The Batch3 Integrated Concept for batch handling at the furnace represents an economical and viable solution to reduce the specific energy consumption and the CO2 emission of a glass melting furnace by using the energy in the waste gas. The concept comprises three components, each of which can make an important contribution to at least one operational aspect: the SORG® Batch Preheater, the EME‐NEND® Batch Charger, and the IRD® Doghouse.
The SORG® Batch Preheater features a combination of closed and open heat exchanger modules. Through this combination the problem of clumping caused by water is now eliminated. The water can leave the system through the open batch surface. Bonding and clumping are destroyed by activating the heat exchanger modules.
The installation of a SORG® Batch Preheater is only possible in combination with the EME-NEND® Batch Charger and the IRD® Doghouse. The EME-NEND® Batch Charger can be equipped with either one, two or three screws. By combining the screws with a pusher arm, the batch is delivered to the glass bath in the doghouse and further into the main part of the furnace.
With the twin or triple solution, the screws are controlled by individual frequency converters that provide independently variable charging speeds. This independent control allows variation in the amount of batch moved out of the doghouse – without any machine movement. Instead of screws the EME-NEND® is also available with vibratory chutes.
The IRD® Doghouse utilises two major changes to conventional doghouse designs to increase the heat transfer to the batch and does not create problems with dusting and carry‐over by glassing the batch surface. The doghouse is made larger to longer expose the batch surface to the heat from above inside the doghouse. Furthermore, the doghouse crown is raised to allow more radiation into the doghouse from the hotter crown areas of the furnace. Due to this energy and the longer residence time in the enlarged doghouse, the batch surface will be glazed. The most important advantage of a completely sealed doghouse is that the uncontrolled and often unstable entry of false air through the doghouse is eliminated. This also leads to a reduction of NOx in production.