air quantity measurement

• extraction valves to remove oil from the burner during thereversal period to avoid solid build-up and so extend cleaning intervals

10

Advantages

■ the burner operates as a pure compressed air atomiser

■ useable for all applications

■ short, sharp or long and lazy flames can be produ-ced with the correct oil nozzle diameter and atomising air quantity

KomE/10.12.V2.2

SORG® NL4 oil burners installed on an end-fired regenerative furnace

The oil burner comprises a bodywith air and oil connections, theoil and air pipes, the nozzlesand accessories, such as seals.The nozzle is available in shortor long versions. The short ver-sion produces a shorter, widerflame for smaller furnaces whilstthe long version is used in largerfurnaces, where it provides alonger, narrower flame.

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Gas and Oil Burners for Recuperative Furnaces

In furnaces with recuperativeheating sys tems the combu-stion air is preheated in therecuperator and passedthrough the actual burner,where it mixes with the gas oroil to form the flame.

SORG® burners for recuperativefurnaces consist of a cast ironcasing, a high tem per ature resi-stant refractory lining and eithera gas or oil lance.

11

Advantages

■ The cast iron burner casing provides a safe, permanent and sealed connection between the furnace wall and the bur-ner. This prevents the infiltration of cold air

■ These burners ensure smooth and almost main-tenance-free operation

■ The burner pressure can be adapted to suit that of the heating system

KomE/10.12.V2.2

SORG® HTG gas burners installed on an end-fired recuperative furnace

The burners are available inthree versions:

• the HTG series is used for gaseous fuels

• the HTO series is used for oilfiring

• the HTK series can be used for either gas or oil, where-by the burner lance must be changed to convert from one fuel to the other.

Non-return valves, shut-off valves and gas or oil hoses aresupplied as standard.

Our standard equipment

A total of 10 standard burners isavailable in each series, withmaximum capacities rangingfrom 50 – 1500 kW (operationwith preheated combustion air).

Page 12: KomE/10.12.V2.2 _KomE/10.08/V2.2

Furnace Reversal Systems

When the firing is reversed,the reversal unit switches theincoming combustion air flowand the outgoing waste gasflow between the two regen -erator chambers from oneside to the other. Slide or flapreversing systems are used todo this.

Slide Reversing System

The slides themselves aremanufactured from cast ironand fit into a cast frame. Thisproduces the best possible seal.

Slides are installed in the wastegas chan nels of both chambers.The two devices are connectedto one another and are opera-ted synchronously by a singledrive. One valve is always openand the other closed, depen-ding on which side is firing. Theposition of the two valves ischanged during the rever singprocedure. Simultane ously thepassage of the combustion airis changed by a flap in a Y-pipe.

The reversing flaps are driven byspecial pistonless cylinders,which shortens the reversingtime. This minimises thetemper ature drop during thereversing proce dure and there-fore influences the purge timesfor the regenerator chambers.As a result the NOx emissionlevels are also decreased.

12

Advantages

■ improved sealing of the reversing unit and signifi-cant reduction in the amount of air induced

■ shorter reversal times, resulting in a reduction in NOx emission levels

KomE/10.12.V2.2

Our standard equipment

The following reversal unit sizesare available from SORG®:

Type 11/9channel height 1100 mmchannel width 900 mm

Type 13/11channel height 1300 mmchannel width 1100 mm

Type 15/13channel height 1500 mmchannel width 1300 mm

Type 17/15channel height 1700 mmchannel width 1500 mm

Options

• a double drive chain for larger units

• a conventional pneumatic cylinder, or an electric motor, as alternative drive methods

SORG® slide reversal system for

regenerative furnaces

Page 13: KomE/10.12.V2.2 _KomE/10.08/V2.2

Options

• refractory material for insulation

• hand winch

Furnace Reversal Systems

Flap Reversing Unit

This type of reversing unit utili-ses a single swivelling flap forthe reversal of the com bustionair supply and waste gas ex -haust between the two regene-rator chambers.

The reversal unit consists of ametal casing, that must be insu-lated with refrac tory material onsite, two combustion airconnections and a reversingflap with drive assembly.

The flap is driven by a pneumaticcylin der through a lever arrange-ment. The lever and flap shaft

Our standard equipment

The SORG® flap reversal unitshave the following dimensions:

Type 18/37channel depth 1800 mm channel width 3700 mm

Type 18/39channel depth 1800 mmchannel width 3900 mm

Type 18/41channel depth 1800 mmchannel width 4100 mm

Type 18/43channel depth 1800 mmchannel width 4300 mm

Type 18/45channel depth 1800 mmchannel width 4500 mm

Type 18/47channel depth 1800 mmchannel width 4700 mm

13

Advantages

■ compact equipment to fit limited building space

■ shorter waste gas paths –more economic solution

■ short installation time

■ long operating life

KomE/10.12.V2.2

SORG® flap reversal system for

regenerative furnaces

are connected by a spring clampthat operates as a slip couplingin order to protect the shaft fromtorsion stresses. Limit switchesare provided to signal the openand closed limit positions.

This system is designed for usewith double-pass regenerators,where it can be installed directlyon the top of the second cham-ber. It is not suitable for installa-tion in waste gas channels.

Page 14: KomE/10.12.V2.2 _KomE/10.08/V2.2

Waste Gas System Equipment

The furnace waste gas system generally includes equipmentfor the control of the furnace pressure, and may also include amethod of producing, or increasing, the suction effect whichpulls waste gases from the furnace. These functions areimportant for stable operation of the furnace combustionsystem.

Furnace PressureControl Valve

This valve is installed in thewaste gas channel after theregenerators and is used to varythe draught, in order to maintaina constant pressure in the fur-nace superstructure.

This flap valve is made of a spe-cial cast iron, resistant up to700 °C, as is the frame in whichit sits and rests against when inthe fully closed position.

A pneumatic actuator is used tomove the flap.

Our standard equipment

SORG® furnace pressure controlflaps are available in 4 standardsizes:

Type 11/9 channel height 1100 mmchannel width 900 mm

Type 13/11 channel height 1300 mmchannel width 1100 mm

Type 15/13 channel height 1500 mmchannel width 1300 mm

Type 17/15 channel height 1700 mmchannel width 1500 mm

Advantage

■ the use of a pneumatic drive improves reaction time and helps to reduce NOx production

14KomE/10.12.V2.2

Options

• a vertical slide valve in place of the swivelling flap valve

• an electric actuator

Page 15: KomE/10.12.V2.2 _KomE/10.08/V2.2

Waste Gas System Equipment

15KomE/10.12.V2.2

Advantages

■ simple method of creatingsufficient draught when flue draught losses are high

■ can also be used to con-trol furnace pressure

Advantage

■ can eliminate the need fora high chimney to achievesufficient draught

nozzle, and the fan with a fre-quency converter are all inclu-ded in the SORG® scope ofdelivery.

Our standard equipment

Each injector chimney is specifi-cally designed for the actualoperating conditions of theinstallation. SORG® injectorchimneys can be designed forwaste gas flows of 10000 –50000 Nm3/h.

Option

• the steel stack can be supplied by SORG®

Waste Gas Exhauster

Wherever the natural draughtproduced by a stack is limited,or where the losses in the wastegas flues are too high, it may benecessary to use a method ofproducing a draught which isindependent of the stack. Thisis often the case, for example,when an electrostatic preci p -itator is installed in the wastegas flue between the furnaceand the stack.

A waste gas exhauster is basi-cally a fan which is used to pullthe waste gases from the furn -ace and expel them through thestack. The exhauster operatesin a hot environment and isdesigned for waste gas temp - eratures of up to 500 °C.

The fan speed can be varied bya frequency converter, and so itis possible to use the exhausteras a method of controlling thefurnace pressure, with the out-put of the furnace pressure con-troller being used to vary theexhauster speed.

SORG® waste gas exhaustersare supplied complete with inletside flap valve, compensatorand frequency converter.

Our standard equipment

SORG® waste gas exhausterscan be supplied for waste gasflows up to 60000 Nm3/h.

Injector Chimney

In cases where it is not possibleto achieve sufficient naturaldraught an injector chimney canbe used. An injector nozzle isplaced pointing upwards in thecentre of the chimney base, anda jet of air is blown through thenozzle. The injector effect cre -ated by this jet of air is used toprovide a draught to pull wastegases from the furnace andexpel them through the stack.

The injection air is provided by adedicated fan. The draught pro-duced is dependent upon theamount of air passing throughthe nozzle, and this is varied bymanipulation of the fan speedthrough a frequency converter.This method is used to controlfurnace pressure.

The injector unit is normally toppedby a simple steel stack, typicallybetween 15 and 60 m high.Higher versions may require aswing damper.

Design and engineering, theinjector unit complete with

Page 16: KomE/10.12.V2.2 _KomE/10.08/V2.2

Metallic Recuperators

Recuperators are used totransfer heat from the furnacewaste gases to the combus -tion air. Most recuperativefurnaces in the glass industryutilise steel recuperators,which can give air preheattemperatures of up to 750 °C.

SORG® uses two basic typesof steel recuperator: the doubleshell recu perator and thetube cage recuperator.

The Double ShellRecuperator

This type of recuperator con-sists of two concentric high-temperature resistant steeltubes. The hot waste gasespass through the inner tube,whilst the com bustion air passesthrough the annular gap be -tween the two tubes. The airmay be passed in the samebasic direction as the wastegases (parallel flow) or in theopposite direction (counterflow).Single modules of this type canbe used alone, or can be placedone after another to form acomplete unit.

In most applications the wastegases flow upwards through therecuperator, but it is also possibleto design the recuperator for adownward waste gas flow.

Double shell recuperators arecapable of giving a typical airpreheat temperature within therange 450 – 650 °C. Theseunits are normally used for smallfurnaces up to a melting capacityof approximately 50 t/24 h.

Our standard equipment

Recuperators are always de -signed for individual applications.

16

Advantage

■ can also be produced as small units for small furnaces, working ends or forebays

KomE/10.12.V2.2

SORG® recuperator

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The Tube CageRecuperator

The tube cage recuperator con-sists of a large number of smalldiameter steel tubes, installed ina ring around the inner circum-ference of a large diameterouter tube. The outer tube ismade of steel, but is lined withrefractory material.

