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The 83rd Conference on Glass Problems (GPC) was organized by the Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, NY, and The Glass Manufacturing Industry Council (GMIC), Westerville, OH. The Program Director was S. K. Sundaram, Inamori Professor of Materials Science and Engineering, Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, Alfred, NY. The Conference Director was Bob Lipetz, Executive Director, GMIC, Westerville, OH. The GPC Advisory Board (AB) included the Program Director, the Conference Director, and several industry representatives. The Board assembled the technical program. Donna Banks of the GMIC coordinated the events and provided support. It started with a full-day plenary session followed by technical sessions.

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Table of Contents

COVER

TITLE PAGE

COPYRIGHT

FOREWORD

PREFACE

ACKNOWLEDGEMENTS

PLENARY

EVOLUTION OF REFRACTORY IN THE GLASS INDUSTRY

ABSTRACT

INTRODUCTION

REFRACTORY EVOLUTION OF THE GLASS CONTACT AREA

REFRACTORY EVOLUTION OF THE MELTER CROWN

REFRACTORY EVOLUTION OF THE MELTER BOTTOM

REFRACTORY EVOLUTION OF THE REGENERATOR

SUMMARY AND LEARNINGS

REFERENCES

HOW BIG IS MY CARBON FOOTPRINT…REVISITED

ABSTRACT

INTRODUCTION

ELECTRICITY GENERATION BY SOURCE

HYDROGEN

CONCLUSION

REFERENCES

GLASS MELTING OF THE FUTURE

ABSTRACT

INTRODUCTON

CONCLUSION

REFERENCES

QUALITY

DIGITAL MEASUREMENT OF CORD STRESSES IN CONTAINER GLASS

ABSTRACT

CORD DETECTION

SAMPLE PREPARATION

MANUAL MEASUREMENT

DIGITAL MEASUREMENT

MEASUREMENT CHALLENGES

PERFORMANCE COMPARISON WITH GAGE R&R ANALYSIS

SAMPLE SELECTION

TEST PLANNING AND EXECUTION

MEASUREMENT RESULTS

MEASUREMENT TIMES

OBSERVATIONS

GAGE R&R ANALYSIS RESULTS

CONCLUSION

THE ELECTRICAL SYSTEMS WILL BECOME THE GAS SKITS OF THE FUTURE

INTRODUCTION

OUR PAST

OUR PRESENT

OUR ELECTRIC FUTURE

HOW CAN SCHNEIDER ELECTRIC CONTRIBUTE?

