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Modernization of glass melting furnace No 4 for production of glass rovings by direct melting process

Joint-stock company «Polotsk-Steklovolokno» is planning to carry out the reconstruction of glass melting furnace №4 in 2016, and it is interested in finding an investor, who is able to do the whole complex of works flat-to-flat according to the technical requirements. The project cost is estimated to be 5 million U.S. dollars. 
Contact person – Deputy General Director - Chief engineer Bliznev R.P. Tel. of the reception desk +375 214 415551 or tel./fax +375 214 431707. 

Technical assignment for modernization of glass melting furnace No 4 for production of glass rovings by direct melting process. 


Purpose: increase of a productivity from 15 thousand tons /year up to 20 thousand tons/year of roving. 
While designing of a glass melting furnace there should be used up-to-date technical achievements of world technologies in construction of glass melting furnaces for production of rovings, batch preparation, production and transportation of glass rovings. 

Brief description of the existing technology of glass roving production by direct melting technology. 

1.Batch preparation. 

Batch preparation for melting of “Е” glass is made on the existing weighing-mixing equipment. 
The following raw materials are used: 
  • Silica flour 
  • limestone 
  • alumina 
  • colemanite 
  • cullets 
  • fluorspar 
  • sodium sulfate 
Defects: losses of batch components on the belt conveyer (unsealed old-fashioned system). Separation of batch while transportation. 

2. Glass melting furnace. 

Glass melting process is made in a melter of recuperative gas/electric furnace of direct heating. The capacity of a furnace in glass melt is 15 thousand tons per year. As fuel natural gas is used (the price is 331,04 USD per 1000 m3), as an oxidizer air is used at the temperature ≈ 650 оС. There is a system of additional electric boosting with the capacity 500 kWt. Bubbling system is available. Electric power cost is 0,126 USD per kWt/hout. Glass melter area is 32 m2. 
E-glass type composition: 
SiO2 53,5 – 54,5% 
B2O3 8±0,5% 
Al2O3 13,2-14,2% 
CaO 21-22,5% 
MaO 0,8-1,6% 
Fe2O3 not more than 0,4% 
R2O not more than 1,0% 
F2 not more than 0,5% 

3. Glass fiber forming area. 

The existing technological line of fiber forming is in two levels. 
The quantity of spinning positions is 42 pieces. 
Demands in types: 
11 microns (200 tex) -2900 t 
12 microns (168, 360, 480 tex) -700 t 
13 microns (270, 400) –3350 t 
14 microns – (300, 480, 600) - 8100 t 
15 microns (500 tex) – 2700 t 
16 microns (400, 600, 1200)–800 t 
23 microns (2400 tex) – 1450 t 

Special requirements to glass roving: 
  • package weight is 20-25 kg, 
  • limits on linear density: ±5% from nominal value, 
  • diameter of elementary filament ±1 micron from the nominal value. 
Requirements: 
1. Modernization of a batch preparation area in order to eliminate the above listed defects; 
2. Modernization of a melter and determination of its optimum area, its design and feeder design; 
3. Reduction of batch losses while charging of batch; 
4. Usage of energy-saving technology in order to reduce power consumption and heat losses; 
5. Oxygen consumption;
6. Increase of furnace service life up to 7-8 years (existing service life is 5 years); 
7. Effective process of roving production with contents of В2О3 6,5% in glass composition; 
8. New designs of high-performance bushings for production of rovings from 11 to 23 microns; 
9. Air conditioning system in fiber forming area and distribution of air flows in under-bushing zone; 
10. Modernization of recirculated water system for cooling of technological equipment; 
11. Evaluation of the existing electric equipment of fiber forming area, 
12. Modernization of size supply to sizing applicator in order to reduce its consumption (it is planned to use simultaneously 8 types of sizes on a furnace); 
13. Automatic package doffing and automatic transportation of the products; 
14. To provide identification of packages with roving (weighing, marking).
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