sorg equipment

8/11/2019 SORG Equipment

1/56

Equipmentfor the Glass Industry

Perfect Solutions for the Glass Industry


2/56

2KomE/10.08.V2.2


3/56

ContentsOil 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/10.08.V2.2


4/56

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 is

the fact that the furnace, work-ing end and forehearths areviewed as a complete unit, sothe equipment can be designedspecifically to meet the variousrequirements. This is backed bya detailed knowledge of thedifficult conditions under whichthe equipment must operate, 24hours a day, 7 days a week, yearin and year out.

This high level of reliability and

quality was not achieved over-night. Many years of experience,both positive and negative, liebehind the development of almost 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 of the equipment we supply. Thefrequent heading our standard

equipment 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/10.08.V2.2

Regulations and standards

In some cases reference ismade to certification standards,in particular to DIN-EN stan-dards. Even where this is notspecifically mentioned in thishandbook, all equipment sup-plied by SORG corresponds to

either the relevant harmonisedEuropean 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 melting and conditioning installations perform well, producing good glass quality, with low energy consumption, and operating reliably throughout a long campaign. One reason is definitely related to the quality of 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 production

is not frequently interrupted as a result of faulty equipment.


5/56

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 be

supplied to the furnace burners. The viscosity must be reduced to an acceptable level by increasing the temperature, and it

must also be held constant, so that the control equipment and the 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 pump

unit (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 (witha 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 kPaElectric 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 temperaturebefore the station and atthe burner

oil freezing unlikely (thisdepends on the distancesbetween the components)

fewer deposits in pipes orfittings (less cleaningrequired)

increased flame stabilitydue to less pressurefluctuation

KomE/10.08.V2.2

SORG heavy oil pump unit


6/56

Oil Control Stationsfor Recuperative and Regenerative Furnaces

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

preparation of the oil supply for the heating system

regulation of the oil volume according to the automaticcontrol system requirements

preparation of atomising air

safety related functions

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


Standard oil control stations canbe supplied for capacities of 400, 700, 900, 1000 and 2000litres/hour.

Options

stations for single burnercontrol, with metering andcontrol equipment providedfor each burner

electrically operated controlvalves

enclosed station, installed ina sheet steel casing

The atomising air and oil pres-sures are maintained at a con-stant level in the station, whilstthe oil quantity is measured 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 withatomising 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 certifiedcomponents ensure highoperational security

KomE/10.08.V2.2

SORG oil station for a regenerative furnace


7/56

Gas Control Stationsfor Recuperative and Regenerative Furnaces

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

preparation of the gas supply for the heating system

gas quantity regulation according to the requirements of the automaticcontrol system

safety related functions

In the station the gas pressure isreduced to a suitable level andmaintained at a constant value. If the 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 of a 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 conversion 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 operationalsecurity


high level of operationalsecurity as a result of theuse of DIN-EN certifiedequipment

KomE/10.08.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.


The following standard stationsare available:

throughput:150 3000 Nm 3 /hnatural gas or equivalent

pipe size:DN 25 250

Options

stations for single burnercontrol with metering andcontrol equipment for eachburner

enclosed station, installed ina sheet steel casing

electric actuator for controlvalve


8/56

Gas Burnersfor Regenerative Furnaces

Gas burners form an impor-tant part of the regenerative

heating system. They areused to influence flame size

and shape, both of which can affect the melting process and the fuel efficiency of thefurnace.


SJG 221:0 300 Nm 3 /h natural gas

SJG 231:0 700 Nm 3 /h natural gas

SJG SeriesIn the SORG SJG series of burners the gas quantity isregulated by a perforated drumwithin the burner body. Thedrum can be adjusted bymeans of a hand wheel. The

flame 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-off valve 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 plateproduces an efficient andpermanent seal at theconnection between fur-nace wall and burner, toprevent the infiltration ofcold air

KomE/10.08.V2.2

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


9/56

SGB200 Series The SORG SGB200 series of gas 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 higher

velocity 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 a

separate 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 nozzleimproves combustionadjustment (flame lengthand sharpness)

NOx reduction is achievedby the combination ofadjustable outlet nozzleand variable gas streamseparation

cast iron sealing plateproduces an efficient andpermanent seal at theconnection between fur-nace wall and burner, toprevent the infiltration ofcold air

KomE/10.08.V2.2

mum operation at all times. Thismeans that SGB200 burnersare particularly suitable for appli-cations where NO x 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.


