Technological Innovations for Heating and Process Control of Glass Melting Furnaces

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STG DeNOx Technology helps industry to meet governmental requirements for NOxreduction as well as CO2 reduction and emission trading. STG DeNOx Technologycombines the primary goal of NOx reduction with energy savings.

STG DeNOx Technology is based on two main principles:A remarkably increased energy transfer from flame to glass and batch decreasesNOx and furnace and flue gas temperatures.Control of combustion air with Lambda Control® reduces and compensates infiltration of excess air which will decrease NOx formation as well as the amount of flue gas.

By the combination of STG DeNOx burners, Process Control Systems usingLambda Control® based on STG Oxygen Sensors as well as an optimized portdesign and flame adjustment, we are able to offer a STG DeNOx technology thatachieves very low NOx target values of 400 – 1,000 mg/Nm3.

Parallel side effects are:Saving energy input, Increase of melting capacity, Improvement of overall technological process control

STG DeNOx Technology is a reasonable and efficient alternative to process-externalDeNOx-methods and can even be combined with significantly smaller sized filterfacilities.

Example: 6-Port Float glass furnace

FLOAT GLASS6 – 8% Energy savings35% NOx-reduction30 t/d increased melting capacity25 K Temperature reduction

S lowers NOx

Dual-injectors for combined usage of gas ando

Energy savings and low e

- A Joint Venture of STG and GLASS SERVICE

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Unlike the measuring value O2

0,96 < � 1,5 ,l excess or missing combustion air.

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DeNOx Technology – Energy savings and NOx reduction

STG Oxygen Sensor

STG DeNOx Gas/Oil Burner

STG Optical Melting Control

STG Air Curtain Baffle

STG DeNOx Technology

Results

STG Process Control System

Port 1-4 low-turbulence DeNOx burners

Initial situation Port 1-4 with STG DeNOx Technology

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Energy saving DeNOx gas and oil burners STG Oxygen Sensors and Lambda Control® Process Control System and Optical Melting Control

DeNOx FreeJet Gas injector

STG Gas injector’s flame design follows precisely the flow characteristics of a freegas jet, resulting in a low turbulence combustion with low flame temperatures andlow tail fire. The unique installation of the injector inside of the furnace wall, burner head flush with the furnace inside, eliminates negative influence of knownburner blocks and results in excellent service characteristics.

With a controlled delay of combustion reaction high temperature peaks of theflame will be avoided and emissivity increases significantly. Self carburization intensifies energy transfer onto glass and batch, which reducesflame and crown temperatures by up to 50 K , lowers NOx formation - and lowerflue gas temperatures reduce flue gas energy losses.Two separate gas inputs allow stageless control of firing parameters as flamelength and combustion speed.

Injector can be easily adapted to different furnace constructions. Taking in accountdifferent air flows and port geometries STG defines the best position to install, inorder to achieve optimum firing performance. There are available eight injector sizes, covering a range from 50-1100 Nm3/h. Complementary STG also provides Dual-injectors for combined usage of gas andoil for underport installation.

Describing the DeNOx Gas injector in short terms: Energy savings and low emissions are ideally combined.

FLAMMATEC® - A Joint Venture of STG and GLASS SERVICE

FLAMMATEC® as a producer of energy efficient, low NOx burners relies on the sameprinciples of low turbulent combustion as originally developed by STG: The resulting low turbulence provides improved emissivity of the gas flame, whichresults in lower flame temperature, lower NOx-emission and lower energy consumption. The FLAMMATEC® Flex Burner will be installed in the traditional bur-ner position, using a sealing plate and injector block. Operating experience of theFLAMMATEC® Flex Burner has shown improvements in energy transfer of low

turbulence gas flames, comparedto other common designs withsealing plate. Two separate gasinputs control the flame characte-ristics and qualify the FLAMMA-TEC® Flex Burner to be used as dualinjector for combined usage of gasand oil for underport installation.

DeNOx gas injector in underport position

DeNOx gas injector

FLAMMATEC® Sideport and Flex Burner

Unlike the measuring value O2

0,96 < � 1,5 ,l excess or missing combustion air.

