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Mathematical Modelling of Regenerators

The glass melting process involves large amounts of energy at relatively high process temperatures. In order to use this energy as efficiently as possible, regenerators are used for heat recovery. With modern regenerators, 50 to 75 % of the enthalpy contained in the hot exhaust gases can be returned to the system, i.e. it can be saved. On the other hand, the cost of the high-quality heat reservoir material account for a considerable part of the entire capital expenditure of a plant so that an optimal design of the regenerators is important for economical operation.

Therefore, HVG developed a computational program for the simulation of the heat engineering of a glass tank regenerator. This simulation program can calculate not only the heat and gas flows with the corresponding temperatures in the regenerator can be calculated, but also the combustion processes and the heat exchange in the superstructure dependent on the throughput, the amount of fuel, the cullet content, etc.

Based on a reference state preferably safeguarded by operational experience, the calculation scheme is capable of calculating different variants of the regenerator or the operating conditions in order to determine the resultant changes in energy consumption as well as temperatures and heat flows, respectively.

In the software package, a module is contained for the modelling of ageing processes (deposit of sodium sulphate in particular areas of the regenerator). This module was designed by TNO, Eindhoven.

The data for the calculation are gathered by HVG via a questionnaire on the regenerator. Alternatively, a licence of the program can be acquired.