SGB 221:0 300 Nm 3 /h natural gas

SGB 231:0 700 Nm 3 /h natural gas

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

Options

rotameter flow meter, so thatgas distribution between

burners can be observed

individual control valves oneach burner, for regulationof gas distribution

flow meter with electrical out-put, for registration of gasdistribution

Gas Burners for Regenerative Furnaces


10/56

Oil Burners for Regenerative Furnaces

Oil burners form an important part of the regenerative heating system. They are used to influence flame size and shape, both of which can affect the melting process and the fuel efficiency of thefurnace.

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

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

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


Burner type NL4

3 sizes of oil nozzlesize 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 quantitymeasurement

extraction valves to removeoil from the burner during thereversal period to avoid solidbuild-up and so extendcleaning intervals

10

Advantages

the burner operates as apure compressed airatomiser

useable for all applications

short, sharp or long andlazy flames can be produ-ced with the correct oilnozzle diameter andatomising air quantity

KomE/10.08.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.


11/56

Gas and Oil Burners for Recuperative Furnaces

In furnaces with recuperative heating systems the combustion air is preheated in the recuperator and passed through the actual burner,where it mixes with the gas or oil to form the flame.

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

11

Advantages

The cast iron burnercasing provides a safe,permanent and sealedconnection between thefurnace wall and the bur-ner. This prevents theinfiltration of cold air

These burners ensuresmooth and almost main-

tenance-free operation The burner pressure can

be adapted to suit that ofthe heating system

KomE/10.08.V2.2

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

The burners are available inthree versions:

the HTG series is used forgaseous fuels

the HTO series is used for oilfiring

the HTK series can be usedfor either gas or oil, where-by the burner lance mustbe changed to convert fromone fuel to the other.

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


A total of 10 standard burners isavailable in each series, with

maximum capacities rangingfrom 50 1500 kW (operationwith preheated combustion air).


12/56

Furnace Reversal Systems

When the firing is reversed,the reversal unit switches the

incoming combustion air flow and the outgoing waste gasflow between the two regen-erator chambers from one

side to the other. Slide or flap reversing 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 channels 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 reversingprocedure. Simultaneously 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 thetemperature drop during thereversing procedure and there-fore influences the purge timesfor the regenerator chambers.

As a result the NO x emissionlevels are also decreased.

12

Advantages

improved sealing of thereversing unit and signifi-cant reduction in theamount of air induced

shorter reversal times,resulting in a reduction inNOx emission levels

KomE/10.08.V2.2


The following reversal unit sizesare available from SORG :

Type 11/9channel height 1100 mm

channel width 900 mm

Type 13/11channel height 1300 mmchannel width 1100 mm



Options

a double drive chain forlarger units

a conventional pneumaticcylinder, or an electric motor,

as alternative drive methods

SORG slide reversal system for

regenerative furnaces


13/56

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 combustionair 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 refractory material on

site, two combustion airconnections and a reversingflap with drive assembly.

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


The SORG flap reversal unitshave the following dimensions:

Type 18/37channel depth 1800 mmchannel width 3700 mm

Type 18/39channel depth 1800 mm

channel width 3900 mm Type 18/41

channel depth 1800 mmchannel width 4100 mm




13

Advantages

compact equipment to fitlimited building space

shorter waste gas paths more economic solution


long operating life

KomE/10.08.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 directly

on the top of the second cham-ber. It is not suitable for installa-tion in waste gas channels.


14/56

Waste Gas System Equipment

The furnace waste gas system generally includes equipment for the control of the furnace pressure, and may also include a

method of producing, or increasing, the suction effect which pulls waste gases from the furnace. These functions are important for stable operation of the furnace combustion system.

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.


SORG furnace pressure controlflaps are available in 4 standardsizes:


Type 13/11channel height 1300 mm

channel width 1100 mm Type 15/13

channel height 1500 mmchannel width 1300 mm


Advantage

the use of a pneumaticdrive improves reactiontime and helps to reduceNOx production

14KomE/10.08.V2.2

Options

a vertical slide valve in placeof the swivelling flap valve

an electric actuator


15/56

Waste Gas System Equipment

15KomE/10.08.V2.2

Advantages

simple method of creatingsufficient draught whenflue draught losses arehigh

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 of delivery.

Our standard equipmentEach injector chimney is specifi-cally designed for the actualoperating conditions of theinstallation. SORG injectorchimneys can be designed forwaste gas flows of 10000 50000 Nm 3 /h.

