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All Electric Furnaces
Electroglass has earned a worldwide reputation for technical innovation in the development of all-electric melters with exceptionally low energy consumption, coupled with high glass quality and flexibility of operation.
Capacities from 200 kg/day to over 250 tonnes/day
Cold-top melters with superstructure temperatures typically less than 125 deg.C
Exceptionally low energy consumptions, usually 20% to 40% less than other designs
Negligible volatilisation and consistent thermal history mean high glass quality
Minimal environmental pollution, even from volatile glasses
Silent operation
Flexible operation with turndown to 50% of rated output or less
Ability to withstand long power interruptions without emergency measures
Even energy distribution for minimum refractory-glass contact temperatures and low refractory wear• Uniform refractory wear pattern and extended furnace life
Uniform refractory wear pattern and extended furnace life
Short cold repair time for maximum productivity
Low cold repair costs: glass contact equipment and substructure refractories only
No wall cooling or electrode changing required
Programmable CNC-controlled batch charging system on most furnaces
Critical equipment, such as control panels, electrode holders, batch chargers, designed and manufactured in-house
Choice of control systems using advanced PC/PLC technology and user-friendly software with options to suit particular customer requirements
Individual physical modelling and design studies carried out for each furnace project
Typical Energy Consumptions
850 kWh/tonne for 20 tonnes/day borosilicate cookware
770 kWh/tonne for 40 tonnes/day fluoride opal tableware
750 kWh/tonne for 80 tonnes/day soda-lime cosmetics
720 kWh/tonne for 160 tonnes/day soda-lime containers
Glass Types And Products
Soda Lime flint, green and reduced amber and greens
Fluoride Opal
Borosilicates
Lead Crystal
Glass Fibre/Wool
Containers
Cosmetic
Tableware
Ovenware
Lighting
Automotive
Insulators
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Electroflex Distributors & Forehearths
Highly efficient All-Electric Forehearths to cool and condition non-volatile glass types providing precise temperature control and consistent thermal homogeneity.
Forehearth completely electrically heated during normal operation and initial heat up
Actual case histories show operating cost savings of up to 80% when compared to equivalent gas-fired forehearths
Flexible design makes conversion of existing gas-fired or electric forehearth possible even during furnace campaign
No cooling air or other fuels required
Fast temperature response when increasing or decreasing gob weight ensures minimum production down time during job changes
Special profile heating elements and multiple heating zones allow precise containment of heating and cooling
Automatic power/temperature and manual control facility for each heating zone
Extremely high thermal efficiency due to low thermal mass superstructure and insulation
Special substructure design reduces temperature gradients and heat loss from the channel
Centre line radiation cooling and profile heating greatly reduce side to centre temperature differential
Optional additional Temptrim conditioning section electrode heating for precise gob weight control in low thermal transmission glasses
Electroflex Forehearths
Standard channel widths
305mm (12") 400mm (16")
660mm (26") 915mm (36")Special channel widths also available
Lengths to suit existing layout and gob drop points, where applicable
Electroflex and Electroflex-W Distributors
Channel widths, depths and lengths to suit existing layouts, where applicable
Simple, accurate temperature control
Substantial energy cost savings compared with gas-fired and other all-electric distributors and working ends
Passive centreline radiation cooling for optimum side to centre and top to bottom temperature homogeneity
Electroflex-W Forehearths
Standard channel widths
1220mm (48") 1370mm (54")
1525mm (60")Special channel widths also available
Lengths to suit existing layout and gob points, where applicable
Independent side to side heating compensates for temperature imbalance
Glass Types and Products
Soda Lime
Potassium Barium
Containers
Cosmetic
Tableware
Lighting
Insulators
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Electroseal Distributors & Forehearths
Highly efficient All-Electric Forehearths to cool and condition volatile glass types providing precise temperature control and consistent thermal homogeneity.