CONCLUSION

REFERENCES

MELTING AND CONTROL

ALL‐ELECTRIC‐FOREHEARTH DESIGN WITH ZERO EMISSIONS

INTRODUCTION

SPECIALLY DESIGNED PROFILED ROOF BLOCK

RADIANT HEATING ELEMENTS

CENTRE LINE RADIATION COOLING IN REAR ZONES

TARGETED INSULATION

LOW THERMAL MASS INSULATION

IN‐GLASS TEMPERATURE MEASUREMENT

AUTOMATED COOLING DAMPERS, FH DESIGNED READY FOR AUTOMATED CONTROL

EASY ACCESS GUARDING AND LOW MAINTENANCE

ZERO CO

2

EMISSION

ENERGY EFFICIENCY

THE FULLY COMPARTMENTALIZED GLASS FURNACE

INTRODUCTION

P‐10 PROCESS FLOW

10‐1 ROTARY KILN

10‐3 RECEIVER

10‐4 VACUUM COLUMN REFINER

10‐5 TRANSITION

PERSPECTIVE ON P‐10

REFERENCES

5‐YEAR OPERATING EXPERIENCE WITH THE OPTIMELT™ HEAT RECOVERY TECHNOLOGY ON A TABLEWARE FURNACE

ABSTRACT

INTRODUCTION

GENERAL PROJECT EXPERIENCE

GREEN GLASS ISSUE

BACKWALL‐PORT CONNECTION

BURNER PORT ISSUE

REFRACTORY WEAR DOWNCOMER PORT – DAMPER DOOR

REGENERATORS KEEP CLEAN WITH OPTIMELT TECHNOLOGY

OXYGEN SENSOR ISSUE

OPTIMELT IMPACT ON FLUE GAS SYSTEM

ENERGY EFFICIENCY

FURNACE EMISSIONS

CONCLUSION

MODERN CONTROLLER AND SENSOR TECHNOLOGY TO ACHIEVE OPTIMUM ENERGY EFFICIENCY

INTRODUCTION

COMBUSTION CONTROL

GLASS FURNACE SIMULATION

SUPPORT THE DESIGN OF THE FURNACE OF THE FUTURE

SUPPORT DAILY PRODUCTION

GLASS MELT CONTROL

REFERENCES

REFRACTORIES AND RAW MATERIALS

HOW WILL THE ELECTRIFICATION OF GLASS FURNACES IMPACT REFRACTORIES?

ABSTRACT

INTRODUCTION

EFFECT OF ELECTRICAL BOOSTING ON REFRACTORIES

SIDEWALL CORROSION

BOTTOM PAVING CORROSION

ELECTRODE BLOCK CORROSION

CONCLUSION

FUTURE‐PROOFING YOUR DUST COLLECTION SYSTEM BEST PRACTICES IN DUST COLLECTION FOR THE GLASS INDUSTRY

ABSTRACT

INTRODUCTION

STEP 1: UNDERSTAND YOUR DUST

STEP 3: CONTAIN DUST‐PRODUCING PROCESSES

STEP 4: CHOOSE A DUST COLLECTION APPROACH

STEP 5: DUST COLLECTOR SELECTION AND SYSTEM DESIGN

CONSIDERATIONS FOR FUTURE‐PROOF DUST COLLECTION SYSTEM DESIGN

CONCLUSION

REFERENCES

COMBUSTION AND SUSTAINABILITY

PARTIAL OXY-FUEL CONVERSION OF GLASS FOREHEARTHS: A COST-EFFECTIVE WAY TO REDUCE CO2 EMISSIONS BY 50%

ABSTRACT

INTRODUCTION

LINDE’S PARTIAL OXY‐FUEL FOREHEARTH SOLUTION

CFD MODELLING

SINGLE‐ZONE BETA TEST

FULL FOREHEARTH CONVERSION

CONCLUSION

ADVANCES IN GLASS INDUSTRY ENERGY SAVINGS USING HEAT OXYCOMBUSTION

ABSTRACT

INTRODUCTION: ENERGY EFFICIENCY IMPROVEMENT

RADIATIVE HEAT EXCHANGE

CHALLENGES OF IMPLEMENTING HEATOX R

COMPUTATIONAL FLUID DYNAMICS (CFD)

COMPARISON OF EXPERIENCE VS. CFD

CONCLUSIONS ON THE PILOT SYSTEM & NEXT STEPS

REFERENCES

BLUE AND GREEN HYDROGEN PRODUCTION, DISTRIBUTION, AND SUPPLY FOR THE GLASS INDUSTRY AND THE POTENTIAL IMPACT OF HYDROGEN FUEL BLENDING IN GLASS FURNACES

INTRODUCTION

BLUE AND GREEN HYDROGEN FOR THE GLASS INDUSTRY

THE POTENTIAL IMPACT ON HYDROGEN FUEL BLENDING IN GLASS FURNACES

CONCLUSION

REFERENCES

DESIGN AND IMPLEMENTATION OF OPTIFIRE™ FLEX BURNER FOR FOAM REDUCTION IN OXY‐FUEL GLASS FURNACES

ABSTRACT

INTRODUCTION

PRIMARY FOAM

SECONDARY FOAM

EFFECT OF FURNACE ATMOSPHERE ON FOAM STABILITY

STAGED COMBUSTION

FOAM MITIGATION APPROACH WITH FLEX BURNER

BURNER ATTRIBUTES AND INSTALLATION

FOAM MITIGATION TRIAL AT CUSTOMER SITE

FIELD RESULTS

IN FURNACE GAS ANALYSIS DURING FLEX BURNER TRIAL

CURRENT STATUS OF FLEX BURNERS

SUMMARY OF FLEX BURNER TEST RESULTS IN 500 TPD CONTAINER GLASS FURNACE

REFERENCES

END USER LICENSE AGREEMENT

List of Tables

Chapter 4

Table I Gage R&R % Study Var

Table II Bottle Ring Samples Used in the Gage R&R Study

Table III. All Measurement Results

Table IV. Measurement Results Separated by Measuring Device and Operator

Table V Gage R&R Analysis Results

Chapter 8

Table I. Emission under various conditions

Chapter 11

Table 1 Exposure Limits for Respirable Crystalline and Amorphous Silica Dust...

