Digital Twin for GLASS MELTING FURNACE

What are the challenges for glass melting furnace?

Glass melting furnace operation faces challenges of nonlinear dynamics, uncertainties, and temperature distribution at the glass melting furnace. Factors such as glass material, furnace design, gas calorific value, excess air control, and melting temperature affect the process efficiency. Radiation efficiency, batch temperature, and batch chemical consistency also impact the melting process. Deviations in radiation efficiency can cause temperature imbalances in the furnace, affecting glass quality. Batch temperature fluctuations throughout the day due to inertia affect radiation efficiency, energy efficiency, flue gas temperature, and furnace lifespan.

Achieve optimal glass melting furnace operation 

Digital Twin of a glass melting furnace monitors, analyses, and estimates the process parameters, and controls the furnace by providing optimal operation set points. As a result, Digital Twin increases efficiency without requiring any additional investments in the equipment. 

How does it work? 

EA-SAS platform continuously collects real SCADA metering data and performs calculations in the Cloud. Real-time Digital Twin performs enabling mass and energy balance calculations, evaluates efficiency, and production monitoring, and identifies losses at each process stage.  

The platform generates control set points for operators based on calculated KPIs either on an hourly basis or through advanced automated control directly to the SCADA system, eliminating the need for manual intervention. The main output is the optimal flue gas temperature setpoint or gas quantity. 
EA-SAS platform stabilizes furnace operation, tracks product quality and line efficiency, automates glass formation recipes, and suggests predictive maintenance actions.