The waste gases flow throughthe large outer tube, whilst thecombustion air passes throughthe inner tubes. The small dia-meter air tubes are suspendedfrom the top, and are sealed atthe bottom with refractorymaterial in such a manner thatthe tubes are free to expand. Therefractory material can be instal-led before delivery, or added onsite after the recuperator hasbeen placed in position.

This type of recuperator cangive air preheat temperatures ofup to 750 °C. They are usuallyinstalled on larger furnaceswhich require a greater quantityof combustion air.

Our standard equipment

Recuperators are always de -signed for individual appli cations.

Combination Aggregate

A tube cage and a double shellunit can be combined to pro -duce a complete aggregate forhigh capacity installations. Theair preheat temperatures pro -duced by such combinationsare similar to those produced bya tube cage recuperator, but thetotal heat exchange capacity ishigher.

Metallic Recuperators

17

Advantages

■ offers higher air preheat temperatures than doubleshell recuperators

■ less susceptible to pro-blems caused by the con-densation of easily volatilecomponents of the glass

KomE/10.12.V2.2

SORG® recuperator and

hot air pipework

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TV Equipment

TV monitoring equipment canbe used for continuous andsimple monitoring of impor-tant furnace parameters, suchas flame shape and batchcover on the glass bath.

The SORG® sensor unit for thecom bus tion chamber consistsof a water-cooled casing, an airpurge unit, lens and camera.The complete unit is mountedon a mov able carriage, that canbe removed auto matically fromthe danger area if a fault shouldoccur.

The camera can be fitted withdifferent lenses in order to maxi-mise the field of vision in each

furnace. The aperture setting isautomatically controlled. Theoutput signal from the camera isa normal video signal.

Electricity, water and air aresupplied from a free-standingcontrol and supply station.

The image is shown on a 17”monitor, available either as afree-standing unit or for integra-tion in a control panel.

18

Advantages

■ robust camera system, suitable for continuous operation in the glass industry

■ high quality lenses produceexcellent image quality

KomE/10.12.V2.2

SORG® furnace TV camera unit

Our standard equipment

Lenses with diagonal imageangles of 70°, 94°, and 110°are available. Fisheye lensescan also be supplied.

The standard sensor diameter is70 mm. Other diameters up to129 mm are available, so thatsensors can be adapted for usewith existing camera blocks inthe furnace superstructure.

Options

• a separate water cooler can be supplied if the customer does not have a cooling water circulation system

• video recording equipment, configured especially for long-term monitoring

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Furnace Transformers

Transformers with steplesslyvariable voltage outputs areused for electric boostersand all-electric furnaces.

SORG® can supply two diffe-rent types of transformer:

• oil-cooled, three-phase induction regulators

• air-cooled, single-phase, fixed ratio transformers with thyristors

Induction Regulators

The output voltage is variedunder load by the rotation of aninduction winding. An electricdrive motor for the inductionwinding permits either remoteoperation or fully automaticcontrol.

There are no moving electricalcontacts, and the principle ischaracterised by a high level ofreliability and low main tenancerequirements.

Induction regulators are normallysupplied as three-phase unitsfor high voltage connection upto 30 kV. The transformers areoil-cooled and are suitable forindoor operation with natural airconvection. Double-chamberBuchholz relays, primary voltagesurge arresters, an oil temp -er ature gauge with limit contact,air de-humidifier, and transport rollers are supplied as standardaccessories.

Double-Wound FixedRatio Transformerswith Thyristors

Air-cooled, double-woundtransformers with thyristors arevery well suited to installationswith relatively low powers (e.g.less than 200 kVA), and whereextremely fast voltage adjust-ment is necessary. Typicalsystems on which these trans-formers are used are throatboosters and melting boostersfor certain borosilicate glasses.

The transformers are providedwith two or more voltage taps,so the voltage range can bepre-set. The thyristors operateon the phase angle control prin-ciple and provide steplessadjustment of the output voltageunder load, making remote orfully automatic control possible.

The transformers are designedfor capacities between 40 and200 kW, as single-phase unitsfor connection to the low volt -age network (normally 380 –440 volts).

Our standard equipment

SORG® induction regulators areavailable for nominal powers of300 – 4500 kVA.

Options

• bus bar distributor system onsecondary side

• secondary current trans -formers for current and powermeasurement

• transformers with combined forced air/oil or water/oil cooling for difficult locations

• tapped transformers with off-load tap change, up to 1000 kVA

19

Advantages

■ improved furnace operation,owing to stepless powervariation under load

■ extremely reliable, low-maintenance operation, as a result of non-contact voltage adjustment

Advantage

■ high flexibility – even in temporary exceptional circumstances – owing to selectable voltage ranges

KomE/10.12.V2.2

All components are in stalled inenclosed steel ca sings, to pro-tection standards IP23. Currenttransformers and transport rol-lers are supplied as standard.

Our standard equipment

60 to 100 kVA as throat boosterunits, 100 kVA as booster unitsfor furnaces

SORG® 2100 kVA induction regulator

Page 20: KomE/10.12.V2.2 _KomE/10.08/V2.2

Electrode Holders and Electrodes for Furnaces

Molybdenum electrodes areutilised in all-electric furnacesand in additional heatingsystems (boosters) in con -ventional furnaces. A verypure form of this metal is used,that does not contam inate theglass.

Normally, water-cooled hol-ders are used to protect themolybdenum from damagecaused by oxidation in thetransition area between theglass and the air.

Standard Electrodes

Rod electrodes are used fornormal applications in boostersand all-electric furnaces. Theindividual rods are usually pro -vided with a male and femalethread so that the electrodescan be screwed together.

Our standard equipment

SORG® can supply electrodeswith the following nominal dia-meters:

32 mm (11/4'') 48 mm 2''21/2''3''

Standard rod electrodes havenominal lengths of 400 or 800 mm.

Option

• rod electrodes in non-standard lengths

SORG® Top Electrodes

Electrodes are normally installedthrough the side walls or bottomof the tank. This method increa-ses the wear on the refrac torymaterial and creates potentialweak spots.

SORG® Top Electrodes are L-shaped, and consist of an elec-trode shaft, which contains thecooling water and electricalsupplies, and the molybdenumelectrode itself. The holder isinserted through an opening inthe superstructure side wallabove the glass melt, and theelectrode enters the glass bathvertically through the surface.

The condition of the electrodecan be checked at any time asthe complete holder and elec-trode unit can be swung out ofthe furnace.

SORG® Top Electrodes are suit -able for use as main electrodesin all types of cold-top electricfurnaces.

The complete initial package ofSORG® Top Electrodes comp -rises holder, swivel bracket anda set of connection items.

Our standard equipment

The standard diameters forSORG® Top Electrodes are 21/2 '',3'' and 4''. Standard electrodelengths are between 600 and1200 mm.

A set of connection items con-sists of pressure hoses (2 x 2.5 mper electrode), needle valve forthe cooling water supply, copperconnection plate with insulators,flexible connecting straps and aconnection clamp.

Option

• the electrodes can be surface-treated to provide temporary protection against oxidation

20

Advantage

■ SORG® molybdenum rod electrodes are bought solely from reputable manufacturers and there-fore meet the stringent quality standards for glassmelting furnaces

Advantages

■ no access holes or water-cooled electrodes holdersin tank blocks

■ electrodes can be checkedat any time and re-insertedas required

KomE/10.12.V2.2

SORG® Top Electrodes installed on a

VSM® all-electric furnace

Page 21: KomE/10.12.V2.2 _KomE/10.08/V2.2

Advantages

■ proven design

■ universal application

Electrode Holders and Electrodes for Furnaces

Water-CooledElectrode Holders

Water-cooled electrode holdersare used for the conventionalinstallation of elec tro des in boosters and in the lower areasof electric furnaces. SORG®

electrode holders have an en -c losed water circul ation channeland are therefore suitable forboth side and bottom installation.

The operating temperature ofthe holder is registered by areplaceable Ni.Cr-Ni mantlethermocouple.

The initial electrode holder package includes a set of connection items.

Our standard equipment

SORG® can supply electrodeswith the following nominal diameters:

32 mm (11/4'') 48 mm 2''21/2''3'

Standard nominal lengths arebetween 700 and 900 mm forside wall installation and between1000 and 1500 mm for bottominstallation.

21KomE/10.12.V2.2

A set of connection items con-sists of pressure hose (2 x 1.5 mper electrode), needle valve forthe cooling water supply, holderwith insulators, copper connec-tion plate with insulators, flexibleconnection straps and aconnection clamp. A safetysupport is also included forbottom electrodes.

Typical SORG® furnace bottom

electrode holder installation

Tin Oxide Electrodes

Special ceramic electrodesmade of tin oxide are installed infurnaces for lead crystal glasses,especially in the throat and riserareas.

Owing to the characteristics ofthe ceramic material these elec-trodes cannot be ad vanced.Therefore tin oxide electrodesare installed permanently, with awater-cooled holder. Corrosionis limited as the electrodes areoperated at a low current density.

Normally rod-shaped electrodesare used. The electrodes arequite short and thick as thismaterial has a relatively lowmechanical strength.

Page 22: KomE/10.12.V2.2 _KomE/10.08/V2.2

Water Cooling Systems

Electrode holders and other metal components used in hotareas must be cooled continuously with water. In the majorityof cases enclosed cooling water circulation systems are usedin order to maintain control of the water quality and minimisethe quantity of fresh water needed.

A typical cooling water circulation system comprises a waterstorage tank, cooler, pump and distribution stations, and allpiping.

Evaporation Cooler

In an evaporation cooler the cir-culation water is fed throughclosed pipes that are cooledexternally by a combination of arising air flow and the evap -oration of external water drippingfrom above. The circulationwater and cooling media arekept separate, and there is noloss of circulation water.

There is no risk of blockages ordeposits as no untreated wateris fed through narrow pipes orchannels.

Evaporation coolers are installedoutside, which can also help tosave space in the factory building.

The electrical control equipmentis installed in a separate controlpanel.

Our standard equipment

Evaporation coolers must bedesigned to suit the specific climatic conditions on site. Thecoolers used by SORG® havecooling capacities up to 170 kW.

Pump Station

Equipment for a number of func-tions is installed in the SORG®

pump station.

Two identical circulation pumpsare in stalled for the coolingwater circulation, so a stand-by is available if a pump fails ormaintenance work must be carried out. Both pumps have afilter. A pressure switch is provi-ded to monitor the operatingpressure in the system.

