HORN Glass Industries AG

Bergstr. 2 , 95703 Plößberg
Germany

Telephone +49 9636 9204-0
Fax +49 9636 9204-10
info@hornglas.de

This company is main exhibitor of

Trade fair hall

  • Hall 13 / B33
 Interactive Plan

Hall map

glasstec 2016 hall map (Hall 13): stand B33

Fairground map

glasstec 2016 fairground map: Hall 13

Our range of products

Product categories

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.01  Batch charging technology

Batch charging technology

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.02  Forehearth technology
  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.03  Melting technology for tank furnaces

Melting technology for tank furnaces

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.05  Gas equipment and supply systems

Gas equipment and supply systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.06  Regenerative systems

Regenerative systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.07  Recuperative systems

Recuperative systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.08  Electrically heated systems

Electrically heated systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.09  Combustion technology
  • 01.04.09.01  Combustion technology for oil and gas fired melting furnaces

Combustion technology for oil and gas fired melting furnaces

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.09  Combustion technology
  • 01.04.09.02  Combustion technology for oxy-fired systems

Combustion technology for oxy-fired systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.10  Feeder colouring

Feeder colouring

  • 03  Glass products and applications
  • 03.01  Flat glass
  • 03.01.01  Float and mirror glass

Float and mirror glass

  • 06  Contracting, consulting, engineering, services

Contracting, consulting, engineering, services

Our products

Product category: Forehearth technology

Forehearth GCS301

The HORN® forehearth GCS 300 system works with indirect centreline air cooling while the forehearth GCS 301 system works with both indirect and direct centreline air cooling.

Both forehearth systems are characterised by the most advanced technology in forehearth design for high-pull forehearths and the highest temperature homogeneity requirements (K-factor). The refractory structure design is an up to date modern construction employing all today’s techniques to achieve optimum thermal homogeneity combined with minimum energy requirement.

DETAILS

High quality refractory material is used for channel blocks. All channel block joints are backed up with zircon mullite split tiles and are surrounded with suitably graded insulation material for minimum loss of energy.

The roof blocks of the superstructure in the cooling sections are of a special shape to separate the atmosphere above the glass bath in a left, middle and right area. The heating of the glass bath in the left and right area is also assisted by reflected flame radiation, due to the inclined design of parts of the roof block. This design provides a reduction in the temperature difference in the glass between the centre and the outer areas of the channel.

Design

The GCS Series 301 is based on the design of the GCS Series 300 with an additional direct forced cooling system to increase response time and flexibility when a wide range of gob temperatures is required. Therefore special roof cover blocks for area separation along the control zones are installed. This results in:
•separated boundary areas to heat the glass particularly at the side of the forehearth
•separated central section to guide direct cooling air.

In addition, the roof contains a separated channel for indirect centerline cooling.

At glass contact, conventional channel design with different refractory qualities is possible (e.g. BPAL, HPAL, Alpha-Alumina, fused cast).

Waste gas openings (chimneys)

The waste gas openings are small openings which are arranged laterally at the outside of the particular zones in order to draw the waste gas to the outside area of the glass in order to heat them significantly. By exact adjustment of the dampers, the residence time of the waste gas moving along the outer area can be controlled.

Radiation openings

Radiation openings are foreseen in the forehearth superstructure at the beginning of each cooling zone. Through adjustment of the damper block above the radiation opening, the heat radiation through the opening is variable. In addition, by adjustment of the dampers, the residence time of the waste gas moving into the central area of the forehearth can be controlled.

Centreline top cooling (indirect)

All cooling zones are constructed with a central channel inside the refractory superstructure. This channel stretches across approximately 70% of the length of the cooling zone.

Between glass surface and cooling channel, slots are positioned to channel heat radiation from the glass to a “heat exchanger plate” with profiled surface for heat convection purposes.Cooling air provided by a fan can be blown through the channel against the glass flow direction and extracts the heat through convection on the “heat exchanger plate”.

Centreline top cooling (direct)

Direct cooling air is applied onto the glass surface in the central section of the forehearth. The cooling air is inserted via holes in the mantle block by fans. Then the cooling air is channelled between the separated boundary areas, underneath the superstructure, and leaves the forehearth through the central radiation opening.

In order to “spread” the air layer on the glass surface to the right and/or left boundary sections, the air can also be released via the right and/or left lateral chimneys.

Centreline bottom cooling

The bottom cooling works according to the same principle as the top cooling. The cooling channel is located under the channel blocks, in the entrance zone of the forehearth.

The bottom cooling channel is a standard installation in GCS Series 200, 300 and 301 for the subsequent installation of a blower in case the product profile changes.

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Product category: Forehearth technology

Electrical Forehearth

Using electricity is the most direct way to insert energy into glass. The HORN® electrical forehearth system works with direct or indirect heating and represents today’s most advanced technology in the areas of forehearth design for special glass applications. The refractory structure design is an up to date modern construction employing all today’s techniques to achieve optimum thermal homogeneity combined with minimum energy requirement.

