AUTOMATION / CONTROL
Optimizing Measurement and Control of Glass Melting Processes
Monitoring and control of glass manufacturing processes is a fundamental and energy-intensive element of the process. With a growing focus on optimizing efficiency and reducing production costs, glass melting is especially under the spotlight.
FurnaceSpection: Advanced thermal imaging camera system for use in harshest environments
design is such that the optical fibers can be replaced on site, in situ, keeping downtime to an absolute minimum.
Portable radiation pyrometers are an important tool for monitoring, allowing operators to measure the temperature at multiple points on the melting tank walls as well as other, often very small, measuring spots. Easy-to-use handheld units such as the Impac Series 8 Pro have convenient through-the-lens sighting and can store data for later recall and analysis.
Continuous Real-Time Monitoring
The environment Inside the furnace is incredibly harsh, but continuous real-time temperature measurement of the product and the melting equipment helps operators quickly identify process problems before they become serious issues leading to outages and unplanned maintenance. Solutions such as AE’s FurnaceSpection infrared thermal imaging camera systems employ a shortwave infrared camera to provide continuous measurements. The inclusion of a water cooled and air purged borescope lens allow to measure inside the furnace via a port through its walls. Meanwhile, special spectral filters mitigate issues associated with burner firing that can affect measurements.
Energy costs account for 21% of the total cost of glass production, with 80% of that energy used in the glass melting process, so anything to minimize energy use can make a big difference to overall OpEx. But the monitoring and management of the glass melting process is also vital for ensuring the quality of products and early detection of problems that could cause costly shutdowns or reduce the lifetime of expensive equipment such as furnaces and melting tanks.
Focus on Glass Melting Process Equipment Temperature Measurement Viscosity, a very important parameter in glass production, is directly related to glass temperature and accurate and frequent measurements are vital for uniformity and quality. Equipment for glass melting is expensive, as is downtime for repairs, and glass is extremely corrosive and the operating environment harsh and wearing. Therefore, monitoring the temperature in and around melting tanks to detect and address problems is vital.
Traditionally, thermocouples have been used to measure temperature, but now radiation pyrometers - which don’t suffer the same problems with aging and drift and allow penetration into the molten glass to measure bulk temperature - provide data more accurately and more economically. This data is then used to better control the melting process, both for improved uniformity and to improve productivity and save money through reduced cycle times.
Both fixed and portable radiation pyrometers are available, and a combination of both is useful for the glass melting process. Fixed derivatives such as Advanced Energy’s Impac IS 50-LO/GL can achieve high measurement accuracy with a repeatability of 0.1%. The units can perform reliably for many years and their
MARCH/APRIL 2024
OPTIMIZED GLASS MANUFACTURING through temperature controlled processes
SCR power controllers and non-contact temperature sensors by Advanced Energy for improved process control and energy efficiency in every step of glass manufacturing
advancedenergy.com
info@aei.com
Enquiry No. 11
www.reviewonline.uk.com 11
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