A small top-up quantity of freshwater is required to compensatefor water losses, and this isadded at this station.

An anti-scale magnetic treat-ment (AMT) unit is installed inthe main water circu lating pipeto eliminate problems causedby solid deposition in the pipe-work.

The magnetic valve that con-trols the emergency supply offactory water during a powerfailure is also mounted on thestation. This valve is open whenthere is no power, and is nor-

22KomE/10.12.V2.2

mally kept closed by the net-work voltage. It opens if there isa power failure to allow waterfrom the factory system to enterthe cooling circuit.

The station is compact, and issupplied ready for connection,complete with all necessaryminor components, and thecomplete pipework. Copper orplastic is used for all pipes.

All electrical connections arecentralised in one control cabinet.

Our standard equipment

Standard stations with capacitiesof 10 m3/h, 15 m3/h and 25 m3/hare available.

Plate Cooler

A plate cooler consists of twopipe sys tems in close contactwith one another. One system isa part of the water circu lationsystem, and the cooling waterused for cooling the electrodeholders or other componentsflows through these pipes.Untreated water from the fac -tory mains flows through thesecond pipe system.

Heat is exchanged between thetwo systems, whereby heat isremoved from the cooling waterof the circulation system.

Both systems are totally enclo-sed and the unit is completelyunaffected by the surroundingconditions. It can therefore beinstalled anywhere, includingoutside.

Our standard equipment

The number of units required canbe combined as the system ismodular. Systems with coolingcapacities up to 170 kW areavailable.

SORG® pump station

Page 23: KomE/10.12.V2.2 _KomE/10.08/V2.2

Water Cooling Systems

Distributor Station

The cooling water is normallydist ributed to the individual consu -mers from a distributor station.

In SORG® distributor stations thewater is monitored by a flowmeter in each return pipe. Thismethod offers more operationalsafety than moni toring in thesupply pipes. The flow metershave an adjustable limit contact,and issue a warning if the requi-red flow volume is not reached.

After the flow meter all returnpipes lead into a common collect -ing trough, covered to preventcontamination of the circulationwater. The cover can be raised sothat the water temperature canbe hand tested. The return flowto the water tank is by gravity.

All electrical connections aregrouped in one control panel.

Our standard equipment

Standard water distributor stationscan be supplied for up to 20consumers.

23

Advantages

■ compact design

■ all important equipment inone place

■ low water consumption

■ low maintenance

■ low total cost solution for small systems

■ added security by flow rate monitoring in return pipes

KomE/10.12.V2.2

Water Tank

SORG® water tanks for coolingwater circulation systems aremanufactured in stainless steel,and are fully enclosed. This pre-vents the water from becomingcontaminated by rust or foreignbodies.

The tanks have flanged connec-tions for the inlet and outlet,drain and vent.

Our standard equipment

SORG® water tanks are availablein sizes up to 3 m3.

Option

• tanks made of plastic, suitablefor regions with particularly aggressive water quality

SORG® CompactWater System

The SORG® compact water cir-culating system contains all theequipment re quired for a com-plete small water circu latingsystem for a limited number ofconsumers. The equipmentcomprises a water storage tank,two circulating pumps (one asreserve), a closed circuit cooler,an AMT (Anti-scale MagneticTreatment) unit that preventssolid de position in the system, a distributor and a collectingtrough. Magnetic valves to pro-vide an emergency supply fromthe factory mains supply in caseof loss of water pressure, arealso included.

The unit only requires connec -t ion to the main water supplypipe, the electrical connectionand the installation of the pipe-work to and from the consu-mers to complete the watercooling circulating system.

The unit is supplied completelypiped and wired and ready forconnection.

SORG® cooling water storage tank

SORG® distributor station

Our standard equipment

The SORG® compact water circulating system is available in5 standard sizes with circulatingcapacities of 1 – 5 m3/h. At atemperature increase of 10 °Cat the consumer this is equi v -alent to between 2 and 10 stan-dard electrode holders.

Page 24: KomE/10.12.V2.2 _KomE/10.08/V2.2

Bubbler Systems

The upward movement of thebubbles from bubbler systemscreates vertical currents. Thisstream can prod uce an homo -genising effect in the glass,but more frequently the aim isto transport hot glass to thebottom in order to in creasethe bottom temperature.

Various types of bubbler tubeare available:

• molybdenum disilicide (also known as Kanthal Super)

• ceramic• ceramic with platinum tip

The supply equipment is nor-mally installed in a commonpanel. The flow volume foreach bubbler tube is set anddisplayed on the controlpanel.

MolybdenumDisilicide BubblerTubes

The material is very heat resistantand also resists attack by theglass. It has a good electricalconductivity (it is primarily usedfor heating elements for hightemper atures) so, in order toprevent earth faults, it must beelectrically insulated againstearth.

The bubbler tubes are cylindrical,with a hole running through thecentre. Those parts of the bub-bler tube that project below thefurnace bottom are protectedby a fibre insulating sheathagainst any damage caused bytemperature changes.

The material is suitable for usein furnaces producing soda-limeglasses, and where the bubblingmedium is air.

All bubbler tubes are suppliedwith an insulating sheath, fixingclamp, short insulating hoseand a connector for the air supply pipe.

Our standard equipment

Molybdenum disilicide bubblertubes have an external diameterof 15 mm and are supplied innominal lengths of 1000 or1200 mm.

Ceramic CapillaryBubbler Tubes

If the gas pressure on the bubblertube is temporarily reduced orcut off, there is the risk thatglass will enter the hole, whereit freezes and blocks the tube. Itis very difficult, if not impossible,to clear a tube that has becomeblocked in this way.

SORG® ceramic bubbler tubeshave several capillaries, all ofwhich are too small for the glass

to run into. As a result there ismuch less risk of a bubbler tubebecoming blocked during abreak in operation. These tubesalso operate successfully in pulsed bubbler systems.

Our standard equipment

SORG® ceramic bubbler tubeshave an external diameter of15 mm and are supplied innominal lengths of 1000 or1200 mm.

Options

• ceramic bubbler tubes with aplatinum sheath at the hotend for use in special glasses,such as borosilicate compo-sitions

• ceramic bubbler tubes can also be embedded in water-cooled steel tubes

24

Advantage

■ excellent material properties

Advantage

■ does not become blockedif bubbling interrupted

KomE/10.12.V2.2

SORG® ceramic bubbler tube installation

Page 25: KomE/10.12.V2.2 _KomE/10.08/V2.2

25KomE/10.12.V2.2

Bubbler Systems

a multiplexing system, using asmall PLC. It is not necessary tomonitor ceramic bubbler tubesin this way.

Bubbler control panels can beequipped for operation with either air or oxygen. The basicequipment is the same for bothversions but, if oxygen is used,all components and tubes areproduced in stainless steel, andare absolutely fat and greasefree.

The panels are supplied com-plete with all pipework and cabling.

Our standard equipment

The control components for upto 6 bubbler tubes are installedin a standard SORG® bubblercontrol panel. Two or morepanels are erected side by sidefor bubbler systems with morebubbler tubes.

Option

• For special applications the installation can be designed as a pulse bubbler. The pressure pulses are produced by magnetic valves installed in the feed pipe to each bubbler tube and controlled by a PLC

Advantages

■ stable operation achieved by the use of flow meters with automatic pressure stabilisers

■ flow meters can be replaced during operation

■ operational security en-sured by continuous monitoring of voltage to earth (with molybdenum disilicide bubbler tubes)

Bubbler Control Panel

The equipment in a bubblercontrol panel comprises a pres-sure controller with a filter instal-led in the supply line, a flowmeter with automatic pressurestabiliser and a manometer foreach bubbler tube. Each flowmeter is provided with a needlevalve as a by-pass.

The pressure stabiliser providesa constant flow rate, so thequan tity of bubbling air is stable,even when temperature fluctua-tions in the glass cause a changein the viscosity at the outlet ofthe bubbler tube. If it is neces-sary to exchange a flow meter,the by-pass and the needle valveare used to maintain operationof the bubbler tube affected.

Owing to the electric conduct -ivity of the molybdenum disilicidebubbler tubes the voltage toearth of the individual tubes mustbe monitored in order to identifyearth faults. This is achieved by

SORG® bubbler panel – internal detail

showing flow meter by-pass

Page 26: KomE/10.12.V2.2 _KomE/10.08/V2.2

Glass Level Measurement

Glass level measurement isused as the basis for automaticcontrol of the raw materialfeed to the furnace. In manycases the stability providedby the system is also animportant prerequisite of stable production.

an emergency con troller is avail -able within the system elec tronicsto provide temporary control, ifthe normal glass level controlsystem should fail. The emer-gency controller operates byswitching the batch charger onand off.

The system is suitable for instal-lation in working ends andforehearth channels. It is usedwith soda-lime glasses, but canalso be applied to other typesof glass.

If required, the system can beset up to operate as a contactsystem which reacts when theprobe touches the glass surface.

Our standard equipment

The standard device is equippedwith a non-cooled ceramic sen-sor. The length of the sensordepends on the height of thesuperstructure, and is suppliedto suit individual projects.

Mechanical DippingProbe System

This mechanical dipping probesystem has a sensor thatmoves vertically, and normallyoperates without glass contact.

Immediately above the glasssurface there is an electricallyconductive layer of ionised gas.A capacitive measuring me thodis used for accurate determi -nation of the proximity betweenthe descending sensor and theglass surface.

The drive unit is mounted onthe side of the channel, and thenon-cooled, pla tinum-tippedceramic probe is inserted verti-cally through the roof. The elec-tronic evaluation system used todetermine the glass level is inte-grated in the drive casing. Theoutput signal is a comparativevalue for the deviation betweenthe set point and actual value ofthe glass level.

The glass level is controlled byan external controller. However,

26

Advantages

■ non-contact glass level measurement

■ compact design

■ little corrosion on sensor

■ simple fault diagnosis

■ internal emergency controller

KomE/10.12.V2.2

SORG® dipping probe glass level

detector – drive unit

SORG® dipping probe glass level

detector – probe

Options

• water-cooled sensor for glasses with heavy volatilisation

• air purge device to avoid the aggregation of condensate inthe access opening: this is especially important for use with special glasses, or if there is high internal pressureat the measuring location

• water-cooled base plate when ambient temperatures are very high

Page 27: KomE/10.12.V2.2 _KomE/10.08/V2.2

27KomE/10.12.V2.2

Glass Level Measurement

Our standard equipment

The standard system is suitablefor all normal applications.