DETAILS

High quality refractory material is used for channel blocks. All channel block joints are backed up with zircon mullite split tiles and are surrounded with suitably graded insulation material. The roof blocks of the superstructure sections are specially adapted to the heating and glass requirements. High alumina material is used for the superstructure.

The heating with electricity can be made directly into the glass with electrodes or indirectly by installed heating elements above the glass bath.

Direct heating

Direct electrical heating refers to the use of electricity and immersed electrodes in forehearth channels. The glass bath is used as a resistance and the energy is inserted directly into the glass bath.

The nominal specific current loading of the electrodes is very low, so that there is almost no wear of the electrodes. It is not therefore necessary to advance the electrodes during operation and no cooling of the electrode is required.

The most common electrode material is molybdenum. Molybdenum electrodes are suitable for coloured soda lime glasses, and for soft borosilicate C glass. These electrodes are installed horizontally through the channel side walls. Tin oxide electrodes are used for some applications, especially for glass containing lead.

Installations for containers and similar applications utilize short electrodes located at short intervals along the complete length of the channel, with the electrical current passing across the channel. Channels for glass fibre manufacturing operations use a smaller number of longer electrodes installed at greater intervals, with the current flow along the channel.

Indirect heating

This heating system involves the use of radiant electrical heating elements installed in the channel superstructure.

There are two types of element which are commonly used. Silicon carbide elements are generally used in the form of rods, which can be installed horizontally across the channel, with the electrical connections on both sides. These elements can be used at temperatures up to about 1300 °C, and can be expected to operate for about 18 – 24 months.

Molybdenum Disilicide (MoSi2) elements (more commonly known as Kanthal Super) are produced as U-shaped elements, which are installed vertically through the superstructure roof. This material can be used at extremely high temperatures in excess of 1700 °C, and the elements can achieve a life of 4 – 5 years.

This technology is particularly useful for high quality production when no suitable gas supply is available.

Combined direct and indirect heating

Under some circumstances it is advantageous to combine direct and indirect electrical heating systems. Immersed electrodes are installed to provide direct electrical heating of the glass bath. Additional energy is supplied by radiant electrical heating elements installed in the superstructure. In the case of glasses containing volatile components the channel can be enclosed by a cover tile, and the radiant heating elements are installed above the cover tile.

The use of indirect electrical heating above the glass surface in addition to the electrodes in the glass increases the flexibility of the installation. If the power supplied by the heating elements is more than the heat losses of the glass bath to the superstructure then there is a net addition of energy to the glass. However, if the power applied is lower than the heat losses there is a net energy loss from the glass bath and a cooling effect is applied.

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Product category: Forehearth technology

Forehearth GCS200

The HORN® forehearth GCS 200 system works with centreline radiation cooling and represents today’s most advanced technology in the areas of forehearth design for low and medium capacity and accurate temperature adjustment. The refractory structure design is an up to date modern construction employing all today’s techniques to achieve optimum thermal homogeneity combined with minimum energy requirement.

High quality refractory material is used for channel blocks. All channel block joints are backed up with zircon mullite split tiles and are surrounded with suitably graded insulation material.

DETAILS

The roof blocks of the superstructure in the cooling sections are of a special shape to ensure the best possible heating of the glass. The blocks are shaped like flat roof blocks with the central portion lowered towards the glass surface. The lowered centre of the roof block creates turbulences in the flames. Thus the heat transfer to the outer edges of the glass bath is increased. The heating of the outer edges is also assisted by reflected flame radiation, due to the inclined design of parts of the roof block. This design provides a reduction in the temperature difference in the glass between the centre and the outer edges of the channel.

The combustion system is characterized by its long-lasting reliability in any operational situation and includes the constant gas/air ratio CORA system for stable firing by small pencil burners along the whole length of the forehearth.

Centreline Radiation Cooling

For additional temperature homogenization there are one or more radiation cooling openings foreseen in the superstructure cover blocks of the cooling zone. These openings are sized and located according to the cooling requirement. The actual heat loss through the opening is varied by the movement of the damper block which is used to open or close the opening.

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Product category: Forehearth technology

Forehearth GCS300

The HORN® forehearth GCS 300 system works with indirect centreline air cooling while the forehearth GCS 301 system works with both indirect and direct centreline air cooling.

Both forehearth systems are characterised by the most advanced technology in forehearth design for high-pull forehearths and the highest temperature homogeneity requirements (K-factor). The refractory structure design is an up to date modern construction employing all today’s techniques to achieve optimum thermal homogeneity combined with minimum energy requirement.

DETAILS

High quality refractory material is used for channel blocks. All channel block joints are backed up with zircon mullite split tiles and are surrounded with suitably graded insulation material for minimum loss of energy.