Chapter 12

Table I Maximum flame and refractory temperatures predicted by CFD modelling

Chapter 13

Table I Comparison of Test Data with CFD Results

Chapter 14

Table I Typical H

2

and O

2

supply quantities by glass type and assumed furna...

Chapter 15

Table I Example of Flex Burner Switching Pattern (24 Hour Cycle)

Table II Flex burner periodically switching between Heat and Foam Mode

List of Illustrations

Chapter 1

Figure 1. Historic development of furnace lifetime and specific melter load...

Figure 2. Historic development of crown temperatures in glass furnaces

Figure 3. a‐c. Impressions from tank block production in 1960

Figure 4. a‐c. Jebsen‐Marwedel’s explanation of upward‐drilling

Figure 5. Description of rat hole formation process

Figure 6. Silica insulation concepts

Figure 7. Silica bricks with honeycomb structure

Figure 8. Improved efficiency with honeycomb structure in melter crowns

Figure 9. Installation of lime‐free‐Silica (Stella® GNL) in stressed areas o...

Figure 10. Different bottom concepts. No insulation (a), one layer (b), thre...

Figure 11. Typical bottom concept

Figure 12. Different checker systems

Chapter 2

Figure 1. Carbon Dioxide Emission by Furnace Type (Local).

Figure 2. Carbon Dioxide Emission by Furnace Type (National) based on 2009 e...

Figure 3. USA Electricity Generation by Source. Data from US EIA (2022).

Figure 4. Carbon Dioxide Emissions by Electricity Generation Method. Data fr...

Figure 5. Carbon Dioxide Emission by Furnace Type (National) based on 2020 e...

Figure 6. Carbon Dioxide Emission by Furnace Type and Cullet Level. Source: ...

Figure 7. Global Production of Hydrogen (US Department of Energy, 2020).

Figure 8. Current Hydrogen Cost Ranges and Averages by Technology (US Depart...

Chapter 3

Figure 1. Turning down CO

2

Figure 2. CO

2

reduction is a must to rescue your profit

Figure 3. Biofuel has potential (glass futures)

Figure 4. Successful biofuel trials during 2015‐2016 in Germany

Figure 5. Additional successful biofuel trials in 2021 and 2022

Figure 6. Development of renewable energy in the EU

Figure 7. Wind turbines offshore

Figure 8. Solar panels

Figure 9. Oil pumping station using renewable energy

Figure 10. Renewable electric powerFigure 11. Gas peaked at €178/MWh

Figure 11. Renewable electric power Gas peaked at €178/MWh

Figures 12 and 13. Renewable energy dominates electricity pricing in some ar...

Figure 14. Forecast on hydrogen

Figure 15. Hydrogen costs and distribution

Figure 16. Hydrogen costs and distribution

Figure 17. Energy storage versus amount and time

Figure 18. Transport of hydrogen as methane or ammonia

Figure 19. Electric heat transfer efficiency

Figure 20. Electrification of automobiles

Figure 21. Glass melting furnace technology

Figure 22. Most common end‐fired container glass furnace with a specific ene...

Figure 23. Melting costs 2020, NG 0.25 €/Nm

3

, E 0.10/kWh, CO

2

25 €/Ton

Figure 24. Melting Costs 2022, NG 0.55 €/Nm

3

, E 0.15/kWh, CO

2

85 €/Ton

Figure 25. Expected melting costs 2023, NG 0.6 €/Nm

3

, E 0.05/kWh, CO

2

100 €/...

Figure 26. – Melting costs comparison, hydrogen gas, 0.1 EUR/Nm

3

Figure 27. Examples of large known cold top AEM and Hybrid for container gla...

Figure 28. Different examples of cold top AEM designs

Figure 29. AEM doctor

Figure 30. A detailed batch model is important, using the latest technology ...

Figure 31. Center electrodes creating cross spiral recirculation now with mo...

Figure 32. Furnace of the past (80’s) and future?

