Glass Community › Forums › Glass Machinery and Glass Equipments for Flat Glass › Glass Tempering Furnaces › The Best 8 Ways to Reduce Glass Tempering Furnace Energy Consumption (2022 Updated Guide)
- January 25, 2022 at 10:39 pm #6178MartinKeymaster
This article will provide you with information, ideas, and 8 practical methods for reducing the energy consumption of your glass tempering furnace.
Improving Loading of Glass Efficiency to Reduce Glass Tempering Furnace Energy Consumption
Perhaps the most important factor influencing your own production is loading efficiency. For example, if you run a lot of 3 mm and 4 mm glass, the difference between 30% and 60% loading efficiency results in a more than 20% reduce glass tempering furnace energy consumption in your annual energy costs. At the same time, you achieve greater throughput. Here is the 8 ways to reduce glass tempering furnace energy consumption:
- To improve efficiency, analyze loading optimization and production flow planning: Heating energy accounts for a significant portion of total energy consumption. High temperatures, opening doors, and moving components all cause heat losses in the process. Here’s what you can do to reduce heat loss.
- Check that your glass tempering furnace insulation is in good condition and meets current standards: After years of use on tempering lines, insulation begins to crack and lose its insulation properties. Energy consumption is influenced by this. However, energy costs are only one factor driving an upgrade: old insulation cracks and creates dust, which can lead to quality issues like white haze. It’s a good idea to inspect the insulation after a while to see if it needs to be replaced.
- Keeping open leaks to a minimum: door opening time and line structure: People using batch furnaces with long door opening times and a structure with the furnace opening line in the middle of the roller, which means that the upper part is open in the middle of the roller line is something I see a lot. Because the rollers are moving, there must be some space between them and the insulation. This space has a negative impact on the line’s energy consumption because energy is also escaping. Note! This has a negative impact on both standby and production.
- Inverters (variable frequency drives) should be used in blower motors: The heating time is always longer than the tempering time when working with thin glass. This means that the blowers are only running at full power for a short time during the tempering process. Inverters allow you to run the motor at a lower speed during idle time. This is now a must-have feature. Get an inverter if you don’t already have one.
- Choose a quench system that only pressurizes a portion of the area: With thin glass, loading rates of 20-30% are quite common. Cycle times are so fast that operators don’t always have time to load the glass. However, as you recall from Point 1, loading efficiency has a significant impact on your energy costs because tempering pressure is generated throughout the entire quench area. If you don’t need to run a lot of thin glass, choose a system that can generate more pressure in a smaller area of the quench. Because the pressurized area is smaller, your loading efficiency will be higher, resulting in lower operating costs.
- Make sure your furnace is running as fast as it is capable of running: Even when inverters (variable frequency drives) are used, idling blowers consume a lot of energy. The blower speed is so fast with thin glass that it is not mechanically feasible to run the inverter at zero between batches. This means that any downtime is a waste of energy. With the production of 3 mm and 4 mm glass, this waste can amount to tens of thousands of Euros per year.
- Begin tracking and measuring your energy consumption: Make energy consumption a visible measurement for your team, and ensure they understand how they can influence the line’s energy consumption. There is always assistance available for training your team to improve energy efficiency.
- Choose a circulated-air convection system if you have a lot of Low-E glass. It reduces the wasted energy effect of using external compressed air: Convection is required for new energy-efficient coatings. In this case, moving air is used to heat the glass rather than radiation. Convection can be created in glass tempering lines in two ways:
- Compressed air convection occurs when external air from a compressor is blown into the heating section to create air movement.
- Recirculated convection creates air movement with a blower that moves and recirculates the air within the furnace.
I hope that this “Reduce Glass Tempering Furnace Energy Consumption” article will help you to reduce glass tempering furnace energy consumption and give you costs savings in your tempered glass production projects. If you have any recommendation to our readers or questions, please freel free to reply.
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