Option

• a laser system, which operateson the same principle as the optical system described above

Optical Glass LevelDetector

A light beam created by a lenssystem is directed diagonallyonto the glass bath surface,from where it is reflected. Areceiver installed opposite thelight source registers the exactposition of the reflec ted beamand uses this to evaluate thelevel of the glass bath surface.The light source and receiverare installed in suitable free-standing casings.

An air purge unit is used to pre-vent the collection of conden -sates in the access openings bymaintaining a small over-pressure.

The signal is evaluated by a unitinstalled in a separate controlpanel. This type of measure-ment is suitable for soda-limeglasses, but has also been usedsuc cess fully for other glassesthat exhibit heavy volatilisation.

Radioactive GlassLevel Measurement

A weak radioactive source ispositioned so that the radiationcone runs partly through theglass bath and partly throughthe atmosphere above the bath.

More radiation is absorbed bythe glass bath than by theatmosphere. A detector in -stalled opposite the sourcereceives more or less radiation,depending on how much of theradiation cone is covered by theglass bath. Therefore the inten-sity of the incoming radiationcan be used as a comparative

Advantages

■ no mechanical wear as this is a non-contact measuring technique

■ very accurate

■ reliable

Advantages

■ no mechanical wear as this is a non-contactmeasuring technique

■ if little space is available, itis possible to site the source and receiver severalmeters from the measuring point

SORG® dipping probe glass level detector in operation

SORG® optical glass level measuring

system

SORG® isotope glass level measuring

system

value for deter mining the heightof the glass bath surface.

The system comprises a suit -able low level radiation source,housed in a protective casing, adetector and an evaluation unit.

Our standard equipment

The standard system is suitablefor all normal applications.

Page 28: KomE/10.12.V2.2 _KomE/10.08/V2.2

Batch Chargers for Conventional Furnaces

The raw materials for theglass melt – batch and cullet– are introduced into the fur-nace by batch chargers thatoperate with various chargingmethods. The most suitabletype of charger for an instal-lation is usually establishedduring the planning stage.The size and shape of the

dog house must be chosen tosuit the batch charger to beused.

All machines described beloware designed and constructedaccording to current ENmechanical engineering regulations.

28KomE/10.12.V2.2

The new EME-NEND batch char-ger features a unique combinationof multiple screw conveyors thatdeliver batch to the glass bathsurface in the doghouse, and apusher arm. The latter gives thebatch piles that important posi-tive impetus away from thecharging area and out into themain part of the furnace.

The screws are controlled byindividual frequency convertersthat provide independentlyvariable charging speeds. Thisindependent control allowsvariation of the amount of batchmoved out of the two sides ofthe doghouse.

With conventional chargers it isnecessary to swivel the completemachine to achieve this effect butwith the EME-NEND variation ispossible without any machinemovement. This feature assists inthe creation of a better chargingpattern in the furnace.

The use of multiple screw char-gers produces smaller, thinnerbatch piles, a further contributionto an improved charging pattern.

Operational experience hasshown that the new charger canoperate successfully with highcullet ratios of 80 – 85 % withno sign of wear on the screws.

The only movement of any partof the charger that enters theactual doghouse area is the

simple, two-dimensional move-ment of the pusher arm. It isrelatively easy to create a sealaround this type of movementand so an advantage of theEME-NEND charger design isthe fact that it is possible to sealthe doghouse completely.

A completely sealed doghouseeffectively eliminates externaldusting, a fact that has alreadybeen verified by operationalexperience.

However, the most importantadvantage of a completely sea-led doghouse is the fact that theuncontrolled and often unstableentry of induced air through thedoghouse is eliminated, and thisleads to a reduction in the pro-duction of NOx.

Comparative measurementswere made on a typical largeend-fired regenerative furnaceon which a conventional pusherhas been replaced by an EME-NEND charger. The NOx emiss-ions were reduced by 10 %, asaving that can be attributeddirectly to the new batch charger.

The EME-NEND batch charger

EME-NEND batch charger

The EME-NEND charger in operation

Advantages

■ no dust

■ no emissions

■ optimal batch piles

Page 29: KomE/10.12.V2.2 _KomE/10.08/V2.2

29KomE/10.12.V2.2

Batch Chargers for Conventional Furnaces

The Type SB ChuteCharger

The raw materials stored in afurnace bunker are transferreddirectly to a feed hopper instal-led on the charger, from wherethey descend by gravity onto awater-cooled chute. The specialback wards and forwards move-ment of the chute, produced byan eccentric, moves the materialinto the furnace.

The basic charging rate andpattern can be varied by settingthe speed of the chute, and thestroke length and height of aslide baffle installed on thedischarge outlet of the feedhopper. The glass level is thencontrolled by switching thechute on and off. Operation canbe controlled manually or auto-matically by an external glasslevel controller.

This type of charger is normallyinstalled as a single machine onfurnaces with lower capacities,e.g. from 40 – 70 t/24h. Thechargers are supplied complete

with frame, feed hopper, chutewith replaceable water-cooledfront end and an adjustabledrive motor.

Our standard equipment

Type SB 400:chute width 400 mmmax. capacity 40 t/24h

Type SB 500:chute width 500 mmmax. capacity 50 t/24h

Type SB 600:chute width 600 mmmax. capacity 60 t/24h

Type SB 700chute width 700 mmmax. capacity 70 t/24h

Advantages

■ robust system

■ chute movement producesintermittent charging

SORG® chute charger in operation

The Type SBN ChuteCharger

This charger is of the samebasic design as the type SBchute charger, but in this casethe chute is not water-cooled.

This type of charger is frequent-ly used in cross-fired furnaces,where it is possible to installseveral chargers adjacent toone another, so that the rawmaterials are charged acrossthe full width of the furnace. Thechargers are supplied completewith frame and feed hopper, in various chute widths, andwith an adjustable drive motor.

Our standard equipment

Type SB 900 N:chute width 900 mmmax. capacity 90 t/24h

Type SB 1100 N:chute width 1100 mmmax. capacity 110 t/24h

Type SB 1200 N:chute width 1200 mmmax. capacity 120 t/24h

Page 30: KomE/10.12.V2.2 _KomE/10.08/V2.2

Batch Chargers for Conventional Furnaces

The Screw Charger

The raw materials are chargedinto the furnace by a rotatingscrew, whereby the chargingrate is varied by altering therotation speed of the screw. Theequipment is supplied with afrequency-controlled drivesystem.

Screw chargers are normallyused on small furnaces for themelting of special glasses. Inthe majority of cases there is noconventional doghouse and thecharger is installed in a simpleopening provided in the super-structure side wall.

Our standard equipment

The chargers are designed tosuit specific applications.

The Type ESE Enclosed DoghousePusher Charger

The batch stored in the furnacebunker is transported by avibratory or screw conveyor to afeed hopper installed on thebatch charger. From here thebatch falls onto a water-cooledtray that oscillates backwardsand forwards and thereby pushesthe batch in individual portionsinto the furnace. The wholecharger can also be turned fromside to side by a freely pro-grammable swivel mechanism,so that the batch is charged inseveral directions. This gives thebest possible batch coverageon the glass bath surface.

The charger is mounted directlyon the doghouse and seals offthe whole area. This has theadvantage that heat losses arereduced, dusting is low and nofalse air can enter the furnace.

30

Advantages

■ sealed doghouse

■ optimum charging patternin the furnace

KomE/10.12.V2.2

Our standard equipment

Type ESE 400tray width 400 mmmax. capacity 190 t/24h

Type ESE 500tray width 500 mmmax. capacity 240 t/24h

Type ESE 600tray width 600 mmmax. capacity 330 t/24h

Advantage

■ the system provides optimum sealing around the charger

SORG® screw batch charger

SORG® enclosed doghouse pusher

batch charger in operation

Page 31: KomE/10.12.V2.2 _KomE/10.08/V2.2

31KomE/10.12.V2.2

Advantages

■ simple and robust design

■ excellent batch distribution

Batch Chargers for Electric Furnaces

The batch charging methodselected is one of the mostimportant design deci sions forcold-top all-electric furnaces.In the majority of cases thebatch/cullet mixture must bespread as evenly as possibleover the whole surface.

The Distributor ArmBatch Charger

The batch is charged into thesuper structure by one or morevibratory chutes and spread overthe glass surface by a rotating,water-cooled distributor arm.

This arm is L-shaped and it ent-ers the furnace through a slit inthe crown. Its holder and drivemotor are installed outside thefurnace. A hand winch is usedto remove the distributor armfrom the furnace superstructureif the temper ature in the super-structure becomes too high.

The system is designed forhexagonal or round furnacesand it is used on small electricfurnaces with melting areas upto about 5 m2.

Our standard equipment

The distributor arms must bedimensioned exactly to suit indi-vidual furnaces, and thereforestandard chargers are not built.

Advantages

■ completely enclosed superstructure – no dust in factory building

■ can also be operated at high crown temperatures

The Rotating CrownBatch Charger

Several small vibratory chutesare installed above the crown atvarious distances from the centreof the furnace. Batch is chargedby the chutes through smallopenings in the crown, whilstthe complete crown construct -ion (including the vibratory chutesand the hoppers) rotates aroundthe vertical axis of the furnace.As a result the chutes depositthe batch in concentric rings onthe glass bath surface. Thethickness of the batch blanketcan be influenced by adjustingthe amount of batch chargedby each chute.

A sand seal is provided betweenthe side walls and the rotatingcrown. It is also easy to seal thesmall openings for the vibratorychutes in the crown. The rest ofthe superstructure is completelysealed.

If it is necessary to reduce thedust emission level, the batchgases can be drawn off andpassed through a simple bag filter. No cold air is drawn intothe enclosed superstructure.

The system can be used forhexagonal or round furnaces,with melting areas between 5 m2 and 80 m2.

Our standard equipment

No standard equipment is avail -able as each rotating crownmust be individually designed tofit the specific furnace.