Forehearth completely electrically heated during normal operation and initial heat up
Special sealing cover tile arrangement minimises volatilisation without increasing refractory-glass contact
Flexible design makes conversion of existing gas-fired or electric sealed forehearths possible even during furnace campaign
No cooling air or other fuels required
Fast temperature response when increasing or decreasing gob weight ensures minimum production down time during job changes
Low power, electrode heating using special design dry electrodes ensures consistent glass quality without risk of induced DC voltage, a problem common with some other designs
Operating cost savings of up to 80% when compared to equivalent gas-fired forehearth
Multiple heating zones both in glass and above glass allow precise containment of heating and cooling
Automatic power/temperature and manual control facility for each heating zone
Extremely high thermal efficiency due to low thermal mass superstructure and insulation
Special substructure design reduces temperature gradients and heat loss from the channel
Centre line radiation cooling and low power electrode heating greatly reduce side to centre temperature differential
Electroseal Forehearths
Standard channel widths
305mm (12") 400mm (16")
660mm (26") 915mm (36")Special channel widths also available
Lengths to suit existing layout and gob drop points, where applicable
Glass Types and Products
Fluoride Opal for tableware, cosmetic containers and lighting products
Borosilicates for cookware, pharmaceutical, automotive components, optical and lighting products
Lead Crystal for tableware, cosmetics and ornamental pieces
Other specialist and technical glasses
Electroseal Distributors
Channel widths, depths and lengths to suit existing layouts, where applicable
Simple, accurate temperature control
Substantial energy cost savings compared with gas-fired and other all-electric distributors and working ends
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Convection Current Control Boosting
High performance electric boosting systems for all fuel and oxy-fuel fired glass tank furnaces, based on Electroglass' renowned thermal barrier boosting technology.
Increase furnace output by up to 60%
Promotes thermal and chemical homogeneity leading to reduced seeds and stones and providing greater overall glass quality
Significantly improves furnace operating stability by fixing and reinforcing hot spot position
Improves combustion heat transfer allowing burners to operate more efficiently by lifting cold glass to the melting surface, increasing overall thermal efficiency
Careful electrode placement and system design offers greatly reduced refractory wear when compared to other boost system concepts
Individual system design optimised using in-house physical modelling techniques
Greater furnace output without altering furnace footprint or increasing flue gas emissions
Proven hot installation techniques allow integration into existing furnace during operation without need for furnace shutdown or significant production loss
Comprehensive control panels with option for integration into existing plant computer system
All systems incorporate Electroglass proven high quality electrode holder technology
Close cooperation with specialist transformer manufacturers provides robust power systems fit for many years service
Convection Current Control Boosting
Exceptional energy efficiency, typically 20kW per additional tonne/day
More than 150 installations worldwide
Over 65% repeat orders by existing users or associates
Free office based lifetime customer support and monitoring
Special Purpose Electric Boosting
In addition to our main range of Convection Current Control boosting systems, Electroglass has developed, designed and supplied numerous special purpose systems with electrode designs, positions and connection arrangements configured to suit the requirements and properties of a wide range of glasses.
Glass Types and Products
Soda Lime
Borosilicate
C-Glass
E-Glass
Lead Glass
Containers
Cosmetic
Tableware
Ovenware
Automotive
Lighting
Tubing
Glass Wool
Continuous Glass Fibres
Float Glass
Rolled Sheet Glass
TV and Display Glasses
Pharmaceutical
Insulators
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Precision Controlled Bubbler Systems
Highly effective and economical method of homogenising glass during the melting process without the risks associated with conventional bubbling.
Hot-spot bubbling improves thermal and chemical homogeneity in the melt, reducing cord and stone losses
Under batch blanket bubbling can improve melt-rate and increase furnace bottom temperatures
Reduces the overall time to complete a colour change and homogenises colour during the change
Slow precision bubbling eliminates the risk of seed and parasite bubbles in the product
Independent control of bubble size and bubbling rate for each bubbler point
Throat and distributor bubbling for intermittent use during colour or composition change
Unique blockage resistant bubbler tubes allow slow controlled bubbling without the risk of injector damage
Comprehensive operator interface with touch screen HMI allowing easy access to key system information and control variables
Design backed by more than 30 years of continuous development
Bubbling can be suspended for prolonged periods and effectively restarted
Precision Control Bubbler Systems
Bubbler injector tubes available with platinum alloy coating for use in specialist glasses
Various bubbling mediums can be used including oxygen
Bubbler lengths to suit each installation
System can be supplied with an independent stand-alone compressor
Volts-to-earth monitoring is included as standard where electric boosting is present
The ability to suspend bubbling removes the need for advanceable bubbler tubes currently employed in some applications
Bubbler tubes designed to operate for complete furnace campaign with no need for replacement
Proven installation techniques allow system to be installed during operation where suitable refractory construction exists
Control system can be interfaced with factory computer system on request
Glass Types and Products
Soda lime
Borosilicate
TFT
LCD
C-Glass
E-Glass
Crystal
Containers
Lighting
Tubing
Tableware
Pharmaceutical
TV Panel
Float Glass
Rolled Sheet
Fibreglass
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Throat Heating Systems
An economical solution for furnace start-ups and during operation when the need to stop or greatly reduce glass flow means a risk of glass freezing in the throat area.
