Ammat Glass chose SORG Group to deliver a single source for all its melting and conditioning requirements. The Group is comprised of Nikolaus SORG, EME and SKS offered an unrivalled combination of products and services to deliver a seamless hot end process.

Nikolaus SORG was responsible for designing and engineering a new furnace rebuild. The new furnace had to have a 140m² melting surface and 450tpd melting capacity for flint, green and amber glasses. It incorporates Deep Refiner technology, which increased the residence time of the glass in the furnace to improve the glass quality. ARD regenerators were used to achieve the required regenerator height without high costs for civil work and convert the former double pass regenerators to modern, highly efficient single pass regenerators. Two IRD doghouses were also installed to combat the possible problems caused by batch carry-over into the regenerators. By combining the doghouses with the EME-NEND R2 chargers the system is completely closed, avoiding energy losses and dust around the furnace.

Three SORG 340S+ forehearths were installed supplying three IS 12 section triple gob machines to increase production capacity, with the ability to add a fourth forehearth in the future. Boosting was also used throughout to assist with melting, thermal barrier boosting and throat boosting.

After auditing the batch plant, EME worked out a concept to upgrade the facility. The main goal was to increase the plant's capacity and improve the dosing and weighing accuracies. EME replaced pieces of equipment to enhance accuracy and installed a new high duty pan mixer. The company also supplied a new cullet return system, including a single forked-link chain scraper conveyor for a capacity of 450 tpd. The electric control system was upgraded to a more modern system completely controlled by the PLC. SKS supervised the erection of the steelwork for the furnace rebuild and provided support with the refractory installation, with over 100 workers present on-site at any one time. In addition, SKS guided the heating and commissioning of the furnace.

“The aim of the SORG Group has always been to offer more to glass manufacturers. By working together with a shared belief in quality, performance and support, Nikolaus SORG, EME and SKS were able to demonstrate to Ammat Glass, the power of three in action.” Said Hartmut Jaques, Head of project department. “The SORG Group transformed the hot end process with minimal disruption and will continue to provide Ammat Glass with the support they need to continuously monitor, analyse and improve efficiency throughout the furnace lifecycle.”

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Image: SORG supplied a full hot glass solution for the Ammat Glass furnace rebuild.