SORG® rotating crown batch charger in operation

Page 32: KomE/10.12.V2.2 _KomE/10.08/V2.2

Air Supply Equipment

Fans

SORG® supplies fans for:

• combustion air for furnaces• tank and throat cooling for

furnaces• combustion air for working

ends and forehearths• cooling air for working ends

and forehearths• emergency combustion air

for recuperative furnaces

All fans are of welded construc-tion and are suitable for industrialapplications. Motor, bearings,impeller and casing are allinstalled on a common steelframe. Blade design is based onstate-of-the-art flow technology.The mechanical parts are de -signed for continuous operationat ambient temperatures from -10 °C to +40 °C.

The nominal capacities are cal-culated for an air temperature of20 °C and an ambient pressureof 1013.25 Pa.

The fans are supplied with com-pensators, rubber mountingblocks, shut-off valves on theoutlet side and inlet filters asstandard.

Advantages

■ fans are designed for specific installations, so that energy is not wasted as a result of over-sizing

■ the fan characteristics prevent unwanted pressurevariation when the throughput changes

■ high quality material is used for the equipment, to ensure a long operatinglife under difficult conditions(heat, dirt etc.)

32KomE/10.12.V2.2

The SORG® programme of airsupply equipment for furnaces,working ends and forehearthsincludes both fans and theirauxiliary equipment, and hotair pipework for pre-heatedcombustion air on recuperativefurnaces.

Combustion Air forRegenerative Furnaces

Normally two identical radialfans are installed on these fur-naces. One fan supplies the fur-nace, and the second is kept inworking order, as a stand-by.

The equipment is supplied com-plete with a Y-pipe connectionbetween the two fans.

Our standard equipment

SORG® can supply fans withcapacities between 5000 and30000 Nm3/h.

Option

• axial fans are also available

Combustion Air forWorking Ends andForehearths

In order to save energy andmaintenance costs, the combus -tion air supply for the workingend and all forehearths of a fur-nace is usually centralised. Twoidentical radial fans are installed,one runs during normal operation,whilst the second is a stand-bythat can be run up at any time.

The fans are supplied completewith a Y-pipe connection betweenthem.

Our standard equipment

Combustion air fans with capacities between 300 and6000 Nm3/h are available.

Option

• an automatic control system for the air pressure, comprisingpressure transmitter, controllerand frequency converter, designed to improve the operation of large fans at lowspeeds

SORG® combustion air fans for a

working end and four forehearths

Page 33: KomE/10.12.V2.2 _KomE/10.08/V2.2

33KomE/10.12.V2.2

Air Supply Equipment

Tank and ThroatCooling for Furnaces

Two identical radial fans areusually provided for the tankcooling. During normal operationonly one fan runs, and the otheris kept in working order, as astand-by.

For operational security a sepa-rate radial fan is provided for thethroat cooling.

Our standard equipment

Cooling air fans with capacitiesfrom 15000 to 65000 Nm3/h areavailable.

Emergency Air Supplyfor RecuperativeFurnaces

A radial fan with a diesel motor isinstalled so that an air supply isensured even during a power cut.The volume of air is sufficient tocool and protect the recuperator.However, the fan is not largeenough to provide the completecombustion air supply.

The fan has an automatic starterso that it runs up automatically ifthere is a power failure.

Options (applicable to all fans)

• a conventional control system for the fans using star/delta starters, mounted in a local control cabinet

• a control system with an electronic soft-start function for larger fans installed in a local control cabinet

• all fans can be fitted with a suitable frequency converter for a smooth run-up and fully automatic air volume and/or air pressure control, with all components installed in a local control cabinet

Hot Air Pipework for RecuperativeFurnaces

In furnaces with recuperative airpre heating, the hot air from therecuperator must be fed to theburners. As the air should loseas little energy as possible be t -ween recuperator and burner,special insulated hot air pipe-work is required.

The pipes are made of heat-resistant steel and are surroun-ded by mineral fibre insulation.This is protected againstmechanical damage by an outersteel casing. In order to facilitatetransport and handling on site,the pipes are delivered in pre-assembled sections that can be connected easily during construction.

Air Cooling forWorking Ends andForehearths

Cooling air for working ends andforehearths is normally providedby single fans for each part ofthe system (working end orforehearth). Stand-by fans are notinstalled, as an emergency supplycan be provided by makingconnections to other fans.

The cooling air is produced byradial fans.

Our standard equipment

Cooling air fans with capacitiesbetween 300 and 3000 Nm3/hare available.

SORG® hot air pipework for preheated

combustion air on a side-fired

recuperative furnace

Advantage

■ pre-assembled sections result in short assembly times

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Temperature Measurement

Temperatures are measuredat many locations in furnaces,working ends and forehearths– either in the air, in therefractory material or in theglass bath itself. SORG® cansupply a range of sensors, inthe form of pyrometers orthermocouples.

Thermocouples in theFurnace

Thermocouples with protectiveceramic sheaths are used formeasuring the temperatures inboth the superstructure andsubstructure of the furnace.

For the most important meas -uring points SORG® provides:

• type B (Pt.30%Rh–Pt.6%Rh) thermocouples for high temperature areas

• type K (Ni.Cr-Ni) for waste gas areas

Our standard equipment

SORG® thermocouples are avail -able in nominal lengths from710 to 1800 mm.

Options

• type R (Pt–Pt.13%Rh) andType S (Pt–Pt.10%Rh)

• other nominal lengths

Advantage

■ these thermocouples provide important information relevant to theglass quality and the thermal homogeneity

Advantage

■ the equipment is suitable for the particular operationalrequirements of the glass industry

In-GlassThermocouples

These thermocouples have aplatinum sheath and are usedfor measuring the temperatureof the glass in difficult areas,such as the throat, melting endbottom and side walls of all-electric furnaces.

Option

• pyrometers can be used to monitor the control thermo-couple and this temperature measurement is used for comparative purposes

SORG® furnace bottom thermocouple

installation

SORG® working end in-glass thermo-

couple installation

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Advantages

■ special design ensures long operating life

■ channel – easy to replace as installation from above

Pyrometers forWorking Ends andForehearths

Only a lens is needed on theworking end or forehearth itself.The radiation from the glassbath is trans mitted by a fibreoptic cable to the actual sensor,which can be installed at a moreacceptable location nearby.Clean, oil-free air for purging thesight path must be available.

Pyrometers are supplied with anair purge unit, fibre optic cableand transmitter unit as standard.

Our standard equipment

Standard SORG® working endand forehearth pyrometers canbe used for all applications.

Option

• an air supply unit for the purge air, com prising filter, pressure controller and combined adjustment valve/flow meter

35KomE/10.12.V2.2

Temperature Measurement

Thermocouples inWorking Ends orForehearth Channels

SORG® thermocouples for work -ing ends and forehearths haveprotective ceramic tubes andplatinum sheaths. The mecha - nical stability of the preciousmetal is augmented by an innerceramic tube.

The thermocouples are installedfrom above through the super-structure to take measurements inthe glass bath. Virtually mainten -ance-free type S (Pt–Pt.10%Rh)thermocouples are supplied asstandard.

Our standard equipment

SORG® working end and fore -hearth thermocouples are avail -able with nominal lengths of1100 mm for working ends and825 – 925 mm for forehearths.

Options

• triplex unit with extended platinum sheath and 3 thermocouples

• version with extended platinumsheath for glasses with strongvolatilisation, such as C glass

• type B (Pt.30%Rh–Pt.6%Rh) or type R (Pt–Pt.13%Rh)

• other nominal lengths

Advantage

■ contactless measurement,independent of fluctuationsin the glass levelBowl Thermocouples

for Forehearths

These thermocouples have aheat-resistant steel tube and aplatinum sheath and are instal-led in the side wall of the bowl.Measurements are made in theglass bath.

Our standard equipment

A type S (Pt–Pt.10%Rh) thermo -couple with a nominal length of300 mm

Options

• type B (Pt.30%Rh–Pt.6%Rh) or type R (Pt–Pt.13%Rh)

• other nominal lengths

SORG® forehearth spout in-glass

thermocouple installation

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Oxygen Measurement

Oxygen Measurementin the Furnace

A measurement of the oxygencontent in the waste gases isan important pre- re quisite foroptimum furnace operation.The lower the oxygen con-tent, the lower the waste gaslosses and the lower the fuelconsumption.

The requirement to minimiseNOx emiss ions can only beachieved with a near-stoichio-metric combustion. However,CO may be produced in the

regenerators if there is a near-stoichiometric combustion,with less than 1 % O2 in thewaste gases. The CO valuecan be estimated on the basisof oxygen measurements.

An oxygen content measure-ment can also be used forautomatic air/fuel ratio con-trol. However, for this a relia-ble method for continuousmeasurement of the oxygencontent is necessary.

The Sensor

The sensor is a zircon oxidesensor, which measures theoxygen concentration differencebetween the furnace atmos -phere and the surrounding airoutside the furnace. A thermo-couple is provided in the sensoras the differential concen trationmeasurement is temperaturedependent.

In end-fired furnaces sensorsare normally installed at the topof both regenerator chambers.In the case of cross-fired furnacesthey are placed at the top of the chamber on the axis of the burner ports.

The Signal Processor

The signals from the sensor andthe thermocouple are processedin an electronic unit, that ana lysesthe data and determines theoxygen concen tration at thesensor.

Advantages

■ furnace operation can be optimised on the basis of the oxygen measurement,so that minimum NOxvalues can be achieved

■ the quality of the combus -tion can be monitored and recorded continuously

SORG® oxygen sensor installed in

regenerator crown

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Advantages

■ the air/gas ratio productionof the heating system is monitored

■ an exact and reproduciblesetting of the air/gas ratio can be found

Oxygen Measurement in Forehearths

For certain applications it isadvan tageous to be able tocheck the combustion inforehearth zones. This maybe the case, for example, inthe melt ing zone of a fore -hearth colouring installation,but it could also apply in anyzone where a very sensitiveglass is involved.

To check the combustion, asmall part of the air/gas mix-ture being supplied to thefore hearth burners is divertedand burnt in a reference burner. A small zircon oxide

Oxygen Measurement

The Measuring Unit

The reference combustion, themeasure ment of the oxygencontent of the waste gases andthe processing of the result ingdata all take place in a singlecabinet. A representative valuefor the oxygen content is shownon a digital display.

The cabinet can be configuredfor one or more zones, themaximum number in a singlecabinet being 5 zones. The ref -e rence combustion for all zonestakes place in the same burner,the samples from the variouszones being switched into themeasuring circuit one after another.

