MELTING

FURNACE
COMBUSTION BURNERS REGENERATIVE & RECUPERATIVE FURNACE
WASTE DUCT EQUIPMENT BATCH CHARGERS CONTROL AND SUPER
GAS AND OIL CONTROL STATIONS GAS BURNERS FOR REGENE
DRAUGHT REGULATING VALVE BURNER FOR REGENERATIVE FURNACE
BUBBLER BOOSTER SYSTEM BUBBLER
TANK AIR COOLING STATION
GLASS LEVEL EAGLE
BURNERS WASTE GAS SHUT-OFF VALVE
THROAT BOOSTER
COMBUSTIONEQUIPMENT SECTIO
DELIVERY SYSTEMS WORKING-END PLANT UTILITIES

Excellence. Your Industrial Partner in Glass

FURNACES | FOREHEARTHS | IS MACHINES
QUALITY IS NEVER AN ACCIDENT.
BDF INDUSTRIES, SINCE 1906.
 PRODUCT LINES

FURNACES FOREHEARTHS IS MACHINES AUTOMATION ENERGY SERVICE

Thanks to our wealth of experience In order to work the glass gob better The historical core business of BDF Being able to integrate highly- Glass Plant is a highly energy-consuming From the Furnaces to the IS Machines
gained over the years, the Furnaces and create a perfect bottle, you need Industries, in which regard we have over sophisticated process systems such as and polluting industry, in which enormous passing through Working End and
Division of BDF Industries is able to excellent glass conditioning. The Division 60 years of experience in the hollow hollow glass from the Batch house to amounts of energy are wasted and Forehearths, in a single strategic Partner:
engineer hollow glass melting furnaces of BDF Industries dedicated to the glass world. the annealing lehr is not for everyone. thrown away, especially in the form of for BDF Industries, the Customer
using the most modern techniques and Working Ends and Forehearths is able Through our elevated know-how gained BDF Industries, thanks to the vertical heat and fine dust. satisfaction is always its goal from
technologies available on the market, to offer and install complete systems in the engineering and manufactoring of integration developed over the years, Thanks to the synergy of highly- the phase of offer issuing up to after
simultaneously combining efficiency in which are able to fully satisfy the requests machinery, the company’s IS Machines has managed to specialise in the specialised teams between the sales. This is why it makes use of a
consumption, durability and quality of of our customers. Division currently produces the most engineering of all the automation of the Furnaces and Automation Divisions, strong and cohesive Service structure
glass requested by our Customers. The Forehearths of the GTFS and complete range of solutions, from hot end. The R&D Department, working BDF Industries is able to supply with more than 80 people at the service
The studies and research developed over GTHP series can be equipped with machines with pneumatic handling to in close contact with the Furnaces, specific products for the protection of Customers all over the world,
recent years combined with cutting-edge ad hoc systems guaranteeing a servo-assisted handling machines, with Forehearths and IS Machines Divisions, of the environment and for energy capable of helping the Customer in daily
design tools are today able to guarantee thermal homogeneity in the different angular or parallel mould openings/ is aimed at constant research into the recovery, using the most innovative operations and able to find the most
stability and flexibility in the Furnaces configurations in the conditioning closures, combined with all the variable most advanced control and supervision solutions and products in compliance effective solutions to solve problems
management, for all types of production zone which is as close to 100% as equipment and accessories in order to systems to best meet the demands of its with the fundamental production and increase performance. Not only
taking in consideration the strictly possible, possibly installing Stirrer and/ better intercept the requests of the end customers. and consumption requirements of after-sales service, among the activities
environmental regulations of reduction of or Booster systems where required or customer. glassworks, always paying attention that the Service Division performs all over
NOx, SOx and all waste pollution related. recommended. The internal R&D Department is focused to the fundamental parameters to be the world every day, there are also those
BDF Industries is able to create a every day on finding the best solutions considered without affecting the daily of supervision, auditing, installation,
strategic connection between Furnaces- to be applied in IS Machines which not tasks of the operators of the Furnaces. overhauling of machines and melting
Forehearths-IS Machines: the Furnaces only allow the production of perfect glass minor repair to guarantee complete
technology developed for the Forehearths containers, but also a high-performance coverage of the hot part of the glassware:
in fact allows you to bring the glass to the production, reducing costs: flexibility, from the Furnaces to the Forehearths
correct temperature from the Furnaces to reliability and production efficiency have to IS Machines with highly-qualified
the IS Machines. always been the fundamental advantages technicians specialised in the individual
Our advanced knowledge of the which BDF Industries makes available to areas of competence.
machines allows us to associate the its customers all over the world.
most suitable Forehearth according to A distinctive feature is the fully Made
the IS Machine. in Italy production: the machines are
fully designed, manufactured and
assembled in Italy, where there is an
important knowledge of the production
process.

