CHALLENGE

Based in Dubai, Ammat Glass Industries produces glass bottles and jars for the food and beverage industry and required their furnace and batch house system to be rebuilt.

SORG APPROACH

SORG Group, which is comprised of Nikolaus SORG, EME and SKS, delivered a full turnkey solution. Powered by glass melting and conditioning technologies, SORG Group combined its unique offering of products and services to deliver a seamless hot end process.

Nikolaus SORG designed and engineered a new furnace rebuild, with a 140 m² melting surface and 450 tpd melting capacity for flint, green and amber glasses. The furnace features Deep Refiner® technology to increase the residence time of the glass in the furnace, improving the glass quality. ARD regenerators were used to achieve the required regenerator height and convert the former double pass regenerators to modern, highly efficient single pass regenerators without high costs for civil work. To alleviate possible problems caused by batch carry-over into the regenerators, two IRD doghouses were also installed. By combining the doghouses with the EME-NEND R2 chargers the system is completely closed, avoiding energy losses and dust around the furnace.

To keep pace with Ammat Glass Industries’ requirements three SORG 340S+® forehearths were installed to supply three IS 12 section TG machines, with the ability to add a fourth forehearth in the future. Boosting was also used throughout to assist with melting, thermal barrier boosting and throat boosting.

EME replaced the dosing and weighing equipment of the batch plant and installed a new cullet return system to deliver a capacity increase of ca. 30 %. Meanwhile, SKS supervised the steelwork erection, refractory installation and the overall commissioning of the furnace.

RESULTS

By harnessing the Power of 3, SORG Group were able to offer one solution for hot end processes, from batch and cullet handling to melting technologies and furnace design, to furnace construction and complete lifecycle services.