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[August 2001]
Superthal Heating Elements Reduce Energy Consumption by 40%
Development of its production techniques followed by close monitoring of energy consumption has enabled leading German glass producer Walther-Glas GmbH (Bad Driburg), in cooperation with heating specialists Kanthal AB, to record a 40% reduction in consumption on its forehearth feeder systems.
Walther-Glas presses mainly domestic and all-purpose glassware for the gift sector and also diffusing screens for automotive headlights. The company operates three production tanks, each with a capacity of between 24 tons and 30 tons per day. The forehearths convey molten glass at temperatures of 1450°C to processing machinery consisting of four sliding tables and 12 circular table presses. Processing temperature is around 1150°C.
In cooperation with Kanthal, Walther-Glas developed a forehearth channel system using Kanthal's Superheat flat panel heating modules to replace a conventional vertical heating system. As a result, the heating area has been reduced by 55% - an inner cross-section of 100mm x 244mm is now sufficient whereas 250mm x 400mm was required previously.
The panels are rated at 5kW and are customised by Kanthal to a specified length and width. Rebuilding of the first new forehearth was completed in only three days, minimising production downtime.
An immediate effect on energy consumption has led to a reduction of 40% - down from 63,000kWh per month to approximately 38,000kWh.
ENDS