4 | MELTING FURNACE MELTING FURNACE | 5

PRODUCT LINES

MELTING
FURNACE
ENERGY
CONDITIONING ON GLASS
WORKING END
FOREHEARTH

FORMING
FORMING DELIVERY
IS MACHINE

WARE
HANDLING

INDEX | GLASS
MELTING FURNACE
REGENERATIVE & RECUPERATIVE FURNACE PAG 10
FIRING SYSTEM PAG 12
BURNERS PAG 13
EQUIPMENT FOR REGENERATIVE FURNACE EXHAUST DUCT PAG 15
FURNACE EQUIPMENT PAG 18
BATCH CHARGERS PAG 20
LEVEL MEASUREMENT SYSTEMS PAG 24
FURNACE CONTROL AND SCADA PAG 26
REGENERATIVE & RECUPERATIVE
FURNACE

MELTING
perfect knowledge of production
FURNACE
Our long experience in the field and The expertise acquired throughout
the years and the big number of fully-
Thanks to our internal division, the
BDF Industries share not only the
processes allow our engineers to functioning plants installed allow technological know-how and a big
professionally cope with all projects, BDF Industries to offer new and push for innovation, but also expertise,
resulting in the optimization of the innovative solutions when it comes to enthusiasm and a deep sense of
preparation and presentation times implementing plant engineering projects. belonging that makes it possible to
needed for the technical/commercial Not only does our Group supply turn-key understand and satisfy the requirements
proposal. plant solutions, but our commitment and of the Hollow Glass Maker.
responsibility is from the beginning to
the stage we are there to start the plant
ourselves.
 REGENERATIVE & RECUPERATIVE
FURNACE

Vista

REGENERATIVE RECUPERATIVE
In Regenerative Furnace, air preheating In Recuperative Furnace, air preheating is The system is composed with:
REGENERATIVE & RECUPERATIVE is achieved by two regenerators cham- achieved by the heat exchange from the • Tubes in stainless steel.

FURNACE bers. The chambers are filled with layers

of refractory checkers, arranged in offset
exhaust to the combustion air by means
of metal recuperator.
• Casing of the tube cage made of car-
bon steel, internally lined with ceramic
position. fibre+rock wool.
• Low furnace energy consumption The exhaust pass through a metal heat • Double shell recuperator internal plate
• High furnace pull exchanger and transmit the heat to the
The exhaust from the furnace and the made of stainless steel.
• Low NOx emissions combustion air.
cold combustion air are passed, alter- • Air intermediate duct made of carbon
• Best glass quality To increase the air temperature, the
nately, through one and other chambers steel.
• Best furnace operation to assure minimum operating costs at fixed glass quality recuperator may be configured in a
for a certain period of time. • External insulation of the double shell
• High furnace lifetime in terms of metric tons/m2 double stage reaching 750°C typically. recuperator and of the intermediate
The checkers, heated by hot waste gas- The preheated air is conveyed to the duct with rock wool finished with galva-
TYPE / TPD 20 200 400 600 800 1000 es, releases the accumulated heat allow- burner by metallic ducts, where it nised plate.
END-FIRED ing to reach a high temperature typically matches the fuel developing the flame. • Air inlet and outlet flanged connections.
REGENERATIVE
CROSS-FIRED 1300° C to the combustion air. • Tightness test in our workshop
RECUPERATIVE

