Experimental and industrial evaluation of a new fused cast modular checker design for decreasing regenerator plugging

Abstract

The plugging of regenerators of glass furnaces resulting from deposition of condensated gases is an important concern of glassmakers since it always leads to a reduction of the regenerative efficiency and sometimes causes strong corrosion of the refractories. SEPR has been working on technical solutions for regenerator problems for a long time. Special products like ER 5312 RX (β''' alumina, 85 % AI2O3) have been developed to protect the top of the packing and increase regenerator life. To improve fuel savings, type 4, a corrugated surface product, was introduced to the market in 1989. This product has since become the standard solution for cruciform packing. In 1997, to meet glass-maker's requirements, SEPR designed a new packing solution aimed at decreasing regenerator plugging risks. This new solution consists of a combination of two products: type 6 and type 4. Type 6 is designed for large flue sizes (up to 350 mm) and reduces plugging in the sulfate condensation zone. Type 4 is used at the top of the packing to maintain high thermal efficiency. Α complete thermal characterization of the new checker, based on laboratory tests and industrial on-site measurements, and including computer model development and adjustment, was performed. This paper presents the technical benefits of this new solution and the results of both laboratory experiments and industrial experience.