Development products

Development products - batch feeder 415x290 Read-Ox is developing a batch redox sensor for in-line measurement of the redox state of the glass melt in the batch charging area of industrial glass furnaces.

The system design is based on the proven concept of the feeder glass melt redox sensor, featuring a water-cooled jacket and an exchangeable ceramic sensor element. However, due to the highly corrosive nature of the melt in the batch zone, the batch sensor requires a significantly more robust construction to ensure a minimal required lifetime and reliable performance.

The batch sensor responds rapidly to changes in incoming batch materials, making it a powerful tool for implementing a fast and effective redox control loop, enabling real-time adjustments and improved process stability in glass melting operations.

Batch and feeder

Development - correlation batch feeder - 470x295

A simultaneous measurement of the glass melt redox state in the batch charging area (red line, 1-hour moving average) and in the feeder channel (blue line) was performed. The data reveals that distinct redox dips observed in the batch zone, caused by individual “dirty” cullet batches (high COD), reappear 8 to 10 hours later in the feeder channel as less pronounced dips, due to glass melt mixing within the melting tank.

From this simultaneous measurement, the residence time distribution of the glass melt in the melting tank can be accurately calculated. Once the residence time distribution is known, the redox state of the melt in the feeder, and consequently the redox condition of the final glass product, can be predicted up to 10 hours in advance (green line). This demonstrates the significant potential of the batch sensor as a key component in a fast and effective redox control loop for industrial glass production.