The cabinet produces an outputsignal for each zone, and thiscan be used for an externalindicator or to implement fullyautomatic control of the air/gasmixture.

Our standard equipment

Complete cabinet, configuredfor 1–5 zones

SORG® forehearth oxygen cabinet in operation

sensor is installed in thewaste gas chimney of thisburner, to measure the oxy-gen content of the wastegases from the referencecombustion of the sample.

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38KomE/10.12.V2.2

Control Equipment

Accurate measurement andgood control of furnace work -ing end and forehearth para-meters are important pre -requisites for successfuloperation. Furnace pressure control can have a significanteffect on energy con sump tionand refractory wear, whereasair/fuel ratio control influencesboth energy efficiency andenvironmental emissions.

Temperature control of thefurnace, working end andforehearths is the basis forstable operation and high-quality production.

Furnace PressureControl

The furnace pressure is meas -ured relative to the atmosphericpressure outside the furnace.

Two pressure probes are instal-led through the superstructureside wall refractory, on the twosides of the furnace and op pos ite one another. The pres-sure connections of these twoprobes are connected beneaththe furnace. Two further probesare located directly along sidethe furnace probes, at the sameheight, but outside the furnace.These two probes are alsoconnected to one anotherbeneath the furnace.

The pressure connection of theprobes inside and outside thefurnace are attached to a differ -ential pressure trans mitter, whichproduces an output signal inrelation to the difference betweenthe two pressure measurements,i.e. in relation to the furnacepressure.

The pressure connections to thetransmitter are made through aspecial triple valve assembly, sothat the connections can beshort-circuited for calibration ofthe transmitter. A water-filledequalising vessel is installed inthe pipework between the fur-nace probes and the differentialpressure trans mitter to preventthe deposition of con densatesin the pipes and shield thesens itive differential pressuretransmitter from the gases ofthe furnace atmosphere.

The transmitter output signal ispassed to the furnace pressurecontroller, the output of whichcontrols either a flap valve in thewaste gas channel, the air sup-ply to an injector chimney or thespeed of an exhauster, depen-ding on which method is usedto influence furnace pressure.

Our standard equipment

The SORG® furnace pressurecontrol system comprises thefollowing parts:

2 furnace pressure probes2 atmospheric pressure probes1 differential pressure

transmitter with triple valve block

1 PI single loop micro -processor-based controller

These items are applicable to allfurnace types and sizes.

SORG® furnace pressure sensor

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Control Equipment

Furnace Temperatureand Fuel/Air RatioControl

The temperature and fuel/airratio controls are combined in asingle control system, which uti-lises three independent singleloop controllers for temperature,fuel and combustion air.

In fossil-fuel fired furnaces thetemperature is measured by athermo couple installed in thesuper structure, usually in thecrown. The signal is passed toa trans mitter which converts themillivolts into a standard mAsignal, which is passed to thefurnace temperature controller.

Fuel flow is measured by themeter in stalled in the fuel controlstation, and the output signal ispassed to a transmitter, whichconverts the signal to a standardmA signal. With liquid fuels thissignal is then passed to the fuelcon troller. For gaseous fuels thesignal is taken to a small PLCfor conversion to normal cubicmetres on the basis of temp -erature and pressure measure-ments made in the gas station.

The corrected output signal ispassed to the fuel controller.

Air flow measurement is normallymade with an orifice plate in thefan inlet nozzle. A differentialpressure transmitter produces astandard mA signal, which isused as an input signal for thecombustion air controller.

The output of the temperaturecontroller is connected to aninput channel of the fuel control-ler, where it provides an ex ternalset point. The output of the fuelcontroller is taken to the fuelcontrol valve, which varies thefuel flow rate, depending on therequirements of the temperaturecontroller. The fuel controlleroutput also passes to an inputchannel of the com bustion aircontroller, where it forms anexternal set point, which allowsthe con troller to act as the ratiocontroller. The output of the aircontroller is con nected to the aircontrol valve, and the air quantityis varied to maintain the requiredfuel/air ratio.

Our standard equipment

The SORG® furnace temperatureand fuel/air ratio control systemcomprises the following parts:

1 temperature transmitter2 metering inlet nozzle units

for the combustion air fans2 differential pressure trans-

mitters for air quantity measurement

1 fuel flow transmitter3 PI single loop micropro-

cessor-based controllers

Options

• separate left/right ratio control for reduced NOxproduction

• multiple zone control for side-fired furnaces

• individual burner control for reduced NOx production

• air-led ratio control

Glass Level Control

The glass level controller receivesa signal from the glass leveldetector (see page 26 of thecatalogue). The controller outputis a continuous signal (4 – 20 mA)which is used for variable con-trol of the speed of the batchcharger.

Our standard equipment

The SORG® glass level controlsystem comprises the following:

1 PI single loop micro-processor-based controller

This item is applicable to all furnace types and sizes.

Option

• the controller can be configuredfor on/off operation of the batch charger

SORG® furnace and working end

control panel

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Control Equipment

Working End andForehearthTemperature Control

SORG® temperature controlsystems for working ends andforehearths normally utilise in-glass temperature measure mentby means of thermocouples(see page 35 of this catalogue).Temperature control is carriedout exclusively through the heating system.

The millivolt output of thethermo couple is passed to atransmitter, which con verts thesignal to a standard 4 – 20 mAsignal. This is passed to thetemperature controller.

The 4 – 20 mA temperaturecontroller output signal is passed to the actuator of the aircontrol valve for the relevantzone.

Cooling ControlSystems

SORG® working end andforehearth cooling systems arecontrolled by a unique steppingcontrol system based on a PLC.The PLC monitors the output ofthe heating controller and adjuststhe position of the cooling step-wise in order to keep the outputof the heating con troller withinacceptable limits.

The output of the heating tem-perature controller is passed tothe PLC parallel to the connect -ion to the air control valve. Acheck routine based on a speci-ally developed logic is carriedout in the PLC and, if the heat -ing controller output exceedscertain programmable limits, the PLC sends a step signal tothe cooling system actuator tochange the position of the cool ing system.

Operator access to the step-ping control system is providedby a small operator panel withLCD display.

A single PLC can be used to

Our standard equipment

The SORG® working end andforehearth temperature controlsystem comprises the followingparts for each zone:

1 temperature transmitter1 PI single loop micro-

processor-based controller

These items are applicable to allworking end and forehearthzones.

operate the stepping controlsystem for several cooling sec -tions. The stepping controlsystem can be used for openradiation, direct air or indirect aircooling systems.

Our standard equipment

The SORG® working end andforehearth stepping controlsystem for cooling systemscomprises the following parts:

1 PLC unit1 operator terminal

These items are applicable to allworking end and forehearthtypes and sizes.

SORG® forehearth control panel

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Alarm Warning System

Many pieces of equipmentinstalled on the furnace,work ing end and forehearthsproduce warning signals toalert the operator to the exi-stence of unusual operatingconditions or a fault.

Centralised operation super -vision makes it necessary tocollect all such warning sig-nals at a single location, sothat the operator can easilydetect the existence of a faultwarning and identify the sourceof the signal.

PLC Version

A version of the SORG® alarmwarning system based on asmall PLC is available.

Fault warning signals generatedby external (field) equipment areconnected to the input channelsof the instrument. Each warningsignal must be provided in theform of a potential-free contact.

Operator access is by means ofa sep arate operator panel, sui-table for mounting in the frontface of a control panel. Faultwarnings are shown as textmessages on the operatorpanel, and can be ack no w -ledged on the panel by the ope-rator. If the alarm is still presentthe warning message remainsvisible.

The PLC has connections for awarning horn and a flashinglight. When an alarm is acknow -ledged the horn is switched off,but the lamp continues to flashuntil the warning is no longerpresent.

Stand-alone systems utilise anoperator panel with a small LCDdisplay, whereas larger PLC-based systems use touchpanels for operator access.

Our standard equipment

Input channels (for potential-freecontacts on field equipment) areprovided in groups of 8 (stan-dard input blocks for the PLC).

Single Instrument Version

This is a panel-mounted instru-ment, which combines illumin atedindication fields, outputs for optical and acoustic warnings,and acknowledgement function.

Fault warning signals must beavailable on external (field)equipment as potential-freecontacts.

When a fault signal occurs, therelevant warning field on theinstrument is illuminated, theoptical and acoustic warningsare initiated and a master warning lamp on the instrumentflashes. The warning can beacknowledged by pressing abutton on the front of the instru-ment, at which point the externalacoustic warning is switchedoff, and the master warninglamp on the instrument itselfchanges to steady illumination.The external optical warningremains activated. These warnings are only eliminatedwhen the fault signal has beenremoved.

The SORG® safety system isavailable in two forms: thePLC version and the singleinstrument version.

The acknowledge function canalso be provided from an externalsource by means of a binaryinput to the instrument.

Our standard equipment

The instrument is available with8 or 16 input channels for warning signals.

Advantage

■ All fault warnings are grouped at a single location,so that the operator is always presented with a clear overview of the statusof the complete installation.

PLC operator access panel

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Drain System Equipment

Sometimes glass must be re -moved from the lower regionsof the glass bath through abottom drain. It may also benecessary to remove glass

from the bath surface.

Drains can be installed in the furnace, working

end or forehearth, or even agathering bay. On someinstalla tions a drain is instal-led to maintain the necessaryminimum melting capacitywhen production rates arelow.

The CONTI DRAIN®

System

This system has direct electricheating, whereby a currentflows between the heat resistantsteel outlet nozzle and a counterelectrode in the glass bath. Theamount drained can be regula-ted as required and maintainedat a constant level by the heat -ing control system.

The CONTI DRAIN® system canbe used in the front part of fur-naces, for example before orafter the throat, or in forehearthchannels. It is suitable for themajority of glasses producedcommercially, includ ing opal andborosilicate compositions.

The system consists of mech -anical components – the actualoutlet nozzle with its holder andelectrical connections – and thecorresponding electric heatingsystem. This comprises primaryswitch gear, double-woundtransformer with thyristor unitand a control system, includinga thermocouple and 50 m ofcompensating cable.

Our standard equipment

A standard system is suitablefor use in both furnaces andforehearths.

Option

• under certain circumstances the CONTI DRAIN® system can be retrofitted in a furnaceor forehearth channel

Advantages

■ easy to operate

■ reliable

■ nozzle simple to replace, even when installed in a furnace

Regardless of the location,and whether glass is to beremoved from the surface orthe bottom, the glass mustalways be drained in a con-trolled manner, and in themajority of cases, slowly aswell.

