Hybrid melting is an innovative way to optimize melting inside industrial furnaces specific to the glass industry. Hybrid melting combines two methods of heating: injecting electricity directly into molten glass and natural gas combustion to facilitate the melting process. This allows furnace operations to use the most cost-effective energy sources at a given time, compared to either 100% natural gas or all-electric melting alone. Hybrid melting has the potential to changing the future of glass melting, or at least give operational management energy flexibility during the next campaign.
Energy markets are changing rapidly. We see a rising price for carbon in Europe and rising natural gas costs almost everywhere. Renewable energy sources are coming online, to bring more electricity to market. Glass furnaces are large capital investments, built for campaigns of 10-20 years. How can a company build a furnace today for the energy market of 2032?
Hybrid melting yields a more flexible process for melting glass, in some concepts, certain areas can be sectioned off to keep the products of combustion in certain areas. In other concepts, the melter gas space is completely open. Manufacturers can use customized ratios of electric and gas boosting to create a melting process that meets their needs while also allowing them to shift the ratios at any time for a more cost-effective system.
Spurred by carbon reduction technology, this innovation allows companies to move towards more sustainable practices by using renewable energy and electricity to power their furnaces. Hybrid melting uses a field of electrodes to eliminate the need for expensive carbon while also keeping dust and vapor down. This makes it a cost-efficient investment.
Merkle’s existing technologies, such as Modu-Lok and Strut-Air systems, can be used and adapted to fit many of the published hybrid melting furnace concepts. In addition to providing refractory walls and flat crowns, we also supply separating walls to section off specific areas of the furnace.
“While switching to new technology is risky, it’s not risky to use Merkle,” says Timothy Park, Vice President of Merkle International, Inc.
At Merkle International, our quality service does not end with great designs. To promote product longevity, we offer ongoing support and inspections so you can have confidence in adopting new hybrid melting technology.
At Merkle International, we are a global leader in energy-efficient suspended refractory systems and related furnace equipment. For more than 50 years, we have provided state-of-the-art designs to meet our customers’ complex needs. We make it our priority to improve processes and create solutions for our clients’ specifications. Our dedicated staff continuously researches new concepts and technologies that can benefit the refractory industry such as hybrid melting.
Contact us to learn more about our adaptable products.
Read More From Merkle International:
Merkle Promises Innovation & Efficiency
Safety Is Our Highest Priority
Project Management: A Key Component When You Work with Merkle International