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DeNOx oil injector in underport position

DeNOx oil injector

Self carburisation

Controlled mixing delay

Low turbulent combustion

Working principle: Low turbulent Gas injector

Improve radiation transfer flame to Glass/Batch

Lower flame temperature by 50 °K

Reduce NOx

Save Energy

Longer service life

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crown temperature

Lower flue gas temperature by 50 °K

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Improved radiation Gas

Cooling

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Port 1-4 with STG DeNOx

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STG Oxygen Sensors and Lambda Control® Process Control System and Optical Melting Control

S lowers NOx

Dual-injectors for combined usage of gas ando

Energy savings and low e

- A Joint Venture of STG and GLASS SERVICE

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STG Zirconium Oxide Oxygen Sensors – Lambda Control®

In-situ measurement of residual Oxygen content in the waste gas flow is thebasis for an energy efficient and NOx reducing operation of glass melting furnaces.Being installed in more than 200 furnaces worldwide, STG Oxygen sensors havebecome an essential tool for combustion analysis and set a new standard.Their longevity and reliability allows it to use O2 signals as the basis for a permanent measurement and sophisticated control algorithms.The more exact and the more reliable the measurement of residual oxygen inthe flue gas, the closer the furnace may be operated to the low stoichiometricoptimum without safety margin of excess air, which wastes energy and causes NOx .A simple ratio control is limited to adjustment of air and fuel without any feedback of the actual results of the combustion. Only STG Lambda Control® allows it to control and to compensate the inputof ingressed air (about 2 – 10% of total air) and thus really decides the efficiency and NOx emission.Process value Lambda will be derived directly from the measuring result of theOxygen sensor. Unlike the measuring value O2%, the calculated value Lambdawill be made available in the technological interesting range 0,96 < � < 1,5 ,linear dependent to excess or missing combustion air.

Using our rent-and-service system for Oxygen sensors, the customer only buyswhat he really needs – the reliable O2% measurement signal – and he leavesinstallation, maintenance and predictive replacements of sensors to experienced STG service personnel.

STG Air Curtain System to Control Combustion Air Flow without regenerator section walls

STG Air Curtain System allows to control combustion air distribution even for furnace constructions without regenerator section walls, by utilizing a controllable compressed air barrier, that forces unwanted excess of preheatedcombustion air to distribute to where it is needed. Through this, Lambda Control® can be used efficiently even without section chambers.

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Air curtain baffle, installed in the port bottom

Distribution of combustion air

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O2 (%)

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Port 6

Port 5

Port 1 – 4

Oxygen probes installed

Signal processing of Oxygen Sensors

Zirconium oxide Oxygen probe

Protection tube

Carrier tube

Integrated thermocouple

Zirconium oxide tube

Reference air

Inner tube with reference airInner electrode

Signal cable to inner electrode

Signal cable to outside electrode

Outside electrode

Zirconium oxide Oxygen probe - The Sensor

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Process Control System and Optical Melting Control

S lowers NOx

Dual-injectors for combined usage of gas ando

Energy savings and low e

- A Joint Venture of STG and GLASS SERVICE

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Unlike the measuring value O2

0,96 < � 1,5 ,l excess or missing combustion air.

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Intelligent solutions for process control for glass melting and industrial furnaces

There is no other European company having more experience in Process Automation of Float line or in fiber glass facilities than STG Cottbus. The reference list of STG includes more than 45 float lines and more than 30fiber glass and container glass lines.Based on many years of cooperation with SIEMENS Automation, and years ofwork on glass and industrial furnaces, STG has the experience to execute complex automation projects in PCS7, Teleperm M DCS systems, or SIMATICPLCs. In addition, STG has expertise with WinCC, WinTM or Intellution FixDmacs and IFix. The scope of STG project capabilities includes CAD design, mounting andtesting of control panels, field installation, industry specific process expertise,and the programming and commissioning of DCS, PLC and Visualisationsystems. Detailed system testing at STG, training of customer’s staff on site or at STG, and even jointly working with customer’s engineers on programming at STG facilities, is a common practice.STG has at its disposal a library of proven advanced process control softwaresolutions especially for glass and industrial furnace applications.

For example:BTR (Fuel-Temperature) control for regenerative furnacesFlexible energy control for gas and oil simultaneously firingLambda Control® – taking control and compensating any ingressed airRedundant solutions with CPUs or backup controllersElectrical power management controlling power limitsProviding long-time Excel data bases to acquire average data per each shiftSpecial reversal program module for flexible handling of error situations,real time recording of reversal actuators, and coordinating control actionswith a user friendly manual operator layer.

By using a) redundant PLCb) backup controllers orc) distributed redundancy STG has designed system architecturesthat provide sophisticated control functions and robust performance forthe rigorous requirements of the Glassindustry. These control systems are specifically designed to avoid any lossesof production in case of breakdowns or restarts of the control system.

