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Glass Melting Furnace/Melting Furnace/Melting Furnace Is Used to Melt Glass1
Laboratory InstrumentsGlass FurnaceMelting Furnace
Shanghai Anttrans Technology Co., Ltd
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Product Description Product Description1. The glass melting furnace is a specialized high-temperature energy-saving vertical resistance furnace designed for the glass industry to melt glass. It can also be used in laboratories within the ceramic, glass, and enamel industries for preparing frits, low-temperature glass fluxes, enamel glazes, and binders. The main operational process involves placing a crucible (specifically for the glass industry) inside the furnace, then pouring the prepared glass frit directly into the crucible from above. After applying electric current for heating, when the temperature rises above 1200oC, the glass frit melts into a liquid state. A specialized crucible hook is used to open the flow hole at the bottom of the crucible, allowing the molten glass frit to automatically flow into a container below.2.Working Principle The furnace operates primarily based on the resistive heating effect of heating elements or heat generated from fuel combustion. When an electric current passes through the heating elements, heat is generated internally and transferred to the raw materials through thermal conduction and radiation, causing them to melt. In gas-fired melting furnaces, heat is generated through the combustion of gas to heat the raw materials. The temperature control system regulates the current flow or fuel supply to control the furnace temperature, achieving precise control over the raw material melting process.3.Structural Components(1.)Furnace Body: Typically adopts a double-shell structure, with an outer metal shell and an inner layer made of high-temperature-resistant and thermally insulating materials such as alumina polycrystalline fiber, reducing heat loss and lowering the surface temperature of the furnace.(2.)Heating Elements: Electric melting furnaces commonly use silicon carbide rods or molybdenum disilicide rods as heating elements, vertically installed around or at the bottom of the crucible. Gas-fired melting furnaces are equipped with burners to generate heat through gas combustion.(3.)Temperature Control System: Generally employs intelligent temperature controllers, such as Taiwan's intelligent fully automatic temperature controller, featuring a dual-line LED display panel for programmable PID control, high temperature control accuracy, and equipped with deviation and over-temperature alarms, as well as power-off protection functions.(4.)Crucible: Used to hold glass raw materials, commonly made of high-purity zirconium quartz, quartz ceramic, or mullite, with characteristics of high-temperature resistance and resistance to glass liquid erosion.FeaturesTechnical Performance: High-Temperature Stability + Precise Controllability, Ensuring Melting Quality Glass melting involves stages such as "raw material preheating → melting → refining → homogenization," requiring extremely high demands on temperature, atmosphere, and fluidity. Therefore, the equipment exhibits three core technical features: High- Temperature Resistance and Thermal Stability The core areas of the furnace body (such as the melting pool and refining section) need to withstand long-term high temperatures of 1500-1600oC (varying by glass type, e.g., optical glass requires higher temperatures). The inner walls are often made of high-purity alumina or fused zirconia corundum to resist glass liquid erosion and prevent impurity precipitation. Simultaneously, the furnace body structure (such as double-shell design and thermal insulation fiber layer) reduces heat loss, with the outer layer temperature typically controlled between 50-80oC, ensuring internal high-temperature stability and lowering energy consumption.Precise Temperature and Atmosphere Control The temperature control system adopts PID programmable control (with some high-end furnaces equipped with AI adaptive adjustment), achieving temperature control accuracy of up to ±1oC. It can precisely adjust the temperature in various zones according to the raw material melting curve (e.g., high-temperature melting in the melting pool and constant-temperature bubble removal in the refining section). Some furnace models (e.g., for producing low-iron glass or colored glass) require controlling the furnace atmosphere (oxidizing/reducing atmosphere) by adjusting the air-fuel ratio or introducing inert gases to prevent glass oxidation discoloration or compositional changes, ensuring product color and purity. (3) Effective Glass Liquid Homogenization Through furnace interior structural design (such as setting baffles and stirring devices) or utilizing thermal convection, the high-temperature glass liquid is thoroughly mixed, reducing defects such as compositional inhomogeneity, bubbles, and stones. For example, tank furnaces may adopt a "deep melting pool + shallow refining pool" structure, combined with optimized glass liquid flow paths to enhance homogenization efficiency.2.Production Adaptability: Flexible Response to Different Scenarios, Balancing Output and Variety Glass melting furnaces need to adapt to different glass types (such as