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Modernization

Modernization

Batch Plant Modernization Without Production Loss

TECO has the experience and know-how to handle batch plant modernizations without affecting normal glass production. This is true regardless of the task, including complete replacement of the control system.

TECO batch plants are designed for ease of expansion. Interface points are included in the original facility. Additional positions on the raw material distributor accommodate new materials and the mixed-batch distributor has additional positions for delivery of mixed batch to the new furnaces. Furthermore, the control systems are designed for expansion without disturbing glass production.

Batch plants are modernized to accommodate glass production increases and/or product quality improvements. It is easier to modify a batch plant at furnace rebuild time, but they can be modernized during a campaign without interrupting production. They can be repaired during a campaign, but it requires more planning and effort. A scope of work for batch plant cold repair should be developed alongside that for furnace rebuilding.

Important Considerations for a Cold Repair Modernization

Some important considerations are as follows:

General
  • Clean raw material silos
  • Replace dust skirts/vent bags
  • Replace dust collector bags
  • Rebuild gear-boxes for mechanical equipment
  • Rebuild/rewind motors for mechanical equipment
  • Replace all cullet chutes and diverters
  • Replace compressed air components.
Bucket elevators

Replace:

  • Gear boxes, shafts, bearing/seals, and pulleys
  • Belts and splices
  • Buckets
Conveyors
  • Gear-box, shafts, bearings, seals and pulleys
  • Idlers
  • Belts and splices
Turnhead

Replace:

  • Rotor bearing
  • Swivel chute
  • Plunger seal
Feeders
  • For screw type, replace gearbox and bearing/seals
  • For vibratory type, replace feeder liners and re-tune feeders
Cullet crusher

Replace:

  • Jaw plates, rotary drums or impact bars
  • Wear plates
  • Drive belts
Mixer

Replace:

  • Bottom and side liners
  • Plows and paddles
  • Wall scrapers
  • Gear-box and drive belts
Pneumatics
  • Have pressure vessels recertified as safe pressure vessels
  • Replace pneumatic valves and associated filter regulator units
  • Reline or replace elbows and spool pieces
Control system
  • Check all limit switches and sensors
  • Recalibrate all scales and check scale repeatability
  • Evaluate repair versus new control system