HORN hybrid furnaces are specially designed to combine the classic heating method of combusting a fossil fuel with the usage of more electric power by using electrodes in the melting tank. The high electric share leads to a reduction of the fuel consumption and therefore to lower temperatures in the superstructure. In combination with a lower flue gas volume (even more for an oxyfuel furnace), this requires a modification of the superstructure design and possibly of the refractory materials to avoid cold spots and the subsequent damage.
 
In the melting tank, a high number of electrodes are necessary. They can be installed as side or bottom electrodes depending on steelwork, position of burners, glass composition, etc. and preferably form “convection zones” in the tank. In these areas, the typical convection is preserved, despite the influence of all the electrodes, to support the melting process.

To some degree, a hybrid setup offers flexibility regarding the energy contribution between fossil and electric and also for the pull rate.

Currently, hybrid concepts are used for furnaces with smaller pullout of 50 to 400 t/d and/or specialty glass, but in general the maximum furnace size is approximately the same as for the classic fossil furnaces (750 t/d and even larger).

• Low energy consumption

• Low emission values

• Reduced NOx emissions

• Low investment cost for flue gas equipment due to low flue gas volume

• Easy adjustable temperature profile

• High flexibility during load change

• Flexibility regarding energy (fossil <-> electric)

• High specific melting output