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SOLUTIONS FOR THE GLASS INDUSTRY

FOREHEARTHS & DISTRIBUTORS

COMBUSTION SYSTEM

GENERAL DESCRIPTION

An energy efficient forehearth and dis- The combustion system satisfies the demands of
tributor combustion system is essential for todays glass industry:
consistent quality production in the glass • Correct combustion ratio in the full range of
industry. flow (3 - 50 mbar manifold pressure)
Good control is essential, particularly in • Linear flow valve control characteristic
the case of special or coloured glasses (e.g. • Stable ratio condition during burner pressure
green, amber) where a stable redox condi- fluctuations
tion in the forehearth superstructure is es- • Stable ratio conditions after a burner nozzle
sential for good quality production. change or cleaning
• Easy and precise manual setting of the gas/air
The forehearth and distributor combustion
ratio for each zone
system developed by Glass Service is the re-
• Wide range of flows and sizes (from DN25 to
sult of 22 years of experience supplying to
DN100)
the glass industry.
The system used is the premix gas/air type
and can be used with natural gas or LPG.
 GADP COMBUSTION SYSTEM
The GADP combustion system is based on the The GADP technology is recommended for use
constant ratio between the DP (differential in medium and high burner flow applications. In
pressure) at the air orifice plate and the gas reg- the case of high flows, a butterfly air valve can
ulation valve. also be use.

The GADP is not influenced by burner pressure The manifold pressure available using GADP is
fluctuations or by dirty or blocked burner noz- from 6 to 50 mbar and Glass Service is able to
zles. supply burners system for both low and high
pressure applications.
AIR & GAS
premixed

ΔPa / ΔPg = constant

GAS

AIR

Special glass
Table ware
Colouring forehearth
High ratio stability even when burners are dirty

p.3
or blocked
 STANDARD MIXER-ZERO GOVERNOR (ZGT)

The mixer Venturi and zero governor has been The Glass Service solution increase the system
the common standard in the glass industry for performance and the stability of the gas/air ra-
many years and is used in all glass types includ- tio.
ing tableware, containers and special glasses.
Glass Service use a specially designed air valve
That system is based on the constant gas/ air ra- that can be adjusted to give the required max-
tio at the burner. imum flow using a manually adjusted curtain.
The max air flow can be set zone by zone during
Glass Service has developed a new ZGT combus-
installation to set the servomotor valve to the
tion system based on the traditional system but
max value (100% opening).
with a number of changes technically that im-
The full stroke of the servomotor and valve in-
prove the quality and performance of the com-
creases the loop control stability.
bustion system.

AIR & GAS

premixed

Pa/Pg = constant
Zero governor

Venturi
mixer

Pressure tapping

GAS
Air regulation valve

Actuator

AIR

p.4
 The zero governor pressure tapping upstream low and high pressure burner systems.
of the Venturi mixer increases the gas/air ra-
Because of the stability across the full range and
tio range and reduces the risk of gas leakage
in particular at low pressure and low flow, this
should the zero governor be damaged.
system is highly recommended for use in the
The pressure range using ZGT is from 3 to 50 container industry.
mbar and Glass Service is able to supply both

Linear air valve

Manual max air valve flow setting
High loop control stability
High ratio stable on full operating range
Pressure tapping upstream the mixer
Ratio independent control single zone
Recommended for container industries
p.5
 OMN COMBUSTION SYSTEM
Glass Service introduce a new concept of com- Another new innovation is the use of a double
bustion system utilising the new OMN device. stage zero governor.
This increases the ratio stability in the full range
The system uses a new concept of combustion
and in real time.
ratio control.
• High ratio stability over the full operating
It comprises an air orifice plate and a double
range
stage zero governor.
• The ratio is stable and no adjustments are re-
The pressure tapping for the zero governor quired
is taken upstream of the orifice plate flange • The pressure tapping is upstream of the mixer
chamber. In this chamber there is an over pres- • Independent ratio control for each zone
sure which causes a flow restriction. • Ability to operate over a wide range of ratios
• High precision gas regulating needle valve
The gas input is in the orifice plate chamber
• Each air orifice plate and gas needle valve de-
downstream of the orifice plate and is regulat-
signed for each specific combustion zone to
ed by a high precision gas needle valve.
give improved fuel efficiency
The size of orifice plate and needle valve are
designed specifically for each combustion zone.