SORG® offer a series of drain systems for differentapplications.

Power and control panel for a SORG

CONTI-DRAIN® installation

SORG® forehearth CONTI-DRAIN® installation

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43KomE/10.12.V2.2

Drain System Equipment

Standard Drains formaintaining theMinimum MeltingCapacity

Sometimes it is necessary todrain glass in order to maintainthe melting rate above a certainminimum level. This can be ach -ieved by installing a stub fore -hearth at a suitable location in aworking end and adding a con-ventional forehearth spout to it.

Glass is drained through thespout, using a suitably sized orifice ring. The amount drainedis regulated by means of a verti-cally adjustable ceramic tubeabove the drain outlet.

The channel and feeder spoutare normally gas-heated, usingmanifold burners in the channeland spout, and a single burnerfor the drain.

The system consists of a gasburner with supply station (formixture production), a heightadjustable holder for the cera-mic tube, and a steel bowl forthe spout, including a holder for

Advantages

■ simple adjustment of the amount being drained

■ replaceable orifice rings mean that capacities fromless than 1 t to more than 20 t/24 h can be

the orifice rings, and a thermo-couple with 50 m of compensa-ting cable for recording the tem-perature. Automatic control isnot required.

Our standard equipment

The systems are individuallydesigned to suit site conditionsand required capacities.

Option

• the complete refractory material for the superstructureof the channel and bowl

Surface DrainSystems

With certain types of glass itcan be necessary to draw offpoor quality glass from the sur-face, in order to maintain theproduction quality required. It ispossible to install surface drainsystems at various locations,but they are normally locatedin the forehearth spout or a gathering bay.

The surface drain consists of anarrow channel with a metallicbaffle plate that is installed fromabove and sits on the channelbottom. The amount of glassdrawn off is determined by theheight of the glass bath abovethe baffle plate.

The overflow channel is usuallyheated by a combination ofmanifold and single gas burners.Temperature control is not required, as the overflow quantityis only temperature dependentto a limited degree.

The system consists of a gasburner with supply station (mix-ture production) and two baffleplates made of heat-resistantsteel.

Our standard equipment

The systems are designed indi-vidually according to site condi-tions and the capacity required.

Advantage

■ space saving design

SORG® overflow drain for the

production of water glass

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Gas and Air/Gas Stationsfor Working Ends and Forehearths

The incoming gas supply for the instal lation is prepared in thegas station, whereas the air/gas control station is used to varythe fuel volumes according to the require ments of the burnercontrol system, and for setting the air/gas ratio.

Gas Supply Station

Here the inlet pressure is red -uced and maintained at a con-stant level. If over or underpressure occurs, the shut-offvalve installed in the gas pres-sure controller shuts off the gassupply. If a fault occurs, such asa combustion air failure, gaspressure loss or activation of anemer gency-off switch, thesafety system interrupts the gasflow. The total gas volume ismeasured by a turbine meter.

In order to increase operationalsafety, all components, exceptthe quick-acting safety valve,are fitted with reserve equipmentor a by-pass.

The station is designed accord -ing to DIN-EN 746, part 2 standards, and all componentshave the relevant certi fication.The stations are supplied com-plete with all necessary minorcomponents, such as filters,shut-off cocks etc. and all

pipework. They have beenchecked and are ready for connection.

SORG® gas stations for workingends and forehearths are de -signed for use with either LPGor natural gas. No modi fica tionsare required if a change over ismade from one fuel to the other.

The space-saving standard unitis designed for wall installation.

SORG® gas station for a working end and forehearths

Our standard equipment

Various standard stations forcapacities from 300 – 6000 kW

Options

• multiple gas meters to provideindividual consumption data for all parts

• support frame for floor installation

• gas quantity conversion m3 – Nm3

Advantages

■ pressure controller with stand-by

■ short installation times as pipework already complete

■ high operational safety as components are DIN-EN certified

■ designed for both LPG and natural gas

■ space-saving wall installation

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Gas and Air/Gas Stations for Working Ends and Forehearths

Air/Gas ControlStations

All control components for thecombus tion air and gas forseveral zones are installedtogether in the air/gas station.Basically as many zones asrequired can be supplied fromone station. However, in practicethe zones are grouped to corre-spond to clearly defined parts ofthe installation, such as theworking end or a forehearth.

Each station contains the con-trol valves for the air quantity,by-pass valves, gas quantitycontroller and air/gas mixer foreach individual zone. The SORG®

VMC2 system for regulating theair/gas mixture is used. A shut-off valve and a non-return valveare also installed in the gas pipefor each zone.

All components for the gas orair/gas mixture have been certi-fied in accord ance with DIN-EN746, part 2. The stations aresupplied complete with all minorcomponents, such as shut-off

valves etc. and pipework, andhave been checked before delivery.

A standard station has a distri-butor pipe for the combustionair in the lower part of the station.The pipework runs upwards in avertical direction, for connectionto the mixture pipes at the topof the station. The stations havea frame and are free-standing.

SORG® air/gas control stationsfor working ends and fore -hearths are designed for usewith either LPG or natural gas,and can be operated withoutmodifications, if a changeoverfrom one fuel to the other ismade.

Our standard equipment

for 2 to 6 zones for working ends

for 2 or 3 zones and spout zonefor standard forehearths

Advantages

■ compact, space-saving design

■ short installation time

■ high operational security as components are DIN-EN certified

■ designed for use with either LPG or natural gas

Options

• version without mixer for use with individual burners (e.g. in working ends or gathering bays)

• special versions for limited space locations

• with gas meter and/or gas supply equipment

• alternative mixture systems

SORG® air/gas control station for a

working end and two large

forehearths

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Burners for Working Ends, Forehearths and Gathering Bays

The majority of working ends and fore hearths are gas-heated. Normally, so-called manifold burners are used, installed a short distance apart, and supplied with a mixture of gas and

air. Individual burners are occasionally installed in workingends, but they are almost always utilised in forebays or gathering bays.

Manifold Burners

Manifold burners provide a simpleand economic method of distri-buting the heat evenly along achannel or elongated workingend. The individual burners aremounted on a distributor mani-fold that runs parallel to thechannel. The burners projectinto the refractory burner blockswhich form part of the super-structure side walls. The burnermanifold supplies a number ofburners – normally between 4 and 12.

Burners of various lengths andwith different nozzle diameterscan be supplied.

The capacity of the individualburners de pends on the mixturepressure available (heatingsystem dependent) and thenozzle diameter. It is possible toachieve maxi mum capacitiesbetween 4 and 17 kW at eachburner.

The burner manifolds are sup-plied with a height-adjustableholder as standard.

Our standard equipment

Burners can be supplied in 6 standard lengths from 145 – 375 mm, and with nozzlediameters from 4 – 9 mm.

Standard manifolds are designed for 4 – 12 burners.

Options

• ceramic nozzles that are lesssusceptible to heat or dirt contamination

• multiple-head burners, where2 or 3 burner heads are combined and provided with a common connection; used for heating corners and otherrestricted locations

Advantages

■ simple system – operates without problems on mostinstallations

■ wide range of burner lengths and nozzle diameters available

SORG® triple head burner

SORG® manifold burners on a “T” tandem forehearth

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Burners for Working Ends, Forehearths and Gathering Bays

Individual Burners forWorking Ends andGathering Bays

Sometimes individual burnersare required for working endswhen burner manifolds cannotbe installed, either for space orother reasons. Such burners arealso used in gathering bays.

Gas and air are supplied sepa-rately to the burners and thenmixed directly at the nozzle. Theair/gas ratio is maintained at aconstant level by an externalsystem.

The burners are designed foroperation with non-preheatedcombustion air.

As they are of compact design,and operate with a short flame,the burners are especially suitablefor heating narrow combus tionchambers with limited accessfrom outside.

The burners are supplied com-plete with connecting hoses forgas and air, shut-off valves androtameter flow meters for gasand air.

Advantage

■ the compact design renders the burners suitable for many applications

Individual Burners for other Applications

Individual burners are also usedfor heating outlets and drains,and during the heating-up, or asemergency heating for all-electricforehearths.

In such in stances, the burnersare sometimes operated atcombustion space temper atureslower than the ignition tempera-ture of the gas. Therefore it maybe necessary to monitor theignition or flame.

For these applications the burners are normally suppliedwithout flow meters. The gasand air quantities are adjustedindividually and manually.

Our standard equipment

The burners are available in 4sizes between 40 and 230 kW.

Option

• flow meters with an electric output signal so that the flowvolume can be displayed on an external instrument or system

SORG® individual burner installed as

emergency heating on an all-electric

forehearth

SORG® individual burner installed on

an hand gathering bay

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Electrical Heating Equipment for Forehearths

Two types of electric heatingsystems are used for fore -hearths:

• direct heating by means of electrodes immersed in theglass

• indirect heating using radiation elements installedabove the glass surface

Primary SwitchingEquipment

All-electric heating systems forforehearths are connected tothe low voltage net work.Depending on the installedpower, either power contactorswith fuses or compact low vol-tage circuit breakers are used.

A set of primary switchingequipment is normally providedfor each heating zone, so eacharea can be switched individuallyand is also fully electrically protected.

Transformers

Air-cooled, single-phase, double-wound, fixed ratio transformersare used. The double winding isan important safety factor as itprovides a galvanic sepa rationbetween the power supply andthe glass bath.

The secondary output voltagescan be steplessly adjusted bymeans of the thy ristors. Thetransformer specifications aretailored to suit the specificrequirements of operation with

thyristors. Temperature sensorsinstalled in the windings provideadditional overload protection.

Taps are provided so that theavailable secondary voltagerange can be adjusted to suitthe actual operating conditions.Current transformers for secon-dary current measurement arenormally included.

Transformers with nominalpowers above about 20 kVA areusually provided with separatesteel casings, offering IP23standard safety protection.These can be installed at suit -able loc a tions in the factory.Smaller transformers are usuallyinstalled in communal panelsbuilt to IP54 safety standards.The units are designed for per-manent operation at ambienttemperatures up to 40 °C.

Our standard equipment

Standard components are avail -able for nom inal powers between5 and 100 kVA. All componentscan be supplied individually, or ina complete package.

