Glass and Ceramic Kiln: NFPA 86, 1600 °C Gas Burner

Large glass and ceramic plants produce most of Turkey's more than 9 Mt/y of glass and ceramics. Glass kilns run at 1,600 °C and ceramic tunnels at 1,300 °C with natural-gas or oxy-fuel (95 percent O2) burners. NFPA 86 mandates a burner management system (BMS), pilot-flame supervision, a 5-volume purge and oil-free cleaning of oxygen valves.

Kiln Types

• Glass end-port: Regenerative 1,600 °C
• Glass oxy-fuel: Low NOx
• Ceramic tunnel: 1,300 °C 50-100 m
• Electric melter: E-glass (glass fiber) and specialty glass
• Float glass: Tin bath 1,100 °C

NFPA 86 BMS

• Flame scanner: UV/IR pilot
• Purge: 5 volume changes
• Safety shut-off: Dual valve
• High-temp limit: Upper cut-off
• Manual reset: After trip

Oxy-Fuel Risk

• O2 purity: 95-99 percent
• O2 valve fire: No mineral oil
• Halocarbon lubricants: preferred because they do not burn in pure O2
• Critical velocity: <8 m/s pipe
• CGA G-4: O2 cleaning

Tunnel Kiln

• Entry zone: 150 °C drying
• Firing zone: 1,300 °C
• Cooling zone: 100 °C
• Wagon: Refractory
• Emergency exhaust: up to 100 ACH on gas leak

Turkey Plants

• A large float glass plant: 1.8 Mt float
• A glass plant: Soda glass
• A large ceramic plant: 110 Mm2
• Another ceramic plant: 60 Mm2
• Regenerator maintenance incidents: Reminder of NFPA 86 purge-pilot compliance

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