OMC – Optical Melting Control

While STG DeNOx Technology remarkably decreases NOx emissions, reducesenergy consumption and furnace crown temperatures, there is available anew reliable reference for stable melting conditions and glass quality. Optical Melting Control (OMC) is an instrument developed for continuousmonitoring and control of the real energy input into the melting zone and it goes beyond what can be done with a glass bath probe (punctual measuring the temperature of the melting glass).The digital analysis of a standard furnace TV camera signal provides batchpattern scum line, exact unmolten batch covered area and gradient of melting speed. Also OMC provides control of flame length, position of temperature maximum and of bubbling spots. Using the OMC video serveras an intelligent transmitter these data will be sent to the PCS7 controlsystem that combines it with energy inputs and temperatures to form a basisfor a technologically oriented control strategy.

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Example: PCS7-System architecture with redundant PLC

OMC-Picture analysis for an endport furnace

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Port 1-4 with STG DeNOx

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References in more than 35 countries worldwide C

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NORTH & CENTRAL AMERICA

CANADARHI Becancour

MEXICOSaint Gobain Vetrotex America

USACardinal Float Menomonie /WICardinal Float Winlock/WAO-I Winston Salem

EUROPE

BELGIUMAGC MolAGC MoustierAGC MomigniesEMGO LommelSaint-Gobain Glass Auvelais

BULGARIANew Glass Novi Pazar

DENMARKArdagh Holmegard

GERMANYArcelor Mittal Stahl EisenhüttenstadtArdagh Bad MünderArdagh DrebkauArdagh LünenBentrupCognis DüsseldorfDESAG GrünenplanenEuroglas HaldenslebenEuroglas Osterweddingenf | glass OsterweddingenGerresheimer EssenGerresheimer LohrGlasmanufaktur Brandenburg TschernitzGlastechnik PiesauGlaswerk Ernstthal

Glaswerk FreitalGrob GemündenGuardian ThalheimHORN PlößbergHydro Alu RackwitzISOVER LübzJasperKristallglas AG ZwieselLamberts WunsiedelLausitzer Glashütte DöbernNachtmann AmbergNarva Brand-ErbisdorfNoelle & van Campe BoffzenO-I AchernO-I BernsdorfO-I HolzmindenO-I RintelnOWA AmorbachPilkington GladbeckPQ WurzenRHI Didier NiederdollendorfSaint Gobain Glass HerzogenrathSaint Gobain Glass KipfenbergSaint Gobain Glass Köln-PorzSaint Gobain Glass MannheimSaint Gobain Glass StolbergSaint Gobain Glass TorgauSaint-Gobain Oberland Bad WurzachSaint-Gobain Oberland EssenSaint-Gobain Oberland NeuburgSaint-Gobain Oberland WirgesSchott JenaSchott MainzSchott MitterteichSORG LohrSpiegelau GmbH Werk FrauenauStölzle Glas WeißwasserThüringer Behälterglas SchleusingenTU FreibergWoltz WertheimYara Rostock

FRANCEAGC Boussois O-I GironcourtO-I Puy Guillaume (Villeurbanne)O-I ReimsO-I Vayres PQ La MotteSaint Gobain Glass Lagnieu CedexSaint-Gobain Glass AnicheSaint-Gobain Glass ChantereineSaint-Gobain GlassSalaise sur Sanne

UNITED KINGDOMAllied Glass LeedsArdagh DoncasterArdagh IrvineArdagh KnottingleyGuardian GooleSaint-Gobain Glass EggboroughStölze KnottingleyTeco Glass

ITALYAGC Cuneo AGC Salerno Ardagh Montorio O-I Aprilia O-I Marsala O-I Origgio O-I San Gemini O-I VEME Stara Genua

CROATIAVetropack Hum na Sutli

LUXEMBOURGGuardian Luxguard IGuardian Luxguard II

THE NETHERLANDSArdagh DongenO-I LeerdamO-I MaastrichtO-I SchiedamPQ WinschotenRoyal Libbey Leerdam

AUSTRIAVetropack KremsmünsterVetropack Pöchlarn

POLANDEuroglas UjazdGuardian CzestochowaGulfiber GliwicePilkington SandoglassSaint Gobain GlassDabrowo Gornicza

PORTUGALBA Sotancro Venda Nova Gallo Vidro Marinha Grande

RUSSIAAGC Float Klin I / IIGuardian RyazanISOVER YegoriewskVeda Pack KingiseppSalavatsteklo Bashkortostan I/ II

SWEDENArdagh Limmared

SWITZERLANDVetropack St. Prex

SPAINBA Vidrio Leon BA Vidros Villa FrancaGuardian LlodioO-I Barcelona (Rovira)O-I Sevilla Saint-Gobain Glass Arboc Vidrala Llodio

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CZECH REPUBLICAGC TepliceO-I DubiO-I Nove Sedlo

