Oxy-fuel FurnacesCosts & Benefits
|Parent Process: Melting and Refining|
|Energy Savings Potential||
On-site energy savings can be greater than 50 % when small, thermally inefficient furnaces are converted to oxy-fuel firing.
Even for large efficient regenerative furnaces, savings would be between 5 and 20% (Worrell et al., 2008. p.64)
A container glass manufacturer in Germany was able to reduce energy consumption from 5.02 MJ/kg to 3.02 MJ/kg (including energy consumption for oxygen generation) and realized energy savings of 35% by installing an oxy-fuel furnace with preheater (Worrell et al., 2008. p.65).
|CO2 Emission Reduction Potential|
The capital costs of a new oxy-fuel furnace are around 20% lower compared to recuperative furnaces, and 30-40% lower compared to regenerative furnaces. The costs of the on-site oxygen plant are about 10% of the capital costs of the plant. Oxy-fuel furnaces also benefit from reduced costs for flue gas treatment (Worrell et al., 2008. p.64).
However, the necessity to install extra durable refractory material (high duty silica crowns may increase the capital costs by €300 000 to 400 000 and use of fused cast materials may increase the costs by €4–5 million (IPTS/EC, 2013. p. 236). Operation costs will increase.
Oxy-fuel Furnaces Publications
Energy Efficiency Improvement and Cost Saving Opportunities for the Glass Industry - An ENERGY STAR® Guide for Energy and Plant Managers
Prepared primarily with the US Glass Industry, this document provides information about energy efficiency measures applicable to glass manufacturing, including performance and cost benchmarks whenever possible.
Oxy-fuel Furnaces Reference Documents
As a reference of the EU Industrial Emissions Directive (2010/75 EU) this new version provides extensive information on Best Available Techniques (BATs) applicable to European Glass Manufacturing Industry for reducing environmental impact. The document is prepared by the Institute for the Prospective Technological Studies of European Commission's Joint Research Center.