Option

the steel stack can besupplied 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 of producing a draught which isindependent of the stack. Thisis often the case, for example,when an electrostatic precip-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 operates

in 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.


SORG waste gas exhausterscan be supplied for waste gasflows up to 60000 Nm 3 /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 by

manipulation 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


16/56

Metallic Recuperators

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

SORG uses two basic typesof steel recuperator: the double

shell recuperator 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 combustion 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.


Recuperators are always de-signed for individual applications.

16

Advantage

can also be produced assmall units for smallfurnaces, working endsor forebays

KomE/10.08.V2.2

SORG recuperator


17/56

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 diameter

outer 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. The

refractory 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 of up to 750 C. They are usuallyinstalled on larger furnaceswhich require a greater quantityof combustion air.


Recuperators are always de-signed for individual applications.

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 preheattemperatures than doubleshell recuperators

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

KomE/10.08.V2.2

SORG recuperator and

hot air pipework


18/56

TV Equipment

TV monitoring equipment can be used for continuous and simple monitoring of impor-tant furnace parameters, such

as flame shape and batchcover on the glass bath.

The SORG sensor unit for thecombustion chamber consistsof a water-cooled casing, an airpurge unit, lens and camera.

The complete unit is mountedon a movable carriage, that canbe removed automatically 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 17monitor, available either as afree-standing unit or for integra-tion in a control panel.

18

Advantages

robust camera system,suitable for continuousoperation in the glassindustry

high quality lenses produceexcellent image quality

KomE/10.08.V2.2

SORG furnace TV camera unit


Lenses with diagonal imageangles of 70, 94, and 110are 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 canbe supplied if the customerdoes not have a coolingwater circulation system

video recording equipment,configured especially forlong-term monitoring


19/56

Furnace Transformers

Transformers with steplessly variable voltage outputs areused for electric boosters

and all-electric furnaces.

SORG can supply two different types of transformer:

oil-cooled, three-phase induction regulators

air-cooled, single-phase,fixed ratio transformerswith 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 automatic

control.

There are no moving electricalcontacts, and the principle ischaracterised by a high level of reliability and low maintenancerequirements.

Induction regulators are normallysupplied as three-phase unitsfor high voltage connection upto 30 kV. The transformers areoil-cooled and are suitable for

indoor operation with natural airconvection. Double-chamberBuchholz relays, primary voltagesurge arresters, an oil temp-erature gauge with limit contact,air de-humidifier, and transportrollers 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).


SORG induction regulators areavailable for nominal powers of 300 4500 kVA.

Options

bus bar distributor system onsecondary side

secondary current trans-

formers for current and powermeasurement

transformers with combinedforced air/oil or water/oilcooling for difficult locations

tapped transformers withoff-load tap change, up to1000 kVA

19

Advantages

improved furnace operation,owing to stepless powervariation under load

extremely reliable, low-maintenance operation,as a result of non-contactvoltage adjustment

Advantage

high flexibility even intemporary exceptionalcircumstances owing toselectable voltage ranges

KomE/10.08.V2.2

All components are installed inenclosed steel casings, to pro-tection standards IP23. Currenttransformers and transport rol-

lers are supplied as standard.


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

SORG 2100 kVA induction regulator


20/56

Electrode Holders and Electrodes for Furnaces

Molybdenum electrodes areutilised in all-electric furnaces

and in additional heating systems (boosters) in con-ventional furnaces. A very

pure form of this metal is used,that does not contaminate the

glass.

Normally, water-cooled hol-ders are used to protect the

molybdenum from damagecaused by oxidation in thetransition area between the

glass and the air.

Standard ElectrodesRod electrodes are used fornormal applications in boostersand all-electric furnaces. Theindividual rods are usually pro-vided with a male and femalethread so that the electrodes

can be screwed together.


SORG can supply electrodeswith the following nominal dia-meters:

32 mm (1 1 / 4'')48 mm2''2 1 / 2''3''

Standard rod electrodes havenominal lengths of 400 or800 mm.

Option

rod electrodes innon-standard lengths

SORG Top ElectrodesElectrodes are normally installedthrough the side walls or bottomof the tank. This method increa-ses the wear on the refractorymaterial 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 of the furnace.

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

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


The standard diameters forSORG Top Electrodes are 2 1 / 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 a

connection clamp.