Primary voltage to suit individual plant
Employs Electroglass Molycool electrode holders
Fully automatic conductivity control
No need for expensive in-glass thermocouples
Essential during furnace fill-on, shut down or with dark glasses
Throat Heating System
Power, control and metering housed in one free-standing unit
Power and control module can be moved between furnaces if desired
Proven installation techniques allow system to be installed during operation where suitable refractory construction exists
Power provided by an air cooled, single-phase transformer
Electrode holder overall length to suit individual installations
Suitable for flat, sunken or sloping throats
Glass Types and Products
Soda Lime
Borosilicate
Fluoride Opal
Barium
C Glass
Lead Crystal
Containers
Tableware
Lighting
Ovenware
Pharmaceutical
Fibreglass
Rolled Sheet
Automotive
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Temptrim System
Forehearth temperature homogenisation system for installation in gas fired or electric forehearths to ensure accurate gob weight and shape control.
For installation in the forehearth conditioning section
Proven for effectively removing side to side and top to bottom glass temperature differences
Particularly useful in wide forehearths or coloured glass production
Low operating power, typically only a few kilowatts
High installed total power allows quick reaction to changing forehearth conditions
Multiple power zones and flexible configurations allow system operation to be tailored to suit individual job parameters
Utilises Electroglass' special design dry electrodes to ensure consistent glass quality without risk of induced DC voltage, a problem common with some other designs
Automatic power/temperature and manual control facility for each heating zone
Proven installation techniques allow system to be added during operation without the need for draining or cooling down the forehearth
Gob weight differences reduced to only a few grams
Power to each zone provided by an air cooled, single-phase transformer
Electrode overall lengths and immersions to suit individual installations
Automatic power control of each zone as standard
Automatic temperature control utilising existing in-glass thermocouples
Control system bypass for emergency use
Glass Types and Products
Soda Lime
Borosilicate
Fluoride Opal
Lead Crystal
Containers
Cosmetic
Tableware
Ovenware
Pharmaceutical
Tubing
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Glass Level Sensing
A range of Glass Level Sensing and Control Systems from basic level sensors to fully integrated stand alone control systems to meet each individual furnace and production requirements.
System consists of probe block with platinum alloy pins and control or indication unit, connected to single phase power supply
Designed for installation in a furnace working end, distributor or forehearth
System operation not affected by changes in glass temperature or composition
Real time glass level information
Accurate to 0.1mm
Simple and easy to install
Several probe unit designs available to suit individual installation
Various refractory material grades available to suit a wide range of glass types
No moving parts
No water or air cooling required
Minimal maintenance
No on site calibration required
Glass Level Sensor
Sensing unit designed to interface with existing glass level control system
Output signals of 0-5v and 4-20mA are provided
Special interconnection cables included
Proven installation techniques allow system to be installed during operation where suitable refractory construction exists
Glass Level Controller
Free standing control system
PLC based PID block offers full glass level control
Touch screen HMI display with historical trending
Output signals of 0-5v and 4-20mA are provided
Output to existing vibratory feeder or screw charger
Automatic and manual control options
Latest versions compatible with existing Electroglass Glass Level probe blocks
Glass Types and Products
Soda Lime
Borosilicate
Fluoride Opal
Potassium Barium
TFT
CRT
Ceramic
Lead Crystal
Crystalline
Containers
Tableware
Lighting
Ovenware
Pharmaceutical
Automotive
Glass Wool
Fibre Glass
Tubing
Insulators
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Continuous Controlled Drains
Effective continuous or semi-continuous draining of high viscosity sludge glass at controlled rates in throats, working ends, forehearths and gathering bays, for conventional and specialist glasses.