10 | MELTING FURNACE MELTING FURNACE | 11

 FIRING SYSTEM BURNERS

GAS AND OIL CONTROL STATIONS GAS BURNERS FOR REGENERATIVE FURNACES
The gas and oil stations are the systems through which gas or oil are controlled in flow, • HIGH EFFICIENCY LOW NOx FLAME
pressure, temperature to feed the burner properly. For the regenerative furnaces the • EASILY ADJUSTABLE FLAME SHAPE AND LENGTH
systems allow to switch the firing from one combustion side to the other. • EASY ANGLE AND POSITION ADJUSTEMENT

The BDF gas burners have been The different impulse of the two streams A special support allows adjusting the
designed for underport installation in allows controlling the flame shape and zenith and azimuth angles as well as the
End-Fired and Cross-Fired furnaces. length. The knobs installed in the rear vertical and horizontal burner axes.
In order to achieve a better flame shape part of the burner allow adjusting the The support has been designed for tool-
and length on each burner the gas is split two-flow impulse in order to reach the less adjustment as well as the burner
in two streams into the burner and flows best furnace performance. fixing and removal.
into the tank through two concentric Both the internal and the external nozzles When one of the side firing is in stand-by
nozzles. are made of high temperature resistant the relevant burner nozzles are cooled by
stainless steel. a compressed air stream.

inlet section adjustment

outlet section adjustment inlet section outlet section

external gas stream

internal gas stream

external gas stream

gas supply

12 | MELTING FURNACE MELTING FURNACE | 13

 BURNERS EXHAUST DUCT

OIL BURNER FOR REGENERATIVE FURNACES REVERSAL VALVE

The BDF oil burners have been designed Both the internal and the external nozzles Before being sent to the burners the • Up to 600°C (900°C in special execution)
for underport installation in End-Fired and are made of high temperature resistant heavy oil must be heated, by a group of • Low pressure drop design
Cross-Fired furnaces. stainless steel. electric heaters suitable, at a temperature • Driven by a reversible electric gear motor or
In order to achieve a better flame shape A special support is available to adjust up to 120 °C in order to reduce the pneumatic actuator
and length the heavy oil is atomized by the burner position. The support enables viscosity to a value suitable for the best • Emergency driven by manual wheel
compressed air. to adjust the zenith and azimuth angles combustion in the tank. • Tailor-made design for special applications
as well as the burner vertical and
horizontal axes.

BURNERS FOR RECUPERATIVE FURNECES

The BDF preheated air burners have In the body of the burner the air meets
been developed for Recuperative the fuel stream that is introduced by a
Furnaces. gas or oil lance.
The hot air flow from the recuperator
may be independently adjusted per each
For natural gas combustion system
we recommend the use of BDF special
DRAUGHT
burner. design for gas lances using a double REGULATING
stream of gas for a better regulation of
the flame length and shape. VALVE
The burner is suitable for operation with To be installed in the waste gas to control the
air pre-heating temperature up to 800°C. melting tank pressure.

Type 1: vertical stroke guillotine valve

• High temperature resistance steel
• Driver
- Pneumatic servo motor or electrical servo motor
- Emergency manual wheel
• Counter-weight motion assistance

Type 2: vertical shaft butterfly valve

• The servo-actuator can be disconnected
from the air source and manually operated
in emergency

Complete with driving system and transducer

• Emergency manual regulation
• Manual gate up to 20% by pass opening

14 | MELTING FURNACE MELTING FURNACE | 15

 WASTE DUCT WASTE DUCT

WASTE GAS WASTE GAS

SHUT-OFF VALVE EJECTOR
• ESP or bag filtration • High efficiency draught made of high resistance steel
• Counter-weight motion assistance • Fan speed controlled by inverter
• Self-supporting metallic chimney

16 | MELTING FURNACE MELTING FURNACE | 17

 FURNACE EQUIPMENT FURNACE EQUIPMENT

BOOSTER SYSTEM
By exploiting the glass property to be electric conductor at high temperature,
it is possible to feed some additional electric power by means of molybdenum electrodes immerged
in the glass and connected to a variable voltage electric transformer.
The effect of the extra power is to enhance the glass molten, to increase the pull, the quality
and to reduce the NOx emission.
• Bottom or Sidewall.
• Medium voltage or Low voltage.