architectural glass, optical glass, and specialty glass) and production scales, demonstrating significant flexibility in production adaptability: (1) Output Adaptation: From "Small-Batch Customization" to "Large- Scale Mass Production"Crucible Furnaces: With small single-furnace capacities (usually tens to hundreds of kilograms), they are suitable for small-batch, multi-variety production (such as artistic glass and laboratory specialty glass), allowing rapid raw material switching and avoiding cross-contamination of different glass compositions.Tank Furnaces: With large melting pool capacities (up to hundreds to thousands of tons), they adopt continuous production, with daily outputs ranging from tens to thousands of tons, suitable for large-scale standardized products (such as architectural float glass and photovoltaic glass), offering high production efficiency and low unit energy consumption. (2) Glass Type Adaptation: Customized Structural Design Different glass types have varying requirements for the equipment, and the furnace body can be optimally designed accordingly:Producing Optical Glass/Electronic Glass: Requires higher purity, with low-impurity refractory materials inside the furnace (such as low silicon and low alkali) and the addition of fine stirring devices to avoid bubbles and compositional fluctuations.Producing Photovoltaic Glass: Requires low iron content, with strict control over iron oxide introduction inside the furnace and a larger melting pool area to ensure thin and uniform glass liquid.Electric Melting Furnaces (Electric Heating Type): Without dust or smoke generated from fuel combustion, they are suitable for scenarios requiring extremely high purity (such as pharmaceutical glass and fiber optic preforms) and offer more precise temperature regulation.3.Operational Management : Low Energy Consumption + Easy Maintenance, Reducing Production Costs Glass production is a high-energy-consuming industry, with the melting process accounting for 60%-70% of the total energy consumption. Therefore, the equipment emphasizes "energy conservation" and "easy maintenance" in operational management: (1) Outstanding Energy EfficiencyHeating Method Optimization: Electric melting furnaces utilize electrical energy to directly heat the glass liquid (through electrodes inserted into the glass liquid for conductive heating), achieving thermal efficiency of 70%-80% (flame furnaces typically have thermal efficiency of 30%-50%). Flame furnaces reduce energy consumption through waste heat recovery devices (such as preheating combustion air and generating steam for power generation), with some advanced furnace models achieving waste heat recovery rates exceeding 50%.Thermal Insulation Design: The furnace body adopts lightweight thermal insulation fibers (such as ceramic fiber blankets) instead of traditional heavy refractory bricks, reducing heat loss and lowering the furnace body weight while accelerating the heating rate (shortening the time from room temperature to 1600oC by 20%-30%). (2) Easy Operation and MaintenanceHigh Automation Level: Most furnace models are equipped with PLC control systems, enabling automated operation of feeding, heating, temperature control, and discharging, reducing manual intervention and operational errors.Easy Maintenance Design: Key components (such as heating elements, crucibles, and refractory bricks) are modularly installed for easy replacement. Simultaneously, temperature, pressure, and liquid level sensors are equipped to monitor equipment status in real-time and provide early fault warnings (such as refractory brick wear and electrode aging ), reducing downtime.Environmental Protection and Safety: Low Pollution + High Protection, Complying with Industry StandardsWith increasingly stringent environmental requirements, modern glass melting furnaces are designed with more comprehensive environmental protection and safety features: (1)Low Pollution Emissions Flame furnaces are equipped with efficient flue gas treatment systems (such as desulfurization, denitrification, and dust removal devices), controlling nitrogen oxide (NOx) and sulfur dioxide (SO2) emission concentrations below national standards (e.g., NOx ≤ 100mg/m3). Electric melting furnaces generate no fuel combustion waste gases, only producing a small amount of raw material volatiles, which can meet standards through simple tail gas collection and treatment, resulting in far lower environmental pressure than flame furnaces. (2) Comprehensive Safety Protection The furnace body is equipped with over-temperature alarms, power-off protection, and pressure safety valves. In case of abnormal furnace temperatures, gas leaks, or excessive pressure, the heat source/fuel can be automatically cut off to prevent explosions and high-temperature splashes. The operation area is equipped with high-temperature-resistant guardrails and emergency cooling systems, and the furnace body is isolated from the control system to ensure operator safety.Product ParametersProduct NameMelting FurnaceDesign Temperature1700oCFurnace Chamber SizeΦ250 * Height 250Discharging Power15KW (High Frequency)Heating ElementU-type Molybdenum Disilicide RodThermocoupleType B (1800oC)Temperature Control Accuracy±1oCHeating Rate≤20oC/minDetailed Photos
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