Figure 33. Horizontal hot top electric melter (H

2

EM) concept

Chapter 4

Figure 1. Prepared Glass Ring Sample

Figure 2. Polarizing Microscope with Berek Tilting Compensator

Figure 3. StrainScope Cord Tester Apparatus

Figure 4. StrainScope Cord Tester User Interface

Figure 5. Selected Bottle Ring Samples #1 to #8 (from top left to bottom rig...

Figure 6. Mean Measurement Values of the Selected Samples

Figure 7. Average Result Values and Standard Deviations Across Both Measurin...

Figure 8. Average Result Values by Measuring Device

Figure 9. Average Standard Deviations by Measuring Device

Figure 10. Average Result Values for the Polarizing Microscope

Figure 11. Average Result Values for the StrainScope Cord Tester

Figure 12. Average Testing Times

Figure 13. Individual Testing Times

Figure 14. Gage R&R Contributions for the Polarizing Microscope

Figure 15. Gage R&R Contributions for the StrainScope Cord Tester

Chapter 7

Figure 1. P‐10 Process Schematic

Figure 2. Rotary Ablative Melter (from US Patent 4,521,238)

Figure 3. Close Up Schematic of 10‐3, 10‐4, and 10‐5

Chapter 8

Figure 1. OPTIMELT TCR Process

Figure 2. Optimelt implementation table ware furnace l1 leerdamcrisal glass ...

Figure 3. Damper rebuild

Figure 4. A view of bottom generator

Figure 5. Specific Energy Consumption versus Furnace Production

Chapter 9

Figure 1. Flame velocity versus the velocity of the batch piles in a glass f...

Figure 2. Measured CO concentrations versus measured O

2

concentration during...

Figure 3. Schematic view of a laser sensor positioned in the flue gas exhaus...

Figure 4. The cold top furnace experiment in CelSian’s laboratory

Figure 5. Example of a hybrid furnace design (courtesy of Fives Stein).

Figure 6. Modeling and validation of hydrogen combustion

Figure 7. Time transient modeling of a color change and the impact on temper...

Figure 8. Using a detailed furnace simulation to generate a fast and accurat...

Chapter 10

Figure 1. a) shows the modeling of the sidewall corrosion under two differen...

Figure 2. Bottom paving blocks will be influenced by higher bottom temperatu...

Figure 3. Different wear mechanisms that influence the electrode block syste...

Chapter 12

Figure 1. Schematic of common premixed air‐fuel forehearth (left) vs. Linde ...

Figure 2. Theoretical calculation of fuel savings vs. oxygen enrichment

Figure 3. Temperature profile comparison from CFD modelling for a single zon...

Figure 4. Fuel and oxygen nozzle configuration for the distributor section

Figure 5. Oxygen and air/fuel manifolds, partial oxy‐fuel system

Chapter 13

Figure 1. NOx emissions reduction with oxy‐combustion ("ColdOx") and HeatOx...

Figure 2. Energy savings as a function of oxygen and natural gas temperature...

Figure 3a. HeatOx with air as heat transfer fluid

Figure 3b. HeatOx with Radiative Heat Transfer paper, we present the first r...

Figure 4. Flue gas bypass with HeatOx R HX. Perspective view on the left, to...

Figure 5. Installation of HeatOxR): Top right: HX Transport into the plant. ...

Figure 6. HeatOx R heat exchanger model for CFD simulations. Left: overall g...

Figure 7. Qualitative temperature profiles. Left: One side of flue gas enclo...

Chapter 14

Figure 1. Description of Grey, Blue, and Green Hydrogen color classification...

Figure 2. Combustion images of various H

2

blends using the HR

x

burner. Blend...

Figure 3. Oxygen staging allows for control of properties including flame le...

Figure 4. Flame emission spectra measure between 200‐1000 nm with various H

2

Figure 5. Spectral emission measurement of the Hydroxyl (OH) radical using t...

Figure 6. Four thermocouples embedded in furnace breast wall show an increas...

Figure 7. Percent change in NOx emissions levels. Only 6% increase when tran...

Chapter 15

Figure 1. OPTIFIRE™ XD burner showing no signs of buildup

Figure 2. The Flex Burner (right) is seen installed in the commercial trial ...

Figure 3. Outdoor test FLEX burner in Heat and Foam modes at 7 MMBTU/h (~2.1...

