Glass

The refractory lining of the glass tank floor is subjected to significant mechanical loads and leaching caused by the flow of molten glass. For this reason, its construction uses several layers of formed products and a bedding layer of refractory castable. Selecting materials with high mechanical strength and appropriate corrosion resistance is critical for trouble‐free operation. In the layer in direct contact with the glass melt, fused‐cast AZS blocks are used. Below this layer, products from the ANDALUX and MULITEX families are installed; these offer precise dimensional accuracy and high resistance to both temperature and pressure. The deeper, load‐bearing and insulating layers can be made from SUPERTON, NORMATON, and ISOLUX products, which provide the necessary level of insulation and structural stability.

The refractory lining of the glass tank walls is exposed to high temperatures, leaching by the molten glass, and attack from aggressive vapors. A typical lining consists of multiple layers of dense products in order to minimize the risk of chemical reactions and material erosion. In the working lining, fused‐cast products are used in the lower levels and silica‐based refractories in the upper sections that do not come into direct contact with the molten glass. In the insulating layers, dense high‐alumina ANDALUX products and chamotte SUPERTON refractories are employed; both offer high mechanical strength and stability under demanding process conditions.

Lightweight insulating layers are placed as the final lining layer (behind the working and dense insulating layers) and do not come into direct contact with the molten glass. However, they are still exposed to high temperatures and mechanical loads. Depending on the size of the furnace, one or more layers of lightweight insulation are used, and it is essential to select them based on both mechanical strength and thermal conductivity requirements. PCO Żarów manufactures insulating bricks with increased density to provide greater mechanical strength, as well as standard lightweight bricks designed for improved thermal conductivity. This allows precise tailoring of the insulation layers to the specific demands of each project, ensuring effective thermal protection and extending the service life of the entire structure.

The upper dome area of the regenerator operates under exceptionally demanding conditions—very high temperatures and intense erosive action from the flue gases. The working lining in this section consists of a single layer of formed refractory shapes, which must exhibit outstanding thermomechanical properties and high resistance to chemical corrosion. The recommended solution is to use bricks from the MULITEX family—fused mullite materials with a low creep rate and high refractoriness. These perform well not only in the dome but also in the upper layers of the chamber fill (regerenator “chimney” bricks), where they form a stable core of the regenerator’s structure.

The outer layer of the regenerator’s dome and walls is exposed primarily to the effects of lining leaks and high temperatures. In this layer, formed insulating bricks and insulating refractory castables (sprayed for the final layer) are typically used. The key aspect here is to provide a high level of insulation while maintaining mechanical stability. An excellent choice is the higher‐density insulating bricks from the ISOLUX series, which combine high strength with good insulating properties, as well as ISOGUN spray-applied castables, which allow for rapid and efficient installation of protective layers.

Regenerator ports are channels that transport air (including exhaust gases) to the burners and are located in the upper part of the structure. Because aggressive gases and high temperatures flow through this zone, the materials used here must exhibit exceptional resistance to infiltration and chemical corrosion. The most common choice is fused‐cast MULITEX products, which provide dimensional stability and long‐term resistance to thermal and chemical stresses, ensuring reliable regenerator performance.

The regenerator chamber is typically filled using pot‐shaped elements made from chamotte, andalusite, or mullite raw materials—chosen according to the zone and its specific loads. In the lower sections of the fill, mechanical stresses dominate (as these elements support the upper layers). Here, products from the SUPERTON, MULITEX, or ANDALUX series perform well. In the middle areas, alkali vapors often condense, accelerating chemical corrosion. Preferred products in this zone are from the ANDALUX line, distinguished by low porosity and high chemical‐attack resistance. The upper layers—subject to the highest temperatures and most aggressive flue gases—are best protected with high‐alumina mullite shapes from the MULITEX family, which resist thermal deformation and melting.

The supporting arch (rider arch), located beneath the regenerator chamber, is a critical component that carries the entire ceramic fill structure. Therefore, its stability and precise installation are especially important. Before the arch is installed in the furnace, a dry‐fit pre-assembly is performed to verify dimensional accuracy against the design. PCO provides this service as standard. The supporting arch is made from a single layer of formed elements, laid in a wedge (row) pattern. In this demanding zone, SUPERTON or ANDALUX products are most suitable, valued for their high mechanical strength and long‐term stability under intense thermal and mechanical loading.