The roof blocks of the superstructure in the cooling sections are of a special shape to ensure the best possible heating of the glass. The blocks are shaped like flat roof blocks with the central portion lowered towards the glass surface. The lowered centre of the roof block creates turbulences in the flames. Thus the heat transfer to the outer edges of the glass bath is increased. The heating of the outer edges is also assisted by reflected flame radiation, due to the inclined design of parts of the roof block. This design provides a reduction in the temperature difference in the glass between the centre and the outer edges of the channel.

Design

The GCS Series 300 is based on the GCS Series 200 with an additional indirect forced cooling system in order to create more cooling capacity and flexibility. Roof blocks as well as channel blocks are designed with indirect centerline cooling.

Conventional channel design with different refractory qualities is possible (e.g. BPAL, HPAL, Alpha-Alumina, fused cast).

Waste gas openings (chimneys)

The waste gas openings are small openings which are arranged laterally at the outside of the particular zones in order to draw the waste gas to the outside area of the glass in order to heat the glass significantly.

Radiation openings

Radiation openings are foreseen in the forehearth superstructure at the beginning of each cooling zone. Through adjustment of the damper block above the radiation opening, the heat radiation through the opening is variable.

Centreline top cooling (indirect)

All cooling zones are constructed with a central channel inside the refractory superstructure. This channel stretches across approximately 70% of the length of the cooling zone.

Between glass surface and cooling channel, slots are positioned to channel heat radiation from the glass to a “heat exchanger plate” with profiled surface for heat convection purposes. Cooling air provided by a fan can be blown through the channel against the glass flow direction and extracts the heat through convection on the “heat exchanger plate”.

Centreline bottom cooling

The bottom cooling works according to the same principle as the top cooling. The cooling channel is located under the channel blocks, in the entrance zone of the forehearth.

The bottom cooling channel is a standard installation in GCS Series 200, 300 and 301 for the subsequent installation of a blower in case the product profile changes.

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Product category: Float and mirror glass

Float Glass Furnace

Float glass manufacturing is not like the manufacturing of commodities like steel or plastic. Each of the production processes requires raw materials to be weighed, mixed, melted at high temperatures, formed into continuous ribbons, cooled and cut into a size that fits its use.

The melting furnace consists of refractory bricks and special shapes, support and binding steel, insulation, a fossil fuel firing system, temperature sensors and a computerized process control system. The furnace is carefully designed to meet the plant's specific gross daily glass production tonnage goals.

The insulation, special airflow features, and combustion air heating enable the furnace to operate at maximum fuel efficiency with negligible pollutant emissions. The furnace is sized and designed to provide high quality glass with the smallest amount of energy per ton of glass melted.

The float glass furnace can be operated with natural gas, LPG, biogas and oil. Additionally there is the possibility to install specially developed melting assistant devices like electrical boosting or bubbling systems.

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About us

Company details

The cornerstone of what is HORN Glass Industries AG today was laid over 100 years ago, when August Horn founded in the year 1894 a small glass service industry in the Bavaria. HORN Glass Industries AG has carried this tradition further to join the ranks of leading international glass plant-equipment.
Today HORN is, for example, placed amongst the Top 500 of Europe’s Job creating companies by the Europe’s Award and employs about 230 people.

HORN Glass Industries AG has a wide range of experience in the design, manufacture and supply of different furnace types, such as regenerative and recuperative continuous tank furnaces, float furnaces, electrical tank, pot furnaces , day tanks, electrical tank furnaces for domestic and lighting ware, tableware, containers, technical glassware, sheet glass and etc., in different glass types.

HORN’s range of utility equipment includes combustion systems, control and safety equipment, electrical boosting and mixings systems, to name but a few. HORN Glass Industries AG also offers all forehearth systems, supply stations for oil, gas, oxygen, water, regenerative and recuperative burner systems, combustion equipment, boosting systems and process controlling systems of the highest standard. HORN has developed products such as the OPTIBEAM; the internationally applied laser glass level control system.

Another business section of HORN is machinery for the thermal process of glass like annealing lehrs, roller annealing and decorations lehrs. Hot and cold end coating stations and much more.

HORN Glass Industries AG activities generally split in following divisions:

Glass melting furnace engineering und supply
-engineering and planning of complete glass melting furnaces;
-individual planning and design by CAD-technology;
- supply of combustion-, control- and peripheral equipment
-Start-up
-Training

Glass melting furnace service
-setting-up and mounting of complete furnaces;
-hot and cold repairs of all furnace types;
-drilling and draining of tank furnaces;
-heat-up, melt-up and run-in of all furnaces;

Thermoprocess Machinery
-annealing lehrs, roller annealing lehrs and decorating lehrs, which are in
operation at internationally renowned glass producers and decorators
-hot and cold end coating stations

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Company data

Sales volume

20-100 Mio US $

Export content

> 75%

Number of employees

101-500

Foundation

1984

Area of business
  • Glass manufacture / Production technology
  • Tools, replacement and spare parts, auxilliary equipment and fittings
  • Measurement, testing, control technology and software
  • Contracting, Consulting, Engineering, Services
Target groups

Manufacturing, Processing and Finishing