Figure 4. The highly startified oxidative and reductive localized layers wer...

Figure 5. The heated fuel port generates soot. The heated oxygen port preven...

Figure 6. Overnight reduction of UVA Green glass foam layer from FLEX burner...

Figure 7. The reflection of the flame is seen the glass surface throughout t...

Figure 8. Water cooled probe and analyzer used to measure glass surface in F...

Figure 9. Furnace in‐situ gas measurement above glass bed in Foam Mode confi...

Figure 10. The metallic section and refractory block were in excellent condi...

Guide

Cover

Table of Contents

Title Page

Copyright

Foreword

Preface

Acknowledgements

Begin Reading

End User License Agreement

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83rd Conference on Glass Problems

Ceramic Transactions, Volume 271

 

A Collection of Papers Presented at the 83rd Conference on Glass Problems

Greater Columbus Convention Center, Columbus, Ohio October 31–November 3, 2022

 

Edited byS. K. Sundaram

 

 

 

 

Copyright © 2023 by The American Ceramic Society. All rights reserved.

Published by John Wiley & Sons, Inc., Hoboken, New Jersey.Published simultaneously in Canada.

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Library of Congress Cataloging-in-Publication Data Applied for:

ISBN: 9781394200276

Cover Design: Wiley

Foreword

The 83rd Conference on Glass Problems (GPC) was organized by the Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, Alfred, NY 14802, and The Glass Manufacturing Industry Council (GMIC), Westerville, OH 43082. The Program Director was S. K. Sundaram, Inamori Professor of Materials Science and Engineering, Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, Alfred, NY 14802. The Conference Director was Bob Lipetz, Executive Director, GMIC, Westerville, OH 43082. The GPC Advisory Board (AB) included the Program Director, the Conference Director, and several industry representatives. The Board assembled the technical program. Donna Banks of the GMIC coordinated the events and provided support. It started with a full‐day plenary session followed by technical sessions. The themes and chairs of four technical sessions were as follows:

QualityChris Tournour, Corning Incorporated, Corning, NYKenneth Bratton, Bucher Emhart Glass, Windsor, CT

Melting & ControlsJim Uhlik, TECO, Toledo, OHShrikar Chakravarti, Linde Inc., Peachtree City, GA

Refractory & Raw MaterialErik Helin, Johns Manville, Windsor, CTEric Dirlam, SSOE Group, Toledo, OH

Combustion & SustainabilityGlenn Neff, Glass Service USA, Inc., Stuart, FLJan Schep – Owens‐Illinois, Inc., Perrysburg, OH

Preface

This volume is a collection of papers presented at the 83rd year of the Glass Problems Conference (GPC) in 2022. The GPC continues the tradition of publishing the papers that goes back to 1934. The manuscripts included in this volume are reproduced as furnished by the presenting authors but were reviewed prior to the presentation and submission by the respective session chairs. These chairs are also the members of the GPC Advisory Board.

As the Program Director of the GPC, I am thankful to all the presenters at the 83nd GPC. This year’s meeting was a winner on a positive trajectory of recovering and approaching pre‐COVID 19 attendance level. We had a total of ~ 425 registered attendees including 10 students from across the country this year.

I truly appreciate all the support from the members of Advisory Board. Their volunteering sprit, generosity, profes‐sionalism, and commitment were critical to the high‐quality technical program at this Conference. I am indebted to the outgoing Conference Director, Mr. Bob Lipetz, Executive Director of GMIC for his excellent unwavering leadership and support. I welcome Mr. Kerry Ward on board as new Conference Director and Executive Director of GMIC. I also appreciate continuing excellent support from Ms. Donna Banks of GMIC in organizing the GPC.

Please note that the American Ceramic Society and I edited and formatted these papers. Neither Alfred University nor GMIC is responsible for the statements and opinions expressed in this volume.

