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Glass Tank Furnace

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DESIGN OF A GLASS TANK FURNACE
AIM-
Design of a regenerative and fired glass tank furnace of 200ton per day capacity to produce a sheet glass using furnace oil as fuel melted at 1500oC.
Given composition of the sheet glass-
Sio2 Al2O3 CaO MgO R2O Fe2O3
71 0.4 9 3 16 0.6
DIFFERENT PARTS OF A GLASS TANK FURNACE. 1. Doghouse assembly 2. Melting end 3. Crown 4. Bridge 5. Conditioning and Refining end 6. Regenerators 7. Portsland Burneses 8. Bubblers 9. Temprature Measurments 10. Furnace video camera 11. Furnace cooling System 12. Furnace exhust system 13. Auxillary System

Sl.NO. | Refractories | Using Area | Properties | 1. | AZS(alumina-zirconia-silica) | Glass contact zone | 1. High corrosion resistance up to 1600 degree Celsius 2. AZS contains:- Alumina= 46 - 50% Zirconia= 33 - 41% Silica = 12 - 16% | 2. | Siliminite | Used in the back up layer of AZS | 1. High CCS and RUL value 2. High corrosion resistance 3. High refractorinessAlumina =42 – 63% | 3. | Fire clay | Used in the lower temperature zone such as flue line | It is also Aluminosilicate compound but it contains less amount of Alumina. | 4. | Insulation | Exterior area of furnace | It is also aluminosilicate material containing high porosity. | 5. | Zircon ramming mass | Furnace bottom | These bricks contain zirconia which possesses high bulk density and load bearing capacity because of low porosity. | 6. | Super duty silica bricks | Crown of GTF(glass tank furnace) | It has also high spalling resistance. | 7. | Monolithic lubrisol | Crown of GTF(glass tank furnace) | It is mainly used as an insulator. | 8. | Magnetite | Checkers of regenerator | It is vastly used for high thermal conductivity. | 9. | Mag-Zir | Crown of regenerator | It has very high thermal conductivity. |

SHEET GLASS
It is also known as float glass. Float glass is a term for perfectly flat and clear glass.
The raw materials are (silica sand, cao, soda lime, magnesia) are properly mixed and introduced in a FC where they are melted at 1500*c.
The molten glass then flows from the into the bath of a molten tin in a continuous ribbon.
The glass which is highly viscous and the tin which is very fluid do not mix and the contact surface between these two materials is perfectly flat. When it leaves the bath of molten tin,the bath has cooled down sufficiently to pass to an annealing chamber called a lehr.Here it is cooled at controlled temperature until it is essentially at room temperature.
BATCH COMPONENTS I. Glass forming oxides-SiO2,B2O3,P2O5 II. Network modifiers or fluxes-Na2O,CaO,PbO,K2O,Li2O III. Intermediates-Al2O3,Sb2O5 IV. Colorants-CoO,NiO,Fe2O3 V. Firing agents-Na2SO4

DIFFERENT PARTS OF FLOAT FURNACE * Dog house * Melting zone * Refining zone * Regeneration and flu line * Neck combines main furnace to working end * Filler and final shape is given * Canal

MATERIAL BALANCE AND ENERGY BALANCE
MATERIAL BALANCE
Basis: 1000 kg molten glass
REQUIRED GLASS COMPOSITION Component | SiO2 | Al2O3 | CaO | MgO | Na2O | Fe2O3 | Amount(%) | 71 | 0.4 | 9.0 | 3.0 | 16.0 | 0.6 | Raw materials | Sand,feldspar,Dolomite,Limestone & Soda ash | Sand (S) | 99.5 | 0.5 | ..... | ...... | ........ | 0.6 | Feldspar (F) | 69.0 | 18.0 | ...... | ....... | 13.0 | ...... | Dolomite (D) | 1.0 | ..... | 31.0 | 21.0 | ....... | 0.5 | Limestone(L) | 1.0 | ...... | 50.0 | 5.5 | ..... | ...... | Soda ash | ...... | ..... | ....... | ...... | 58.5 | ....... |

Though these are main constituents, but apart from these there are some ingredients present in trace amounts, the addition of which do not affect batch composition or material balance.
REQUIRED GLASS COMPOSITION:-
Total weight of silica in 1000 kg batch = 0.71 * 1000 = 710 kg
Total weight of alumina = 0.004 * 1000 = 4kg
Total weight of CaO = 0.009 * 1000 = 90 kg
Total weight of MgO = 0.03*1000 = 30kg
Total weight of R2O = 0.16*1000 = 160kg
Total weight of Fe2O3 = 0.006*1000 = 6kg

So, during material balance
710 = 0.995 S + 0.69 F
4 = 0.005 S + 0.18 F
Solving,
S = 711.87 kg = Sand required F = 2.448 kg = Feldspar required
Now MgO, CaO required = 30 & 90 kg respectively.
During material balance,
30 = 0.21 D + 0.055 L
90 = 0.31 D + 0.5 L
Solving,
D = 114.27 kg. L = 109.15 kg
R2O in feldspar = 0.13*2.448 = 0.3184 kg
Total R2O required = 160 kg
Remaining R2O will come from soda ash
Amount of which is = (160 – 0.3184) = 159.68 kg
Soda ash required = 159.68/0.585 = 272.96 kg
SiO2 coming from Dolomite = 1.1127 kg
SiO2 coming from limestone = 1.0915 kg

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