BACKGROUND
In an effort to reduce carbon emissions and contribute to meeting netzero targets, a possible route for decarbonising glass melting furnaces is by using hydrogen as fuel for the combustion process. Switching from natural gas to hydrogen results in a big change of the combustion atmosphere. This is particularly true in oxy-hydrogen combustion atmospheres where the water vapour concentration will rise to very high values. The concentration of chemically aggressive vapour phases like alkali-hydroxides and alkali-borates, evaporating from glass melts, will also increase considerably. These vapours may react with refractory blocks in the glass furnace. Thermodynamic modelling provides a tool to study the chemical interactions involved, including the evaporation of volatile components from the glass melt and the vapour phase corrosion of refractory materials.
ABOUT THE ECONOMISER PROJECT
Through the EconoMISER project, The Henry Royce Institute (Royce) was fundamental in facilitating access to thermochemical simulation software FactSage, via fellow FISC partner, the Materials Processing Institute (MPI). Glass Futures, another FISC partner, provided an expert with knowledge in glass, whilst a senior researcher at MPI was brought onto the project as a thermodynamic modelling expert. Thermodynamic modelling using FactSage software has proven to be a powerful tool in predicting corrosion of refractory materials in glass melting furnaces. With all experimental work being digital, the platform provides a rapid, low cost and green avenue for optimising process conditions.
RESULTS
Thermodynamic modelling calculations were completed for glass melting furnaces with hydrogen combustion atmospheres. The high temperature evaporation from two typical glass melt compositions was studied: a typical soda lime silicate melt and a special borosilicate glass. The refractory types studied were selected in consultation with DSF. The results of these calculations inform guidelines to select suitable refractory types and to optimise furnace operating conditions for refractory suppliers and glass producers, respectively. Results from this project have helped inform how different refractory materials will behave under hydrogen fuel conditions before any expensive physical trials are performed
ABOUT DSF REFRACTORIES & MINERALS LTD
DSF are specialists in refractory production, producing high alumina and special refractories. They are specialist suppliers to the Glass Industry and have a wide range of products used in most heat containment industries including Petrochemical production, Carbon Black, Steel, Lime kilns and many other specialist applications.
Collaborators
Royce was fundamental in facilitating access to thermochemical simulation software FactSage, via fellow FISC partner, the Materials Processing Institute (MPI).
"The calculations succeeded in giving us the quantitative effect of oxy-hydrogen combustion on sodium borate vaporisation from the glass and the effect of this on existing and new lining compositions. We were very happy with the quality and speed of the work from Royce, enabling us to move on the practical testing of these materials."
Trevor Wilson
Area Sales Manager, DSF Refractories & Minerals Ltd