Option

the electrodes can be surface-treated to provide temporaryprotection against oxidation

20

Advantage

SORG molybdenum rodelectrodes are boughtsolely from reputablemanufacturers 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/10.08.V2.2

SORG Top Electrodes installed on a

VSM all-electric furnace


21/56

Advantages

proven design

universal application

Electrode Holders and Electrodes for Furnaces

Water-CooledElectrode HoldersWater-cooled electrode holdersare used for the conventionalinstallation of electrodes inboosters and in the lower areasof electric furnaces. SORG

electrode holders have an en-closed water circulation channeland are therefore suitable forboth side and bottom installation.

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

The initial electrode holderpackage includes a set ofconnection items.


SORG can supply electrodeswith the following nominaldiameters:

32 mm (1 1 / 4'')48 mm2''2 1 / 2''3'

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

21KomE/10.08.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 of the ceramic material these elec-trodes cannot be advanced.

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 this

material has a relatively lowmechanical strength.


22/56

Water Cooling Systems

Electrode holders and other metal components used in hot areas must be cooled continuously with water. In the majority of cases enclosed cooling water circulation systems are used

in order to maintain control of the water quality and minimisethe quantity of fresh water needed.

A typical cooling water circulation system comprises a water storage tank, cooler, pump and distribution stations, and all piping.

Evaporation CoolerIn 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 dripping

from 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.


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

Pump StationEquipment for a number of func-tions is installed in the SORG

pump station.

Two identical circulation pumpsare installed for the coolingwater circulation, so a stand-by is available if a pump fails ormaintenance work must becarried 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 circulating pipeto eliminate problems causedby solid deposition in the pipe-work.

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

22KomE/10.08.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.


Standard stations with capacitiesof 10 m 3 /h, 15 m 3 /h and 25 m 3 /h

are available.

Plate Cooler A plate cooler consists of twopipe systems in close contactwith one another. One system isa part of the water circulationsystem, and the cooling waterused for cooling the electrode

holders 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.


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

SORG pump station


23/56

Water Cooling Systems

Distributor Station The cooling water is normallydistributed 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 monitoring 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 so

that the water temperature canbe hand tested. The return flowto the water tank is by gravity.

All electrical connections aregrouped in one control panel.


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 forsmall systems

added security by flowrate monitoring in returnpipes

KomE/10.08.V2.2

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

bodies.

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


SORG water tanks are availablein sizes up to 3 m 3.

Option

tanks made of plastic, suitablefor regions with particularlyaggressive water quality

SORG CompactWater System

The SORG compact water cir-culating system contains all theequipment required for a com-plete small water circulatingsystem for a limited number of

consumers. The equipmentcomprises a water storage tank,two circulating pumps (one asreserve), a closed circuit cooler,an AMT (Anti-scale Magnetic

Treatment) unit that preventssolid deposition 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, are

also included. The unit only requires connec-tion 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


The SORG compact watercirculating system is available in5 standard sizes with circulatingcapacities of 1 5 m 3 /h. At atemperature increase of 10 Cat the consumer this is equiv-

alent to between 2 and 10 stan-dard electrode holders.


24/56

Bubbler Systems

The upward movement of the bubbles from bubbler systemscreates vertical currents. This

stream can produce an homo- genising effect in the glass, but more frequently the aim isto transport hot glass to the

bottom in order to increasethe bottom temperature.

Various types of bubbler tube are available:

molybdenum disilicide(also known as KanthalSuper)

ceramic ceramic with platinum tip

The supply equipment is normally installed in a common panel. The flow volume for each bubbler tube is set and displayed on the control

panel.

MolybdenumDisilicide BubblerTubes

The material is very heat resistantand also resists attack by theglass. It has a good electricalconductivity (it is primarily used

for heating elements for hightemperatures) 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 by

temperature 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 airsupply pipe.


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

Ceramic Capillary Bubbler Tubes

If the gas pressure on the bubblertube is temporarily reduced orcut off, there is the risk thatglass will enter the hole, where

it 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 of which 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 tubes

also operate successfully inpulsed bubbler systems.


SORG ceramic bubbler tubeshave an external diameter of 15 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 canalso be embedded in water-cooled steel tubes

24

Advantage

excellent materialproperties

Advantage

does not become blockedif bubbling interrupted

KomE/10.08.V2.2

SORG ceramic bubbler tube installation


25/56

25KomE/10.08.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 witheither 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.