Removes refractory contaminated glass at a controlled rate, without significant waste of good quality glass
Independent heating and cooling functions ensure that draining can be started, controlled and stopped easily and effectively
Individually controlled air and water cooling facilitate regulation of glass flow
Indirect heating removes the need to apply power through the drain tube or glass
No counter electrode needed
Low energy usage compared to direct heating designs
Eliminates the contamination rather than dispersing it
Proven in reducing 'cat-scratch' and other cord related quality issues
Simple, automatic, temperature and power control options
Drain tube dimensions and materials designed to meet individual installation requirements
Typical continuous draining rates of 8-12kg/hour
System consists of Power and Control Unit, Drain Assembly and Cooling Control Manifold
Proven in Borosilicate, Fluoride Opal, Soda Lime, LCD, TFT, Lead Glass, Potassium Barium, and Alumino-Silicate glasses
More than 70 installations to date with many customers having multiple systems
Free standing power and control module with small footprint for easy location
Engineering solutions to allow installation of forehearth drains without the need for refractory replacement or forehearth cool down
Glass Types and Products
Soda Lime
Borosilicate
Fluoride Opal
Potassium Barium
TFT
LCD
Lead Glass
Containers
Cosmetic
Tableware
Lighting
Ovenware
Pharmaceutical
Automotive
TV Glass
Tubing
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Electrode Holders
Precision made in our own workshops, using high performance heat resisting steels and with strict quality control, the Electroglass range of holders for molybdenum rod electrodes incorporate many advanced design features for energy saving, refractory protection, electrode cooling efficiency and maintenance free long life.
Designs suitable for vertical, angled and horizontal installations
Three key designs in lengths and diameters to suit individual requirements
Support arrangements to suit individual installations
Quality and performance proven over many years in furnaces worldwide in a wide variety of glass compositions
Unique thermal insulation of the holder nose, Electroglass holders can extract less than half the amount of heat energy from the furnace than other water-cooled holders
Energy savings of up to 17,000kWh per year per holder
High temperature thermal insulation between holder and refractory prevents steep temperature gradients, reducing the risk of refractory thermal shock and cracking
Electrical isolation between holder and electrode prevents dissimilar metal contact, eliminating the risk of DC voltage related quality issues
Designed to operate the entire furnace campaign without need for routine replacement
Robust design allows for easy electrode advancing as necessary within a campaign
Construction techniques allow for independent movement of internal components during application and removal of cooling when differential contraction may occur
Molycool Holders (M) Range
Designed for vertical, angled or horizontal installation
Suitable for use with open or closed water cooling circuits
Air pre-cooling to reduce holder temperature prior to application of water cooling
Continuous, weld free, cooling coils minimise the risk of thermal shock fracture
Require a continuous flow of 4-5 litres/minute of softened water per cooling coil
Available to suit 32mm, 50mm and 63mm diameter molybdenum electrodes
Vertical Splashguard (VS) Range
Designed for vertical installation
Suitable for use with open water cooling circuits
Open spray cooling circuit increases cooling efficiency around the electrode whilst minimizing cooling effect on surrounding refractory
Require a continuous flow of 4-5 litres/minute of softened water
Available to suit 63mm, 76mm and 102mm diameter molybdenum electrodes
Horizontal Splashguard (HS) Range
Designed for horizontal installation only
Suitable for use with open water cooling circuits
Open spray cooling circuit increases cooling efficiency around the electrode whilst minimizing cooling effect on surrounding refractory
Require a continuous flow of 4-5 litres/minute of softened water
Available to suit 32mm, 50mm and 63mm diameter molybdenum electrodes
Glass Types and Products
Soda Lime
Borosilicate
Fluoride Opal
Potassium Barium
E-Glass
C-Glass
TV and Display Glasses
Containers
Cosmetic
Tableware
Lighting
Ovenware
Pharmaceutical
Automotive
Tubing
Insulators
Glass Wool
Fibreglass
Float Glass
Rolled sheet glass
All Electric Furnaces
Electroglass has earned a worldwide reputation for technical innovation in the development of all-electric melters with exceptionally low energy consumption, coupled with high glass quality and flexibility of operation.