However, irrespective of thetype of heating involved, theelectrical equipment normallycomprises the following majorgroups:

• primary switching equipment• thyristor unit• double-wound transformer

Heating Elements

Silicon carbide or molybdenumdisilicide radiation elements areused for indirect forehearthheat ing.

Rod-shaped silicon carbide ele-ments are employed in conven-tional forehearths for soda-limeglass. They are normally instal-led horizontally above the glassbath. A special glaze must beapplied to the elements to pro-tect against attack by the volatilecomponents from the glass.

Molybdenum disilicide elementsare usually U-shaped and are

installed vertically through thesuperstructure roof. One appli-cation is in covered forehearthsfor glasses that suffer fromvolati lisation problems. Air purgeunits are required for use in openforehearths. They create a slightover-pressure to prevent the for-mation of condensation depositsaround the element connections.

The characteristics of the twomaterials differ, as do the mostimportant factors to be taken intoconsideration when designingthe electrical equipment.

The heating elements are provi-ded with flexible connectionstraps, fixing clamps and refrac-tory sheaths or blocks.

Our standard equipment

A wide range of rod and U-shaped radiation heating elements are available.Power panel for SORG® forehearth

electrical heating system

Advantage

■ SORG® has extensive experience of the use of radiation heating elements,and is therefore able to advise on and select the correct type and size of element for each individualapplication.

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Electrical Heating Equipment for Forehearths

Thyristor Units

Only thyristor units with phaseangle control are used. Theseare installed on the primary sideof the transformers so they aregalvanically separated from theglass bath. This prevents DCcompo nents being transferredto the glass bath.

The thyristor units employedby SORG® have an adjustablecurrent limit and an overridingcurrent controller. The nominalcurrent depends on the powerof the transformer, taking thespecial charac teristics of theheating type into consideration.

MolybdenumElectrodes

Molybdenum electrodes areused in all-electrically heatedinstallations and for forehearthboosters.

The electrodes comprise amolybdenum head and a heat-resistant steel connector. Theyare installed without water coolingand are sealed against oxidationby the glass in the installationhole. No supplem entary aircooling is required on the majority of installations.

In order to prevent bubble form -ation, the electrodes are opera-ted with very low specific cur-rent loadings. This means thatthere is virtually no corrosion ofthe electrode material and theelectrodes do not need to beadvanced.

The electrodes are suppliedcomplete with a steel sealingring, copper connection plate,fixing clamp and insulator.

Advantages

■ simple installation

■ maintenance-free

Our standard equipment

Electrodes with molybdenumhead diameters of 32, 48 and60 mm are available. The headand total length can be variedto suit site conditions.

Option

• a special protective coating against oxidation for applications where electrodesare subject to an oxidising atmosphere for a limited period of time, such as during the heat-up

Tin Oxide Electrodes

Special ceramic electrodesmade of tin oxide are used ininstallations in lead-containingglasses.

Owing to the characteristics ofthe ceramic material it is notpossible to advance these elec-trodes. Therefore tin oxide elec-trodes are installed permanently, with a water-cooled holder.Corrosion is limited as the elec-trodes are operated at a lowcurrent density.

Tin oxide electrodes are usuallyrod-shaped. As the material hasa relatively low mechanicalstrength the electrodes are quiteshort and thick, quite unlikemolybdenum electrodes.

Advantage

■ SORG® has many years ofexperience with electricallyheated forehearths (more than 150 complete instal-lations supplied). This is very important in view of the complexity involved in desig ning safe and fault-free electrical equip ment to suit the particular character istics of the individual heating systems.

Transformer for SORG® forehearth

electrical heating system

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Stirrers

Stirrers are normally used toimprove the chemical homo-geneity of the glass. In only afew circumstances are stirrersinstalled in an attempt toimprove thermal homogeneity.The use of stirrers in colouringforehearths is well known.

The SORG® ModularStirrer Unit

The SORG® modular stirrer unitis a flexible basic design thatcan accept between 1 and 5stirrers at varying centre distances,depending on the form of therefractory stirrer blades and the relevant dimensions of thechannel at the installation location.

The complete stirrer unit can beraised and moved to the side, sothat it is possi ble to exchange therefractory stirrers in the relativelyamenable conditions alongsidethe forehearth.

The drive unit comprises anelectric motor and a cardandrive shaft. Therefore the motorcan be installed at a locationalong side the channel where itis protected from direct radiation.The steplessly variable rotationspeed is produced by a three-phase motor and a frequencyconverter.

The equipment includes thestirrer unit holders with heatresistant bearings, verti cally andhorizontally adjustable supportframes and all drive components.The electric drive componentsare installed as standard in localcontrol panels, that are alsosupplied.

Our standard equipment

The module stirrer unit is avail -able with between 1 and 5 stirrers.

The EqualisingSection Stirrer Unit

Stirrers are often installed inforehearth equalising sections –mainly to improve the chemicalhomogeneity of the glass beforeit is processed. SORG® havedeveloped a stirrer unit especiallyfor this application.

Space at the front of the forehearthis limited, therefore a space-saving design is required. Thecomplete construction is borneon a single, rotatable column.

This makes it possible to swingthe complete construction tothe side in order to exchangethe stirrers.

The basic design is suitable forsmall paddle stirrers, as thistype of stirrer produces the bestpossible mixing results. Between2 and 5 individual stirrers canbe installed, depending on thechannel width at the installationlocation.

The stirrers are driven by a three-phase motor, integrated in the unit.A frequency converter is used toprovide stepless variation of therotation speed of the stirrers.

Our standard equipment

Equalising section stirrer unitscan be supplied for between 2 and 5 stirrers.

Option

• A simplified unit for 2 stirrers,a fixed distance apart, for 16'' wide channels. These stirrers can only be moved vertically.

SORG® modular stirrer units installed on a colouring forehearth

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Stirrer Units forForebays

When glass is extracted from agathering bay – regardless ofwhether extraction takes placemanually or with a ball gatherer– bubbles and thermal inhomo -geneities occur as a result ofthe extrac tion process. In addition,with certain glasses, volatilisationfrom the bath surface can alsocause a reduction in the glassquality. These problems can bedecreased if a stirrer is installedin the bay itself, as it createscurrents in the glass bath, sothat fresh glass can be trans-ported to the gathering location.

A relatively large paddle stirrer isused for this, normally positionedin the centre of the gathering bay.The refractory stirrer is screwedinto a water-cooled shaft installedvertically through the roof. Theelectric drive motor and waterconnections are located outsidethe gather ing bay. The height ofthe stirrer is adjusted by a handwinch.

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Stirrers

Advantages

■ flexible design – can be used for many applications

■ compact design to suit tight areas

■ operator-friendly as the stirrers can be replaced alongside the forehearth

■ stirrer unit operation greatly improves the qualitywhen glass is extracted from the surface

Stirrer replacement takes placethrough the gathering hole,using special tools, so it is notnecessary to create a roofopen ing as large as the stirrer.

The stirrer rotation speed isstep lessly varied by the combi-nation of a variable speed motorand frequency converter. Allelectric control components areinstalled in the local controlpanel supplied.

The refractory stirrers for thisapplication can be supplied forclockwise and anti-clockwiserotation to suit site conditions.

Our standard equipment

Standard units are available forclockwise or anti-clockwiserotation.

Refractory Stirrers

Several types of stirrer are usedaccording to the different instal-lation locations and type of operation. Two and four paddlestirrers in various sizes, and spiral stirrers are available.

For normal applications, the stirrers are made of zircon mullite as this is resistant tothermal shock. For special glasses fused silica paddle stirrers are available for gathering bays.

SORG® stirrer unit installed on a

hand gathering bay

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Metering Equipment for Colouring Forehearths

To change the glass colour ina fore hearth, a colouringagent is added and mixed inby stirrers. During this processthe feed rate of the colouringagent must remain constant,to maintain a stable colourthroughout a production run.

Metering Equipment

The metering equipment has asmall hopper, from which thecolourant material is transportedalong a small vibratory chute toa weighing cell. From here thematerial is fed along a secondvibratory chute. The controlsystem automatically controlsthe vibration rate of the chutes.

Material is automatically re -plenished from the main bunkerwhen the control system detectsthe minimum level of material inthe small hopper.

The conveying equipment iscontrolled by its own computer,and all operating parameterscan be set on the monitor.

A screw conveyor is supplied asstandard for the feed from themain bunker to the small hopper.

Our standard equipment

The metering equipment can besupplied for maximum capacitiesof 50 kg/h or 100 kg/h.

Option

• a vibratory discharge device for the replenishment (instead of screw conveyor)

Experience has shown that thegrain size distribution of thecolorant material covers a widespectrum, so the colouringagent must be metered gravi-metrically.

Advantages

■ stable material flow rategives even colour intensity

■ simple to operate

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Delivery Pipes

The metering equipment isinstalled above the forehearth,and the colourant material istransported by gravity alongdelivery tubes to the forehearth.

On larger installations the colou-rant is deposited on the glasssurface at two or more locations.The material is roughly dividedby a separating funnel belowthe delivery conveyor and fed tothe individual feed locationsdown separate delivery pipes.

The delivery pipes are made ofpre-formed elements, withstraights, elbows, bends, etc.that can be clamped togethereasily to suit site conditions.

Our standard equipment

Standard components are supplied as required for eachproject.

Metering Equipment for Colouring Forehearths

Feed Pipes

The colourant material is fedinto the forehearth throughwater-cooled feed pipes instal-led in the refractory super -structure. The pipes are provi-ded with a compressed air sup-ply to prevent con densatedeposits forming in the pipe.

A Ni.Cr-Ni mantle thermocouplein the feed pipe monitors theoperation of the water cooling.The ope rating temperature isshown on a digital display,which is normally installed in thecontrol panel for the colouringforehearth stirrer units.

The pipe is supplied completewith holder, thermocouple and50 m of compensating cable.

Our standard equipment

The standard pipe for all normalappli cations has an externaldiameter of 102 mm and a nominal length of 600 mm.

Advantages

■ colourant does not stick to the pipe

■ simple installation

■ can be dismantled quickly for cleaning

SORG® colouring forehearth

colourant feed pipes

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For your notes

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Nikolaus Sorg GmbH & Co KG

P.O. Box 152097805 Lohr am MainGermany

Tel.: +49 (0) 9352 507 0Fax: +49 (0) 9352 507 196

[email protected]

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