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 theinstallation can be designedas a pulse bubbler. Thepressure pulses are producedby magnetic valves installed

in the feed pipe to eachbubbler tube and controlledby a PLC

Advantages

stable operation achievedby the use of flow meterswith automatic pressurestabilisers

flow meters can bereplaced during operation

operational security en-sured by continuousmonitoring of voltage toearth (with molybdenumdisilicide bubbler tubes)

BubblerControl Panel

The equipment in a bubblercontrol panel comprises a pres-sure controller with a filter instal-led in the supply line, a flow

meter 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 thequantity of bubbling air is stable,even when temperature fluctua-tions in the glass cause a changein the viscosity at the outlet of the 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


26/56

Glass Level Measurement

Glass level measurement isused as the basis for automaticcontrol of the raw material feed to the furnace. In many cases the stability provided

by the system is also an important prerequisite of stable production.

an emergency controller is avail-able within the system electronicsto provide temporary control, if the 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 contact

system which reacts when theprobe touches the glass surface.


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 methodis 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, platinum-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 of the glass level.

The glass level is controlled byan external controller. However,

26

Advantages

non-contact glass levelmeasurement

compact design

little corrosion on sensor

simple fault diagnosis

internal emergencycontroller

KomE/10.08.V2.2

SORG dipping probe glass level

detector drive unit

SORG dipping probe glass level

detector probe

Options

water-cooled sensor forglasses with heavy volatilisation

air purge device to avoid theaggregation of condensate inthe access opening: this isespecially important for usewith special glasses, or ifthere is high internal pressureat the measuring location

water-cooled base platewhen ambient temperaturesare very high


27/56

27KomE/10.08.V2.2

Glass Level Measurement


The standard system is suitablefor all normal applications.

Option

a laser system, which operateson the same principle as theoptical system describedabove

Optical Glass LevelDetector

A light beam created by a lenssystem is directed diagonallyonto the glass bath surface,from where it is reflected. A receiver installed opposite the

light source registers the exactposition of the reflected 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 usedsuccessfully 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 asthis is a non-contactmeasuring technique

very accurate

reliable

Advantages

no mechanical wear asthis is a non-contactmeasuring technique

if little space is available, itis possible to site thesource and receiver severalmeters from the measuringpoint

SORG dipping probe glass level detector in operation

SORG optical glass level measuring

system

SORG isotope glass level measuring

system

value for determining 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.


The standard system is suitablefor all normal applications.


28/56

Batch Chargers for Conventional Furnaces

The raw materials for the glass melt batch and cullet are introduced into the furnace by batch chargers that operate with various charging

methods. The most suitabletype of charger for an instal-

lation is usually established during the planning stage.The size and shape of the

doghouse must be chosen to suit the batch charger to beused.

All machines described below are designed and constructed according to current EN mechanical engineering regulations.

chute with exchangeable frontend, water-cooled pusher andadjustable drive motor.


Type CPO 400 D:chute width 400 mmmax. capacity 120 t/24h



Options

for smaller furnaces, that arealso operated at lower specificmelting rates, two chargerswithout an oscillation functionare available:

Type CPS 400 Dchute width 400 mmmax. capacity 120 t/24h

Type CPS 500 Dchute width 500 mm

max. capacity 170 t/24h

28

Advantages

robust mechanism

doghouse radiation reduced

by protective shield independent operation of

feed and charging enablesoptimum charging patternin furnace

KomE/10.08.V2.2

SORG pusher batch charger

The Type CPO PusherCharger

The raw materials that have beenstored in a furnace bunker aredischarged directly into a feedhopper on the batch charger,and then fed into the doghouse by

a vibratory chute. The chute feedrate is controlled automaticallyby a signal from the glass levelcontroller. Finally, the raw mate-rials are pushed in portions intothe furnace by a water-cooledpusher. Chute and pusher operateindependently. A protective shieldsignificantly reduces the heatradiation from the doghouse.

Batch cover is optimised by the

operation of a freely programm-able swivel mechanism on thecharger, which allows the batchto be charged in several direc-tions, at slightly different angles.

A freely programmable PLCcontrols the charger, using asignal from an external glasslevel controller. Both manual andautomatic operation are possible.

Chargers are supplied complete

with frame, feed hopper, vibratory


29/56

29KomE/10.08.V2.2


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 a

water-cooled chute. The specialbackwards 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 then

controlled 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.


Type SB 400:chute width 400 mmmax. capacity 40 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.


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




30/56


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. The

equipment 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.


The chargers are designed tosuit specific applications.

