Furnace lifetime

Both glass and furnace manufacturers consult CelSian to optimize design parameters for rebuild projects. Application of new process sensors, improved furnace design, intelligent control strategy and waste gas heat recovery systems support glass manufacturers to achieve ever increasing requirements concerning product output, energy consumption, emission limits and furnace lifetime requirements.

Joost Laven

furnace lifetime

Glass is a 'green' product: made from abundant natural materials, it helps saving energy, and is unlimited recyclable ''

Furnace lifetime & CFD Modelling

Our advanced furnace design and operation system constitutes a combination of the following features, optimized by the application of Computational Fluid Dynamics (CFD) modeling of the glass melting and combustion process in a fuel fired glass furnace:


  • Optimized insulation of the furnace walls, crown and bottom, using CFD modeling to allow high level of insulation without jeopardizing furnace lifetime;
  • Increased combustion chamber and burner port dimensions to create conditions of delayed mixing of fuel and air and still complete combustion. This will result in high energy efficiency (long residence times of combustion gas in combustion space) and decreased NOx formation levels
  • Optimize positions of burner ports, burner and types of burners
  • Apply advanced Model Predictive Control Systems to optimize the combustion conditions, using O2 and CO sensors in the exhaust gas flow and model based control strategies for stabilizing flow patterns and temperatures of the glass melt to operate at optimum energy efficiency and glass quality conditions.
  • An overall on-line energy balance calculation is the base for stabilizing and optimizing the energy supply (boosting and fuel) to the furnace.
  • Application of economic batch & cullet preheater system in combination with adapted doghouse design to recover flue gas energy but without increasing carry-over tendency by charging dry batch into the melting tank. Direct contact between the flue gases and batch will offer the functionality of a gas scrubbing system
  • Only a filtration system for the removal of batch and primary glass furnace dust is required but no DeNOx or scrubbing systems are necessary.

Glass furnace health check

Our well known glass furnace health check comprises a series of on site measurements combined with glass furnace simulation, in-line sensoring and batch melting trials using our HTMOS equipment.

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