- Capacities from 200 kg/day to over 250 tonnes/day
- Exceptionally low energy consumptions
- Minimal environmental pollution, even from volatile glasses
- Flexible operation with turndown to 50% of rated output or less
Please visit our website on a computer to view the full information on our products.
Electroflex Distributors & Forehearths
Highly efficient All-Electric Forehearths to cool and condition non-volatile glass types providing precise temperature control and consistent thermal homogeneity.
- Operating cost savings of up to 80% compared with equivalent gas-fired forehearths
- Conversion of existing gas-fired or electric forehearths possible during furnace campaign
- Fast temperature response when changing gob weight ensures minimum production down time
- No cooling air or other fuels required
Please visit our website on a computer to view the full information on our products.
Electroseal Distributors & Forehearths
Highly efficient All-Electric Forehearths to cool and condition volatile glass types providing precise temperature control and consistent thermal homogeneity.
- Special sealing cover tile arrangement minimises volatilisation without increasing refractory-glass contact
- Conversion of existing gas-fired or electric forehearths possible during furnace campaign
- Fast temperature response when changing gob weight ensures minimum production down time
- No cooling air or other fuels required
Please visit our website on a computer to view the full information on our products.
Electric Boosting
High performance electric boosting systems for all fuel and oxy-fuel fired glass tank furnaces, based on Electroglass' renowned thermal barrier boosting technology.
- Increase furnace output by up to 60%
- Promotes thermal and chemical homogeneity, improving overall glass quality
- Individual system design optimised using in-house physical modelling techniques
- Greater furnace output without altering furnace footprint or increasing flue gas emissions
Please visit our website on a computer to view the full information on our products.
Bubbler Systems
Highly effective and economical method of homogenising glass during the melting process without the risks associated with conventional bubbling.
- Hot-spot bubbling improves overall glass quality
- Slow precision bubbling eliminates the risk of seed and parasite bubbles in the product
- Unique blockage resistant bubbler tubes prevent plugging
- Bubbling can be suspended for prolonged periods and effectively restarted
Please visit our website on a computer to view the full information on our products.
Throat Heating Systems
An economical solution for furnace start-ups and during operation when the need to stop or greatly reduce glass flow means a risk of glass freezing in the throat area.
- Fully automatic conductivity control
- No need for expensive in-glass thermocouples
- Power and control module can be moved between furnaces if desired
- Suitable for flat, sunken or sloping throats
Please visit our website on a computer to view the full information on our products.
Forehearth Thermal Conditioning
Forehearth temperature homogenisation system for installation in gas fired or electric forehearths to ensure accurate gob weight and shape control.
- Particularly useful in wide forehearths or coloured glass production
- Low operating power, typically only a few kilowatts
- High installed total power allows quick reaction to changing forehearth conditions
- Automatic power/temperature and manual control facility for each heating zone
Please visit our website on a computer to view the full information on our products.
Glass Level Sensing
A range of Glass Level Sensing and Control Systems from basic level sensors to fully integrated stand alone control systems to meet each individual furnace and production requirements.
- Real time glass level information, accurate to 0.1mm
- No moving parts
- No water or air cooling required
- Minimal maintenance, no onsite calibration required
Please visit our website on a computer to view the full information on our products.
Furnace & Forehearth Drains
Effective continuous or semi-continuous draining of high viscosity sludge glass at controlled rates in throats, working ends, forehearths and gathering bays, for conventional and specialist glasses.
- Removes refractory contaminated glass at a controlled rate
- Indirect heating removes the need to apply power through the drain tube or glass
- Low energy usage compared to direct heating designs
- Proven in reducing 'cat-scratch' and other cord related quality issues
Please visit our website on a computer to view the full information on our products.
Electrode Holders
Precision made in our own workshops, using high performance heat resisting steels and with strict quality control, the Electroglass range of holders for molybdenum rod electrodes incorporate many advanced design features for energy saving, refractory protection, electrode cooling efficiency and maintenance free long life.
- Designs suitable for vertical, angled and horizontal installations
- Lengths and diameters to suit individual requirements
- Energy savings of up to 17,000kWh per year per holder
- Designed to operate the entire furnace campaign without need for routine replacement
Please visit our website on a computer to view the full information on our products.