AIR & GAS

premixed
OMN system

Pa/Pg = constant

Air regulation valve

GAS Actuator

AIR

p.6
 NEW AIR & GAS
premixed
Needle valve
Double stage
zero governor

OMN
device

GAS
Pressure tapping

AIR

The pressure range availa-

ble using OMN is from 3 to
50 mbar and Glass Service is
able to supply low and high
pressure burner systems.

Because of the stability

across the full range and in
particular at low pressure
High ratio stability on full range and low flow, this system is highly recommend-
ed for use in the container industry.
High ratio stability in time
The OMN system ensures the best performance
Recommend for high performance Foreheart
of gas/air ratio stability over the full range of
in container industries flows without the need for adjustment over
Recommend for high performance Foreheart time.

in container industries (green and amber)

Air orifice and gas needie size tailor made
on specific combustustion zone flow
p.7
 CONSTRUCTION DETAILS

The forehearth & distributor combustion skid Glass Service can also supply all of the combus-
deigned by Glass Service are compact and easy tion air fans skid mounted, with invertor drive
to instal. for pressure stability, or direct drive.
Glass Service can also supply the gas governor
The combustion system is preassembled on the
redundancy skid.
skid ready for installation, complete with all up
to date equipment necessary for the best per-
formance.

For each zone the required technology is in-

stalled (ZGT; GADP; OMN).
Other equipment are also installed for best per-
formance.
• Pressure indicator for each zone
• Pressure transmitter for each zone
• Explosion relief valve for each zone
• Gas flow meter for each FH or Distributor
• Mix test analysis connection for each zone
• Air pressure switch
• Gas pressure switch
p.8 • Skid cabling and local junction box
 BURNERS & MANIFOLD

Glass Service developed the foreheart and dis-

tributor burner technology along with the nec-
essary manifolds and mountings for the fore-
hearth casing.

The burners are totally sealed to the refracto-

ries.

The burner nozzle are available in several sizes

as standard production, with different nozzle
diameter available on request.
The burners are manufactured in special high
1/4 inches 6,3 mm
temperature resistant steel.
3/8 inches 9,5 mm
9/32 inches 7,1 mm The burners are supplied complete with man-
5/16 inches 7,9 mm ifolds and he brackets that allow 3 directional
movement for better installation and adjust-
ment after heat-up.

Each manifold is supplied with long flexible

connection and manual shut off valve for burn-
er maintenance.

p.9
 STANDARD REQUIREMENTS

The Glass Service combustion skids are design and built according the latest European standards

• EN 746-2

• EN 15001

• ATEX zone II if required

Or GOST standard for Russian market

The equipment design and the materials used in construction are in accordance with EU standards
and best practice.

• Certified valves
• Certified gas pipework
• Certified gas fittings
• Certified welding and X-ray welding control for gas pipework
• Powder coating of pipework
• Certified gas sealing
• Certified leakage testing

p.10
 CUSTOMERS WORLD WIDE

GCS-17-01-E
turn key project SCADA and DCS
batch plants cooling systems
furnaces: robotics
recuperative gathering - 4 or 5 axis
regenerative services:
gas fired installation and supervision
oil fired commissioning
oxy-fuel fired training
mixed fuel preheating
electric technology transfer
forehearths: assistance
colouring forehearths laboratory and analysis
combustion systems refractory consulting
day tanks project financing
mini melters
boosters
bubblers
metallic recuperators
batch chargers
stirring machines
GLASS SERVICE s.r.l.
glass level controls
via Cascina Lari 56028 San Miniato (PI) ITALY
frit dosing and transport tel. +39 0571 4442
control cabinets www.glassservice.it