Energy recovery
The melting process is a very energy-intensive part of the glass manufacturing process, with large quantities of heat energy remaining in the flue gas.
We offer customer-specific solutions for heat recovery. Our portfolio includes batch preheating, cullet de-icing/cullet drying, hot water boilers and power generation using ORC technology.
Energy recovery by Batch Preheater
Today’s Interprojekt batch preheater is the result of more than 30 years of operational experience. Over that time, it has been constantly further developed in close collaboration with our customers. In 2019, the batch preheater was technically revised to bring it up to date with today’s cutting edge technology.
By preheating the raw material with hot flue gas, a significant portion of the thermal energy can be efficiently and directly fed back into the melting process.
There are a number of ways in which this recovered energy can be used:
- It can reduce the amount of natural gas and electricity used for the melting process, which has the additional advantage of improving the CO2 balance and / or
- it can improve the melting performance of the furnace without increasing its size.
In addition, the process and design of the preheater result in the following advantages:
- Through the direct contact of the batch with the flue gas, acidic components such as SOx, HCL and HF are reduced.
- If a batch preheater is retrofitted to an existing furnace, the NOx content can be reduced because of a lower energy level in the combustion process.
Batch Preheater
In our Batch Preheaters the batch is heated by direct and indirect contact with the hot flue gas.
- High efficiency and usually batch temperatures of 300°C.
- Positive impact on the environment by reducing CO2 and NOx emissions.
- Removal of SOx, HCL and HF in the preheater
- Long maintenance-free terms without interruption
- Operating experience since 1987
All information is also available as a PDF download:
englisch: Batch-Preheater.pdf
german: Gemengevorwärmer.pdf
Frozen Cullet system
By recuperators in the exhaust gas system ambient air is heated up and de-icing, drying and heating the cullets in a silo by direct contact.
- Energy savings through drying and culet preheating
- No clumping and clogging on the feeder or batch preheater because of dry cullets.
- Regardless of the season and the weather conditions outside a constant content of moisture and temperature of the cullets is set.
Hot water boiler
We supply heat exchangers for heating domestic water or for district heating use. At higher temperatures and larger amounts of flue gas we offer the possibility of a two-stage arrangement in which two heat exchangers in the raw and clean gas area are installed.
ORC-System
The ORC (Organic Rankine Cycle) is a thermodynamic process in which a low-boiling, organic medium is used as the working medium instead of water. This means that energy can be generated efficiently at temperatures as low as 65°C and low pressures.
ORC systems enable the economical conversion of even small heat sources into electrical energy and are therefore the right solution for generating electricity in the container glass sector.
From a temperature level of over 100°C and a thermal energy in the exhaust gas of > 1.5 MW, we use highly efficient and self-developed turbine-based ORC systems. With these machines, it is possible to use the high-enthalpic heat sources optimally for maximum electrical efficiency and for the generation of high-temperature heat for combined heat and power applications.
We successfully implement the ORC process together with our partner, INTEK GMK.