THROAT BOOSTER
The throat booster system is a safety system used to avoid the glass freezing in the
throat during the furnace heat-up and/or when the production is stopped and no
glass is flowing through the throat.
• Typical power: 60 kW approx (during normal operation, the system is switched off)
• Power supplied by two molybdenum electrodes in glass
• Water-cooled holder
TANK AIR COOLING STATION
• Thermocouple to detect the holder temperature Necessary to cool the melting tank soldier blocks
to prolong the furnace life and to prevent leakage.

THROAT
AIR COOLING
STATION
Necessary to cool the throat
refractory blocks.

BUBBLER
The bubbler principle is to blow a small amount of air into • It generates big improvement of the glass current motion
the glass bath in order to obtain a vertical glass current from • Effective push-back batch force
bottom to top. The air bubbles lift upwards the colder glass • Better heat exchange between flames and glass
from the bottom. • For coloured glass it contributes to increase the pull
and the glass quality.

18 | MELTING FURNACE MELTING FURNACE | 19

 BATCH CHARGERS

BATCH
20 |
batch charger video

MELTING FURNACE
CHARGER
MELTING FURNACE | 21
 BATCH CHARGERS

ELECTRONIC BATCH CHARGERS For double doghouse furnaces, each

machine can be set separately and
• Getting-over of all the mechanical limits synchronized with combustion reversal,
• Servo motor pusher driven in order to feed more or less batch
• Rotation angle and rotation sequence setting by keyboard depending on the combustion side
• More charging position (max 5 memorizable positions)
• Automatic loading control
• Batch quantity setup: independent setting of pusher stroke and velocity
• Remote machine setup from control panel in control room
• No mechanical intervention required for pusher stroke adjustment

3 POSITION BATCH CHARGERS BATCH CHARGERS

• 3 different charging positions
MEAUSURING, CONTROL AND SUPERVISING SYSTEM
• Minimum manual operations
All electronic devices are integrated PLC and HMI touch screen are installed All functions are surveyed and they
• From the control panel it is possible to set
in a single control panel located in the in the control cabinet. are optically and acoustically indicated
the number of pulses of the pusher in one direction control room or in the doghouse area. should any failure occur. If required,
• Less manual setup Operator interface can easy control basic control module is available with
• Pusher stroke: mechanical setting • Rotating position
• Angle std. batch charger.
• Residence time
• Number of strokes
• Rotation sequence

Pusher
• Zero point
• Stroke
• Velocity

22 | MELTING FURNACE MELTING FURNACE | 23

 FURNACE FURNACE
CONTROL AND SUPERVISING CONTROL AND SUPERVISING

EAGLe 3.0
SUPERVISION
CONTROL
SYSTEM
Standard user-friendly
supervision in operation.

