Sustainability right from the start
Energy savings by using furnace waste gases
Rising energy costs mean production processes in glass production must be made as efficient as possible. One way to save costs is to use the waste gases from the melting process to preheat the batch and cullet. This enables a reduction in the melting energy requirement between 10 and 15 %.
Simultaneously, CO2 emissions can be reduced considerably and the capacity of production increased. A batch preheater can be planned as an integrated element of batch processing, but also as a retrofit later. As a pioneer of this technology, Zippe continues to refine its capabilities to offer you the most advanced systems that are also right for the environment.
The advantages of batch preheating are:
- Reduction of melting costs
- Reduction of emissions (CO2 and NOx)
- Increase in energy efficiency
- Increase in plant productivity
- Aging of the regenerators improves preheating efficiency over time (countervailing effect)
Sustainability right from the start
Energy savings by using furnace waste gases
Rising energy costs mean production processes in glass production must be made as efficient as possible. One way to save costs is to use the waste gases from the melting process to preheat the batch and cullet. This enables a reduction in the melting energy requirement between 10 and 15 %.
Simultaneously, CO2 emissions can be reduced considerably and the capacity of production increased. A batch preheater can be planned as an integrated element of batch processing, but also as a retrofit later. As a pioneer of this technology, Zippe continues to refine its capabilities to offer you the most advanced systems that are also right for the environment.
The advantages of batch preheating are:
- Reduction of melting costs
- Reduction of emissions (CO2 and NOx)
- Increase in energy efficiency
- Increase in plant productivity
- Aging of the regenerators improves preheating efficiency over time (countervailing effect)
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2
3
4
1
Preheater
2
Bucket elevator
3
Furnace silo
4
Batch charger
Zippe has been a pioneer in this technology since the early 1980s and today has the most extensive wealth of experience in the glass industry. Over the years, batch preheating technology has reached a very high level of development. The systems run reliably, are easy to operate, and have no moving parts inside, which contributes to low wear and tear and a long service life. The latest systems, such as the Advanced Batch Preheater (ABP®) can operate practically independently of variables such as the cullet ratio. We are therefore in a position to offer preheaters for mixtures/ batches with low cullet contents.
The facts – savings in concrete numbers:
- 10-15% savings in fossil combustibles/fuels and/or electrical energy
- Increase in furnace tonnages in a similar range through accelerated melting process
Zippe has been a pioneer in this technology since the early 1980s and today has the most extensive wealth of experience in the glass industry. Over the years, batch preheating technology has reached a very high level of development. The systems run reliably, are easy to operate, and have no moving parts inside, which contributes to low wear and tear and a long service life. The latest systems, such as the Advanced Batch Preheater (ABP®) can operate practically independently of variables such as the cullet ratio. We are therefore in a position to offer preheaters for mixtures/ batches with low cullet contents.
The facts – savings in concrete numbers:
- 10-15% savings in fossil combustibles/fuels and/or electrical energy
- Increase in furnace tonnages in a similar range through accelerated melting process
Key:
- Preheater
- Bucket elevator
- Furnace silo
- Batch charger
Zippe Fluidized Bed Dryer
The next generation of preheating for batch and cullet using fluidized bed drying
This innovative solution provides dynamic preheating for batch and cullet and stands out with a unique and highly efficient design that sets a new benchmark. Featuring patent‑pending technology, our system ensures high performance while offering a wide range of benefits.
Technical Features
- Dynamic concept: A completely new approach to preheating, utilizing a specially designed fluidized bed dryer that ensures efficient heat transfer through direct material contact with the hot flue gases from the melting furnace.
- Advanced design with integrated cleaning system: The innovative system floor with an integrated cleaning mechanism ensures optimal preheating while preventing clogging – ideally suited for dust‑laden flue gases from the melting furnace.
- Efficient cyclone separator: Downstream of the preheater, a cyclone separator removes process‑related fine particles from the flue gas and directly recirculates them back into the process – maximizing resource utilization.
- Special screw conveyor: Homogeneous recirculation of fine particles via a specially developed screw conveyor.
Key Benefits
- Dynamic operation: Rapid start‑up and shutdown with short ramp‑up times, providing greater operational flexibility
- Space‑saving design: The compact system requires significantly less space, allowing for flexible integration into existing installations. The innovative design eliminates the need for costly roof penetrations and sealing, enabling simpler installation.
- Cost‑effective solution: Due to the reduced space requirements, significantly lower total weight, and minimal need for modifications to buildings or existing plant components, this preheating technology is more cost‑effective than conventional solutions.
- Focus on sustainability: Reduce your environmental footprint through lower CO₂ and NOₓ emissions, contributing to a greener and more sustainable future.
- Reduced operating costs: The efficient use of preheating technology lowers fuel demand (e.g. natural gas or electrical boosting), resulting in reduced operating costs while increasing overall energy efficiency. Increased furnace performance:
As less time is required to melt raw materials, furnace performance can be optimized, leading to higher production capacity. - Tested and proven: The technology has been successfully tested in a pilot plant in Europe, demonstrating its reliability and efficiency under real operating conditions.
With next‑generation preheating, you can increase efficiency, reduce costs, and make a meaningful contribution to environmental protection – all while staying one step ahead of the competition with state‑of‑the‑art technology.
Zippe Fluidized Bed Dryer
The next generation of preheating for batch and cullet using fluidized bed drying
This innovative solution provides dynamic preheating for batch and cullet and stands out with a unique and highly efficient design that sets a new benchmark. Featuring patent‑pending technology, our system ensures high performance while offering a wide range of benefits.
Technical Features
- Dynamic concept: A completely new approach to preheating, utilizing a specially designed fluidized bed dryer that ensures efficient heat transfer through direct material contact with the hot flue gases from the melting furnace.
- Advanced design with integrated cleaning system: The innovative system floor with an integrated cleaning mechanism ensures optimal preheating while preventing clogging – ideally suited for dust‑laden flue gases from the melting furnace.
- Efficient cyclone separator: Downstream of the preheater, a cyclone separator removes process‑related fine particles from the flue gas and directly recirculates them back into the process – maximizing resource utilization.
- Special screw conveyor: Homogeneous recirculation of fine particles via a specially developed screw conveyor.
Key Benefits
- Dynamic operation: Rapid start‑up and shutdown with short ramp‑up times, providing greater operational flexibility
- Space‑saving design: The compact system requires significantly less space, allowing for flexible integration into existing installations. The innovative design eliminates the need for costly roof penetrations and sealing, enabling simpler installation.
- Cost‑effective solution: Due to the reduced space requirements, significantly lower total weight, and minimal need for modifications to buildings or existing plant components, this preheating technology is more cost‑effective than conventional solutions.
- Focus on sustainability: Reduce your environmental footprint through lower CO₂ and NOₓ emissions, contributing to a greener and more sustainable future.
- Reduced operating costs: The efficient use of preheating technology lowers fuel demand (e.g. natural gas or electrical boosting), resulting in reduced operating costs while increasing overall energy efficiency. Increased furnace performance:
As less time is required to melt raw materials, furnace performance can be optimized, leading to higher production capacity. - Tested and proven: The technology has been successfully tested in a pilot plant in Europe, demonstrating its reliability and efficiency under real operating conditions.
With next‑generation preheating, you can increase efficiency, reduce costs, and make a meaningful contribution to environmental protection – all while staying one step ahead of the competition with state‑of‑the‑art technology.
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