TL;DR
Burner block erosion changes the flame shape and melt temperature distribution. Track the burner port temperature on the external scan and plan a hot repair patch or campaign end rebuild when erosion reaches the critical dimension.
What you might see
- flame shape changing from the normal pattern
- burner port temperature rising on external scan
- glass quality defects from uneven melt temperatures
- visible refractory wear at the burner port opening
Likely causes
Erosion of the refractory burner block by the high-velocity flame over the furnace campaign
Incorrect combustion air-gas ratio causing secondary combustion inside the burner block
Batch material splashing from the melt surface onto the burner block opening
Thermal cycling from reversal operation fatiguing the refractory at the port edges
Required tools
- Thermal camera
- Burner port dimension measurement tool
- Aluminized radiant-heat PPE
- Hot castable refractory for repair
Safety first
- Glass furnace burner port areas involve extreme thermal radiation and hot glass splash risk. Aluminized PPE is mandatory.
- Furnace gases contain CO and SO2. Personal gas monitor required near any furnace opening.
- Never introduce moisture near the furnace opening. Water near molten glass is violently steam-reactive.
Procedure
- 1
Scan the burner port area on the furnace sidewall with a thermal camera at each maintenance survey.[1]
- 2
Measure the burner port opening dimensions through the inspection hole if accessible. Compare to the original port design dimensions.[1]
- 3
Verify the combustion air-gas ratio for each burner is at the design value. Excess gas causes secondary combustion inside the block.
- 4
If erosion is significant, consult the furnace engineer. Options include a hot repair patch with castable refractory during a brief production stop, or planning an earlier campaign end.
- 5
For a hot repair patch, follow the approved procedure using refractory materials rated for the burner port temperature.
Warning: Hot repair near an operating burner port involves extreme thermal radiation. Full aluminized PPE and strictly limited exposure times are mandatory. - 6
After repair, monitor the burner port thermal scan for 7 days to confirm no recurrence.
Sources
Sorg Sorg LoNOx Melter Glass Tank Furnace general technical documentation, Sorg
General glass tank furnace burner block inspection and hot repair procedures (general)
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