Thanks to the possibility of replacing the refractory material during the melting process, there is no longer any need of cooling it down within the critical zones. Now - as refractory material will not limit the furnace cycle any more - simpler, budget-priced refractory material manufactured in mass production can be used. Drainages may be replaced by bag-shaped recessions.
As a result of the round geometry, the wetted surface (proportion of surface to volume) is reduced, dead water zones do not exist and ideal flow characteristics are formed. Ideal flow characteristics will reduce the retention period, which fact, in turn, will allow a smaller tank volume.
In addition, ideal flow characteristics will offer wide-ranging fields of application leading to a modular-type of mass production of the steel structure and, consequently, also to a reduction of the assembly costs.
In total, all these benefits will significantly reduce the costs of acquisition.
Reduction of costs of operation
Thanks to the possibility of replacing the refractory material during the melting process, the furnace cycle is multiplied. There will not be effected any cold repairs; the production process is continuous. The refractory material removed from the plant will allow to directly and continuously determine the condition of the melting tank. Thus, tank bursts can be avoided and insurance premiums reduced. There is no longer any need of cooling critical zones; full-faced insulation will be possible. The residual heat may be used for preheating the batch. For heating, unpurified biogas can be used. Thanks to the reduced surface, being a result of the round geometry, the energy consumption will be reduced significantly. CO2 certificates are no longer required.
All these benefits will cut down production costs dramatically.
Adaptation to market and sales situation
Thanks to the possibility of replacing the refractory material, the volume of the melting tank can be individually increased or reduced in size by adding or removing elements during the melting process. For optimization purposes, also the geometry may be adapted. Its round shape always provides for ideal flow characteristics and thus allows an adaptation of the melting level.
Consequently, the production volume may be fully adapted to the respective market and order situation.
Area of applications
Thanks to the possibility of replacing the refractory material during the melting process, highly aggressive melted masses may be transformed into application products, thus opening up new sales markets.
Melting plants for ultrapure melting masses can be produced in a cost-efficient way. Discontinuous melting processes can be transformed into continuous melting processes. Tempering chambers are no longer required and operational procedures can be optimized.
The round geometry allows a continuous discharge of multi-layer melted masses at different levels.
In all cases, the production costs can be reduced significantly.
Demonstration and leasing
Thanks to the possibility of replacing the refractory material during the melting process and due to the round geometry, melting plants, manufactured in modular design, can be offered at favourable price levels.
The modified structure of the production costs of melting plants in combination with the option of adapting the geometry during the melting process, will allow to see and eyeball the individual melting plant in operation prior to purchase.
This constellation, for the first time provides for the possibility of leasing melting plants.