How to save energy in the production process of float glass

[China Glass Network] The glass industry is a high energy consumption industry. The glass melting furnace is the equipment that consumes more energy in the glass production line. The fuel cost accounts for about 35% to 50% of the glass cost. Most of the float glass melting in China is designed by ourselves. The kiln glass liquid consumption can reach 6500kJ/kg～7500kJ/kg glass liquid. The foreign large float glass enterprises only have 5800kJ/kg glass liquid, and we have a certain gap with the international advanced level.

The thermal efficiency of glass melting furnaces in developed countries is generally 30% to 40%, and the thermal efficiency of glass melting furnaces in China is only 25% to 35% on average. The structural design and thermal insulation measures of the furnace are unreasonable, and the quality of the used refractories is low. One of the important reasons for the gap. Secondly, the domestic floating glass process technology is backward and the management is not perfect. It is also the cause of high energy consumption, poor melting quality and short furnace life. Up to now, China has more than 140 float glass production lines, and the glass production capacity has increased rapidly. The market competition is gradually heating up. As the main fuel for glass, the price continues to rise, and the proportion of glass costs is increasing. Therefore, reducing glass energy consumption is of great significance for reducing production costs, improving the market competitiveness of enterprises, reducing environmental pollution, and alleviating energy shortages.

The energy saving of glass enterprises is a long-term task. Domestic and foreign technicians actively carry out research, such as optimizing furnace structure design, oxy-combustion, oxy-fuel combustion, and heavy oil emulsification technology. At present, many enterprises have begun to implement energy-saving measures in the production process, and explore energy-saving measures such as glass production process control.

The moisture, temperature and fuel consumption of the batch are well known, and the state of the water in the batch is closely related to the temperature of the batch. When the batch temperature is greater than 35 °C, most of the moisture adheres to the surface of the refractory sand in a free state, so that more soda ash can be adhered to enhance the fluxing effect. When the temperature of the batch is less than 35 °C, the water in the batch will form Na2CO3.10H2O or Na2CO3.7H2O with soda ash, and form Na2SO4.10H2O crystallization water compound with the mirabilite, so that the surface of the sand loses moisture and appears dry, which weakens the fluxing effect.

In the northern region, due to lower temperatures in winter, the temperature of the batch is generally lower than 35 °C, and in some areas it is only about 20 °C. In order to keep the appearance of the batch material moist, it is usually adopted to increase the moisture content of the batch material. Although it plays a certain role, it will bring more disadvantages, such as aggravation of the silo wall and increased fuel consumption. Someone calculated that the amount of oil needed to enter the kiln was 0.085 kg oil/kg water.

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