Impact of increasing electrical boosting in refractories
Digital simulation and field observations highlight the consequences of increasing electrical boosting rates; glass temperature rises and glass velocity increases. This, by nature, will lead to faster corrosion rates.
Moreover, as the soda contained in the glass diffuses deeply into the refractories during the furnace lifecycle, the electrical resistivity drops. The refractory corrosion resistance declines, accelerating wear due to the higher temperature and convection currents of the glass.
When the glass electrical resistivity gets close to the refractory electrical resistivity, currents can be deviated through the refractory and eventually could lead to the refractory failure.
Consequences could be dramatic for a glass furnace operation:
- Power limitation and pull rate limitation
- Potential glass leaks
- Glass defects
XeBOOST™, a patented AZS material for electrical boosting
Belonging to the AZS refractory family, XeBOOST™ solution is bringing new levels of reliability and safety.
This solution addresses the aforementioned electrical boosting challenges by offering three-times higher electrical resistivity compared to a standard AZS with 40% ZrO2 (ER1711®). This improvement is complemented by a significant increase in corrosion resistance, attributed to its higher Zirconia content. Additionally, its unique chemistry reduces the risk of soda infiltration, making it a highly effective solution for demanding applications.
The superior performance of XeBOOST™ material is providing a cost-effective solution to glass furnace operations by contributing to an increased lifespan in the electrical boosting zone whether it is a bottom or side electrode design.
A global sustainable approach
XeBOOST™ solution enables glassmakers to move toward higher electrification rates, with improved reliability and safety for a longer furnace lifespan, thus helping to decrease a glass makers’ overall Scope 1 emissions.
Every stage of XeBOOST™ refractory manufacturing, from formulation to packaging, maximizes the use of decarbonized energy for the biggest possible reduction on a glass maker's Scope 3 emissions.
Q&A
Does a higher electrification rate require a modification of the bottom paving?
The higher temperature involved by higher electrification rate requires the furnace bottom to be strengthened with the use of specific paving material like ER 2010 RIC or ER 1681 TJ.
Is XeBOOST™ suitable for any type of glass?
XeBOOST™ solution is mainly applicable for sodalime glass and borosilicate glass production. For other types such as Reinforcement glass fiber and textile glass furnaces, Insulation fiberglass, Display glass, SEFPRO provides other types of refractories with high electrical resistivity.
Can XeBOOST™ be used for applications other than electrode blocks?
The high Zirconia content of XeBOOST™ solution and its superior corrosion resistance makes it a good option for any furnace area subject to severe corrosion such as tank side walls, barrier walls, facer blocks, and throat covers.