The Type ESEEnclosed DoghousePusher Charger

The batch stored in the furnacebunker is transported by avibratory or screw conveyor to afeed hopper installed on the

batch 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 off the 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/10.08.V2.2


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



Advantage

the system providesoptimum sealing aroundthe charger

SORG screw batch charger

SORG enclosed doghouse pusher

batch charger in operation


31/56

31KomE/10.08.V2.2

Advantages

simple and robust design

excellent batch distribution

Batch Chargers for Electric Furnaces

The batch charging method selected is one of the most important design decisions for cold-top all-electric furnaces.In the majority of cases the

batch/cullet mixture must be spread as evenly as possibleover the whole surface.

The Distributor ArmBatch Charger

The batch is charged into thesuperstructure 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 temperature in the super-structure becomes too high.

The system is designed forhexagonal or round furnaces

and it is used on small electricfurnaces with melting areas upto about 5 m 2.


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

Advantages

completely enclosedsuperstructure no dustin factory building

can also be operated athigh crown temperatures

The Rotating CrownBatch ChargerSeveral small vibratory chutesare installed above the crown atvarious distances from the centreof the furnace. Batch is chargedby the chutes through small

openings 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 of the superstructure is completelysealed.

If it is necessary to reduce thedust emission level, the batchgases can be drawn off andpassed through a simple bagfilter. No cold air is drawn into

the enclosed superstructure. The system can be used forhexagonal or round furnaces,with melting areas between5 m 2 and 80 m 2.


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

SORG rotating crown batch charger in operation


32/56

Air Supply Equipment

FansSORG 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 temperaturesfrom -10 C to +40 C.

The nominal capacities are cal-culated for an air temperature of 20 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 forspecific installations, sothat energy is not wastedas a result of over-sizing

the fan characteristicsprevent unwanted pressurevariation when thethroughput changes

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

32KomE/10.08.V2.2

The SORG programme of air supply equipment for furnaces,working ends and forehearths

includes both fans and their auxiliary equipment, and hot air pipework for pre-heated combustion 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 in

working order, as a stand-by.

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


SORG can supply fans withcapacities between 5000 and30000 Nm 3 /h.

Option

axial fans are also available

Combustion Air forWorking Ends andForehearthsIn 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.


Combustion air fans with

capacities between 300 and6000 Nm 3 /h are available.

Option

an automatic control systemfor the air pressure, comprisingpressure transmitter, controllerand frequency converter,designed to improve theoperation of large fans at lowspeeds

SORG combustion air fans for a

working end and four forehearths


33/56

33KomE/10.08.V2.2

Air Supply Equipment

Tank and ThroatCooling for Furnaces

Two identical radial fans areusually provided for the tank cooling. During normal operationonly one fan runs, and the other

is kept in working order, as astand-by.

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


Cooling air fans with capacitiesfrom 15000 to 65000 Nm 3 /h areavailable.

Emergency Air Supply for 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 to

cool 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 if there is a power failure.

Options(applicable to all fans)

a conventional control system

for the fans using star/deltastarters, mounted in a localcontrol cabinet

a control system with anelectronic soft-start functionfor larger fans installed in alocal control cabinet

all fans can be fitted with asuitable frequency converterfor a smooth run-up and fullyautomatic air volume and/orair pressure control, with allcomponents installed in alocal control cabinet

Hot Air Pipeworkfor RecuperativeFurnacesIn furnaces with recuperative airpreheating, the hot air from therecuperator must be fed to theburners. As the air should lose

as little energy as possible bet-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 canbe connected easily duringconstruction.

Air Cooling forWorking Ends andForehearthsCooling air for working ends andforehearths is normally providedby single fans for each part of the 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.


Cooling air fans with capacitiesbetween 300 and 3000 Nm 3 /hare available.

SORG hot air pipework for preheated

combustion air on a side-fired

recuperative furnace

Advantage

pre-assembled sectionsresult in short assemblytimes


34/56

34KomE/10.08.V2.2

Temperature Measurement

Temperatures are measured at many locations in furnaces,working ends and forehearths

either in the air, in the refractory material or in the glass bath itself. SORG can supply a range of sensors, inthe form of pyrometers or thermocouples.

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%RhPt.6%Rh)thermocouples for hightemperature areas

type K (Ni.Cr-Ni) for wastegas areas


SORG thermocouples are avail-able in nominal lengths from

710 to 1800 mm.

Options

type R (PtPt.13%Rh) and Type S (PtPt.10%Rh)

other nominal lengths

Advantage

these thermocouplesprovide importantinformation relevant to theglass quality and thethermal homogeneity

Advantage

the equipment is suitablefor the particular operationalrequirements of the glassindustry

In-GlassThermocouples

These thermocouples have aplatinum sheath and are usedfor measuring the temperatureof the glass in difficult areas,such as the throat, melting end

bottom and side walls of all-electric furnaces.