UKRAINEVetropack Gostomel

HUNGARYGuardian Hunguard Oroshaza

BELARUSGomel Steklo

AFRICA / MIDDLE EAST

EGYPTEgyptian Glass Company(Guardian)

IRANIran Float SavehKaveh Float SavehKaveh Soda MarragheLiya Glass Qazvin

ISRAELPhoenicia America Israel Flat Glass (Guardian)

SAUDI ARABIAGuardian Gulfguard Al Jubail

SOUTH AFRICAPQ Durban

UNITED ARAB EMIRATES Guardian Ras Al Kaimah

ASIA

CHINALuoyang FloatO-I ShanghaiSamsung ShenzhenShenzhen Float

INDIAAGC RoorkeeHNG BahadurgarhHNG Float Glass HalolHNG Nashik HNG NeemranaHNG PondicherryHNG RishikeshHNG Rishra

JAPANAGC Kashima Hakuyo Glass Fukushima Nihon-Yamamura Harima Toyo Glass Chiba Toyo Glass Shiga

MALAYSIASamsung Seremban

PAKISTANKhawaja Float

SOUTH KOREASamsung GumiSamsung Suwon

THAILANDOcean Glass

AUSTRALIA

O-I Adelaide

ASIA

INDIACeracon Engineers Pvt Ltd. B-1/75, Janak Puri New Delhi - 110058 Phone: +91 11 2559 8468 Fax: +91 11 2552 5397ceracon@vsnl.comMr. Jay Sarin

JAPANCeramic Forum Co., Ltd.First Komoda Bldg. 5 F1-6-6, Taito, Taito-ku, TokyoPhone: +81 3 5812 3351Fax: +81 3 5812 3352kato-iwa@ceramicforum.co.jpMr. Iwao Kato

EUROPE

PORTUGALTecIndeEquipamentos Produtos e Serviços Industriais, Lda. Av. Almirante Gago Coutinho 132/134, Edifício 2, Portela de Sintra 2710 - 418 SintraPhone: +35 1 21 9248020Fax: +35 1 21 9248022info@tecinde.comMr. Paulo de Botton

SPAINTechnalloy S.A.C/Amposta, 14-18 1° 3a08174 Sant Cugat del VallésPhone: +34 93 586 28 10glf@technalloy.esMr. Guillermo Leopold Fernández

NORTH AMERICA Service point USA

STG Cottbus at INP North America, Inc.11390 Old Roswell RoadSuite 126

Alpharetta, GA 30009Phone: +1 678 527 1400Fax: +1 678 527 1410us@inp-e.com

Mr. Rolf KreyMr. Andreas Droege

STG agencies and representatives worldwide

LEGEND

Process Automation

Zirconium Oxide Oxygen Sensors

Gas- /Oil Burners

Reseller

Company, Team and Production in Cottbus –Partner of the Glass Industry since more than 20 years

Introducing STG Company

STG was founded on the 18th of April 1990 by three chemical engineers who hadknown each other since college. By now this innovative and technology-orientedengineering company has more than 50 employees who have already realized solutions for energy savings, NOx reduction, optimized process control systems, sensors and heating for industrial furnaces in more than 35 countries throughoutthe world.

Traditionally STG finds its customers mainly in the glass industry. However, we alsoprovide solutions for ceramic and metallurgic production.

STG production facilities at the »Great Mill Madlow« offer more than 3.000 m² of space for efficient engineering and production; manufacturing of sensors andburners, software development, test and training area for furnace control systems.

STG Combustion Control GmbH & Co KGKiekebuscher Weg 1403050 Cottbus/Germanyphone: +49 (0) 355-5 9020-0fax: +49 (0) 355-5411 24e-mail: stg@stg-cottbus.deweb: www.stg-cottbus.de

STG production facilities since 2003: » Great Mill Madlow« in Cottbus

Dipl.- Ing. Frank Hegewald

Frank Hegewald was one of thethree partners who establishedSTG. He added a lot of his ideas and visions to form STG’s character and face as we know it today.

He died on the 18th of August2003, a week before turningage 55. We will keep him in ourhearts and minds forever andwill do our best to continue hiswork. STG Foundation Partners (from left): Dipl.-Ing. Helmut Heelemann and Dr.-Ing. Peter Hemmann

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Facilities »Great Mill Madlow«

Spreeaue (Pücklerpark, BUGA, Tierpark)

Cottbus

Harnischdorf 8,1 km

Berlin 120 kmDresden 120 km

Kiekebusch(Kibus)

Old Main Office

A 15

Cottbus-Süd

B 97

E 365

Manufacturing of O2 sensors PCS7 test field and training area

Main building production Manufacturing of burners

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