How will ER 2010 RIC strengthen your glass furnace bottom?

Date
September 24th, 2023
Description

The specific thermal expansion of ER 2010 RIC reduces glass infiltration in the melter bottom of glass furnaces.

 

Why joints in the melter bottom are more critical than ever?

Melting clear glass (typically below 400ppm of iron) or implementing high electric boosting in any type of glass furnace significantly impacts the performance of the melter bottom:

  • First, the refractory corrosion speed increases drastically with temperature. Corrosion law typically shows a doubling of corrosion volume for every 50°C in temperature increase due to the direct impact of the use of electric boosting or due to the high light transmittance in the case of clear glass production.
  • Then the joints between each refractory tile become more critical than ever as the lower glass viscosity, coupled with the higher convection flow, increase the glass infiltration.
     

The consequences are:

  • a much faster corrosion of the tile (upward drilling)
  • an increase of glass defects such as cords and stones
  • and a higher potential blistering in oxidized clear glass production as the low iron content reduces the oxygen solubility and makes blisters more difficult to remove

ER 2010 RIC refractory solution from SEFPRO

By modifying the thermal expansion of the Zirconia crystal in ER 2010 RIC, the joints are completely closed during the heating up phase before reaching the final operating bottom temperature.

Compared to any other AZS material, the Zirconia crystallographic change of ER 2010 RIC occurs at a lower temperature allowing the expansion to reach it maximum as soon as the temperature reaches 1,300°C.

Image
ER 2010 RIC SEFPRO

 

This unique property allows to better close every single joint and to get the full benefit of the tight joint machining. Providing tight and closed joints at the end of the heat up is the most secure way to reduce possible glass infiltration that could lead to premature corrosion and eventually to a bottom glass leakage.

In addition, by ER 2010 RIC having a lower redox reaction in contact with low-iron oxidized glass, it is reducing the oxygen blistering and reducing potential glass defects.

 

Typical bottom paving layouts with ER2010RIC

These specific properties make ER 2010 RIC the most suitable choice for glass contact paving tiles. It could either be used as the top layer in the multi-layer design or as a complete single thick layer for the bottom.

The choice between each layout option, depends on parameters such as bottom operating temperature, type of glass, lifetime, melting area… 

Whatever the option, tight joint (TJ) quality is always necessary, together with the use of the appropriate ERSOL SL or ERSOL MAX FLOW monolithic safety layer.

 

Q&A

Where is ER 2010 RIC refractory paving solution used in the case of a double-layer paving?

ER 2010 RIC dalle TJ is typically used on the very top first layer in contact with hot glass. However, a detailed study is required based on bottom temperature profile and temperature evolution throughout the campaign to determine the most suitable position depending on operating parameters. SEFPRO provides thermal calculations and corrosion simulations to help you select the most appropriate solution.

What is the minimum recommended bottom thickness for sodalime glass furnaces?

For sodalime glass furnaces, operating with either high boosting or producing clear glass, the fused cast bottom thickness could reach 200mm to 300mm thick. Corrosion simulation helps to determine the suitable thickness ensuring a safe operation through the entire campaign based on specific operating conditions.

Is a thin mortar layer between the two AZS bottom layers required?

The use of a thin ERSOL® 06 layer between two AZS bottom layer is an option to allow independent expansion of each layer during heating up. It also helps to reduce gaps between tiles, which in turn helps to prevent the upward drilling phenomenon. Options without the use of any cement are also technically possible but require a tighter machining tolerance and high-quality assembly during on-site installation.