Option

pyrometers can be used tomonitor the control thermo-couple and this temperaturemeasurement is used forcomparative purposes

SORG furnace bottom thermocouple

installation

SORG working end in-glass thermo-

couple installation


35/56

Advantages

special design ensureslong operating life

channel easy to replaceas installation from above

Pyrometers forWorking Ends andForehearths

Only a lens is needed on theworking end or forehearth itself. The radiation from the glassbath is transmitted 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.


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

Option

an air supply unit for thepurge air, comprising filter,pressure controller andcombined adjustmentvalve/flow meter

35KomE/10.08.V2.2

Temperature Measurement

Thermocouples inWorking Ends orForehearth ChannelsSORG 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 (PtPt.10%Rh)thermocouples are supplied asstandard.


SORG working end and fore-hearth thermocouples are avail-able with nominal lengths of 1100 mm for working ends and825 925 mm for forehearths.

Options

triplex unit with extendedplatinum sheath and 3thermocouples

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

type B (Pt.30%RhPt.6%Rh)or type R (PtPt.13%Rh)


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 the

glass bath.


A type S (PtPt.10%Rh) thermo-couple with a nominal length of 300 mm

Options

type B (Pt.30%RhPt.6%Rh)or type R (PtPt.13%Rh)


SORG forehearth spout in-glass

thermocouple installation


36/56

36KomE/10.08.V2.2

Oxygen Measurement

Oxygen Measurementin the Furnace

A measurement of the oxygencontent in the waste gases is

an important pre-requisite for optimum furnace operation.The lower the oxygen con-tent, the lower the waste gas

losses and the lower the fuel consumption.

The requirement to minimiseNO x emissions can only be

achieved with a near-stoichiometric combustion. However,CO may be produced in the

regenerators if there is a near- stoichiometric combustion,with less than 1 % O 2 in thewaste gases. The CO valuecan be estimated on the basisof oxygen measurements.

An oxygen content measurement can also be used for automatic air/fuel ratio con-trol. However, for this a relia-

ble method for continuous measurement 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 concentrationmeasurement 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 ofthe chamber on the axis of theburner ports.

The Signal Processor The signals from the sensor andthe thermocouple are processedin an electronic unit, that analysesthe data and determines theoxygen concentration at thesensor.

Advantages

furnace operation can beoptimised on the basis ofthe oxygen measurement,so that minimum NO xvalues can be achieved

the quality of the combus-tion can be monitoredand recorded continuously

SORG oxygen sensor installed in

regenerator crown


37/56

37KomE/10.08.V2.2

Advantages

the air/gas ratio productionof the heating system ismonitored

an exact and reproduciblesetting of the air/gas ratiocan be found

Oxygen Measurementin ForehearthsFor certain applications it is

advantageous to be able tocheck the combustion inforehearth zones. This may

be the case, for example, inthe melting zone of a fore-

hearth colouring installation, but it could also apply in any zone where a very sensitive glass is involved.

To check the combustion, a small part of the air/gas mix-ture being supplied to theforehearth burners is diverted

and burnt in a reference burner. A small zircon oxide

Oxygen Measurement

The Measuring Unit The reference combustion, themeasurement of the oxygencontent of the waste gases andthe processing of the resultingdata all take place in a singlecabinet. A representative value

for 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-erence combustion for all zonestakes place in the same burner,the samples from the variouszones being switched into themeasuring circuit one afteranother.

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


Complete cabinet, configuredfor 15 zones

SORG forehearth oxygen cabinet in operation

sensor is installed in thewaste gas chimney of this

burner, to measure the oxygen content of the waste gases from the referencecombustion of the sample.


38/56

38KomE/10.08.V2.2

Control Equipment

Accurate measurement and good control of furnace working end and forehearth parameters are important pre- requisites for successful operation. Furnace pressurecontrol can have a significant effect on energy consumption

and refractory wear, whereas air/fuel ratio control influences both energy efficiency and environmental emissions.

Temperature control of thefurnace, working end and forehearths is the basis for

stable 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 andopposite one another. The pres-sure connections of these twoprobes are connected beneaththe furnace. Two further probesare located directly alongsidethe 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 transmitter, 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 of

the transmitter. A water-filledequalising vessel is installed inthe pipework between the fur-nace probes and the differentialpressure transmitter to preventthe deposition of condensatesin the pipes and shield thesensitive differential pressuretransmitter from the gases of the 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.