EAGLe 3.0
GLASS LEVEL MEASUREMENT SYSTEM
• NO OBJECT IN CONTACT WITH GLASS
• NOTHING IN MOVEMENT
• ABSOLUTE LEVEL MEASURE
• EASY TO INSTALL
• PROTECTIVE AIR CURTAIN AGAINST DUST
• MAINTENANCE-FREE
GLASS LEVEL PNEUMATIC
• SELF-CALIBRATING MEASURING SYSTEM
• VIBRATION PROOF
• High accuracy level detection, typically within ± 0.1 mm
• Easy and reproducible height adjustment
The new Generation Glass Level EAGLe 3.0 is composed of video EAGLe 3.0 acquires and processes the • Easy and quick probe replacement
Measurement system. camera placed in a rigid industrial images through advanced algorithms • Electrically earth-insulated probe available for furnaces with booster
casing and mounted at approx. 50 cm controlled by a system of Artificial Vision • Turret suitable to support the glass level probe
The system EAGLe 3.0 “Enhanced from the measurement point using a in an industrial computer equipped of a • Manually adjustable height with graduated scale and position indicator
Absolute Glass Level” (Patented) allows small hole (50x50 mm) in the furnace touch screen operator panel. • Water-cooled glass level probe
to measuring the glass level through working end. • Pneumatic panel
the optical reflection of a fixed pointer The real pointer- reflected image or the
mounted out of contact with glass or A new protective air curtain is designed burner reflection are acquired at high
the burner reflection. in order to avoid the possible dust frequency enabling thus to establish
coming out from the small hole. the actual level of glass with absolute
Innovative and technologically evolution precision higher than ±0.05mm.
of E.A.G.Le 2.0 is achieved: the new All the parameters of calibration and
release 3.0 offers renewed features and tuning can be read and set from EAGLe 3.0 is self-calibrating and
improvements in the measurement and whatever PC (Personal Computer) only vibration-proof.
performance. one cable for data collection and power.
EAGLe 3.0, thanks to the characteristics
described, is the most advanced glass
level measuring device present on the
market.

24 | MELTING FURNACE MELTING FURNACE | 25

 FURNACE
CONTROL AND SUPERVISING

• SCADA SOFTWARE: HISTORICAL, WHOLE CAMPAIGN MEMORY CAPACITY, ALARM MANAGEMENT

(INCLUDED; THROUGH MOBILE AND E-MAIL)
• PLC – DCS ARCHITECTURE: MOST PREFERRED PLC OR DCS BRAND.
PLATFORM AVAILABLE - REDUNDANCY, PLC AVAILABLE

Control systems focused on key- Continuous monitoring and control of The application of a SCADA acquisition
performance factors to grant: parameters such as: system creates a multi-terminal network
• Minimum Energy Consumption and • Pilot Temperatures for a fast access to required information
Operation Cost • Combustion and grants a constant overview of:
• Glass Quality • Electric Energy • Process
• Low Polluting Emission and Energy Consumption • Centralized Controls
• Furnace Life-Time • Historical
• Reliability elaboration of Trend Process Flexible application • Trend
The System allows effective, reliable • Full supply or integration with most • Correlation between different areas
control and recording of real time or best-known PLC brands. of the plant process.
historical data during the whole furnace • Integration with glass plant Supervision
campaign via SCADA system (Supervisory and Access from different places and with
Data Acquisition): hierarchies levels is available to ensure a
- Forehearths proper flexibility and safety managing.
- Batch House
- Forming Area
- Cold-End
- Whole Production Process
- Plant Utilities

GENERAL PROCESS CONTROL ARCHITECTURE

management
level
MES WLAN ERP

operator SCADA
level

UTILITIES CONTROL WARE HOUSE

DUST FILTER CONTROL COLD END
BATCH HOUSE CONTROL ANNEAL. CONTROL
plant
level MELTING CONTROL IS MACHINE CONTROL
W.E. & FOREHEARTH CONTROL

26 | MELTING FURNACE
 MELTING FURNACE CONDITIONING WORKING END FOREHEARTH

10/2018 - studiobrand.it
In order to ensure a continuous improvement of the products, BDF Industries reserves the right to make modifications to the characteristics and pictures (without notice)
FORMING DELIVERY FORMING IS MACHINE
WARE HANDLING ENERGY ON GLASS

HEADQUARTER
BRANCHES
REPRESENTATIVES
WHERE BDF INDUSTRIES IS ACTIVE

BDF INDUSTRIES BDF INDUSTRIES BDF SERVIS

S.p.A. North America LLC D.O.O.
Headquarter 1821 Dickinson Avenue, Hum Na Sutli 107/4,
Viale dell’Industria, 40 Suite E, 49231 Hum Na Sutli
36100 Vicenza - Italy Dickinson, Texas 77539 Croatia
www.bdf.it phone +39 0444 286 100 phone +1 832 404 2292 phone + 385 (0)49 382 222