S. K. SundaramAlfred, NYDecember 2022

Acknowledgements

It is my great pleasure to acknowledge the dedicated service, advice, and team spirit of the members of the GPC AB in planning this Conference, inviting key speakers, reviewing technical presentations, chairing technical sessions, and reviewing manuscripts for this publication:

Kenneth Bratton – Bucher Emhart Glass, Windsor, CTJong Han – Owens Corning, Granville, OHShrikar Chakravarti – Linde Inc., Peachtree City, GADaniel Johnson – Libbey Glass, Toledo, OHEric Dirlam – SSOE Group, Toledo, OHDavid Girvan – Vitro Architectural Glass, Cheswick, PAErik Helin – Johns Manville, Littleton, COBob Lipetz – Glass Manufacturing Industry Council, Westerville, OHLarry McCloskey – Anchor Acquisition, LLC, Lancaster, OHGlenn Neff – Glass Service USA, Inc., Stuart, FLAdam Polcyn – Vitro Architectural Glass, Cheswick, PAJan Schep – Owens‐Illinois, Inc., Perrysburg, OHChristopher Tournour – Corning Incorporated, Corning, NYPhillip Tucker – Johns Manville, Littleton, COJames Uhlik – Toledo Engineering Co., Inc., Toledo, OHJustin Wang – Guardian Industries, Auburn Hills, MIKerry Ward – Glass Manufacturing Industry Council, Westerville, OH

I appreciate excellent leadership of Bob Lipetz, GMIC in making the GPC a big success this year. I am excited about an opportunity to work with Kerry Ward in supporting future GPCs. I am thankful to Donna Banks, GMIC for her patience, support, and attention to detail through the whole process.

PLENARY

 

EVOLUTION OF REFRACTORY IN THE GLASS INDUSTRY

Stefan Postrach, Ignacio Ramirez

RHI MagnesitaKranichberggasse 61120 Wien, AT

ABSTRACT

Since the nineteen‐fifties, the performance of glass furnaces has improved significantly. We have seen a significant improvement in furnace life. There has been an increase in output while energy demand for the process has been reduced. Factors like improved furnace design, construction, and refractory lining concepts, including the quality of refractories, have contributed heavily to this development. A very important step was of course the invention of fused cast products in the 1920s. However, it took decades to implement fused cast products in different areas of the glass furnace; for example, to replace traditionally used alumina‐based bonded products in glass contact areas. In addition, several incremental improvements contributed to the evolution process, but hardly any new product line has been invented. Silica, high‐alumina, zircon‐based and basic products still determine the lining concepts in which case huge improvements were achieved regarding quality, quality assurance and by optimizing the combination of different materials. An important precondition for such improvements is a clear understanding of the processes that influence refractory corrosion.

This paper will describe important refractory developments and will lead through the evolution of refractory for glass furnaces. In addition to the most important developments of fused cast products, examples for certain furnace assemblies will be given, e.g., melter bottom, melter crown including the development of the insulation concepts, regenerator checker pack and casing. These examples show nicely that the development was driven by evolution: once a problem was solved, another aspect ‐which was not consequently in the minds before became the problem. Present day trends will also be mentioned, as these trends may give a glance to the future.

As mentioned above, a key aspect that led to the improvements was by clearly understanding the complex conditions in a glass furnace and the influence on refractories. These important lessons that we have learned in the past 70 plus years can help us solve new challenges that come ahead.

INTRODUCTION

The glass production process experienced huge improvements over the last decades, proven by KPIs like furnace lifetime and specific furnace load [1], see Figure 1, but also observable on the quality of glass products. During this evolution the operation conditions changed permanently and heavily. The most important aspect was of course the temperature increase in the glass melting process [2] (Figure 2). Higher furnace temperatures increased corrosion effects and even new and unexpected mechanism became evident.

Figure 1. Historic development of furnace lifetime and specific melter load

Figure 2. Historic development of crown temperatures in glass furnaces

This paper describes how the lining concepts had been changed over the decades and how the refractories contributed to the improvements in glass melting technology. However, it should not be ignored that other factors supported the improvements as well:

Furnace and refractory design

Installation accuracy

Heat‐up processes

Improved raw material quality including cullet

And improved equipment’s, e.g., the combustion technology and level of automation.

Latest push to prolong the furnace lifetime further resulted out of the development of various hot repair techniques in the last ten years. But now let’s focus on the question how refractories could contribute and even influence the development of furnace design. In total there are four general aspects that are of course connected to each other:

Understanding the refractory behavior: like in every other application of refractories it is of upmost importance to understand the operation conditions and the influence on the corrosion mechanism. Academic