The SORG furnace pressurecontrol system comprises thefollowing parts:

2 furnace pressure probes2 atmospheric pressure probes1 differential pressure

transmitter with triple valveblock

1 PI single loop micro-processor-based controller

These items are applicable to allfurnace types and sizes.

SORG furnace pressure sensor


39/56

39KomE/10.08.V2.2

Control Equipment

Furnace Temperatureand Fuel/Air RatioControl

The temperature and fuel/airratio controls are combined in asingle control system, which uti-lises three independent single

loop controllers for temperature,fuel and combustion air.

In fossil-fuel fired furnaces thetemperature is measured by athermocouple installed in thesuperstructure, usually in thecrown. The signal is passed toa transmitter which converts themillivolts into a standard mA signal, which is passed to thefurnace temperature controller.

Fuel flow is measured by themeter installed 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 fuelcontroller. 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 externalset point. The output of the fuelcontroller is taken to the fuelcontrol valve, which varies the

fuel flow rate, depending on therequirements of the temperaturecontroller. The fuel controlleroutput also passes to an inputchannel of the combustion aircontroller, where it forms anexternal set point, which allowsthe controller to act as the ratiocontroller. The output of the aircontroller is connected to the aircontrol valve, and the air quantityis varied to maintain the requiredfuel/air ratio.


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 quantitymeasurement

1 fuel flow transmitter3 PI single loop micropro-

cessor-based controllers

Options

separate left/right ratiocontrol for reduced NO xproduction

multiple zone control forside-fired furnaces

individual burner control forreduced NO x 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.


The SORG glass level controlsystem comprises the following:

1 PI single loop micro-processor-based controller

This item is applicable to allfurnace types and sizes.

Option

the controller can be configuredfor on/off operation of thebatch charger

SORG furnace and working end

control panel


40/56

40KomE/10.08.V2.2

Control Equipment

Working End andForehearthTemperature ControlSORG temperature controlsystems for working ends andforehearths normally utilise in-glass temperature measurement

by means of thermocouples(see page 35 of this catalogue).

Temperature control is carriedout exclusively through theheating system.

The millivolt output of thethermocouple is passed to atransmitter, which converts thesignal to a standard 4 20 mA signal. This is passed to thetemperature controller.

The 4 20 mA temperaturecontroller output signal ispassed 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 of the heating controller and adjuststhe position of the cooling step-wise in order to keep the outputof the heating controller withinacceptable limits.

The output of the heating tem-perature controller is passed tothe PLC parallel to the connect-ion to the air control valve. A check routine based on a speci-ally developed logic is carried

out 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 thecooling system.

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

A single PLC can be used to


The SORG working end andforehearth temperature controlsystem comprises the following

parts 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.


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


41/56

41KomE/10.08.V2.2

Alarm Warning System

Many pieces of equipment installed on the furnace,

working end and forehearths produce warning signals to alert the operator to the existence 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 easily detect the existence of a fault warning and identify the source

of the signal.

PLC Version

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

Fault warning signals generated

by 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 of a separate operator panel, sui-table for mounting in the frontface of a control panel. Faultwarnings are shown as textmessages on the operatorpanel, and can be acknow-

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.


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 illuminatedindication fields, outputs foroptical 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 masterwarning lamp on the instrumentflashes. The warning can be

acknowledged 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 itself changes to steady illumination.

The external optical warningremains activated. Thesewarnings are only eliminatedwhen the fault signal has beenremoved.

The SORG safety system is available in two forms: the

PLC version and the single instrument version.

The acknowledge function canalso be provided from an external

source by means of a binaryinput to the instrument.


The instrument is available with8 or 16 input channels forwarning signals.

Advantage

All fault warnings aregrouped at a single location,so that the operator isalways presented with aclear overview of the status

of the complete installation.

PLC operator access panel


42/56

42KomE/10.08.V2.2

Drain System Equipment

Sometimes glass must be removed from the lower regions

of the glass bath through a bottom drain. It may also be necessary to remove glass

from the bath surface.

Drains can be installed in the furnace, working

end or forehearth, or even a gathering bay. On some installations a drain is installed to maintain the necessary minimum melting capacity when production rates are

low.

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. The

amount 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, including opal andborosilicate compositions.

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


A standard system is suitablefor use in both furnaces andforehe

sorg equipment

Documents