Glass Melting Technology: A Technical and Economic ... - OSTI

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Reference The report is supplemented with a full reference appendix. A primer for glass fusion provides a basic understanding of the glass melting process. Automation systems and instrumentation devices for glassmaking are specified and promise to improve the economics of the US glass industry. Research projects in process are detailed for review. Relevant glass science and engineering literature and patents awarded by the US government, along with an extensive bibliography, are compiled to provide a major reference tool for glass manufacturing administrators and operators, educators, scientific researchers, government agents, and materials and equipment suppliers. Acknowledgements This technical and economic study has been funded by the US DOE Office of Industrial Technologies and conducted under the auspices of the Glass Manufacturing Industries Council. Glass industry managers, scientists, engineers have contributed time, energy and expertise to provide data and to review the document for accuracy and completeness. ix
Page 1 and 2: Glass Melting Technology: A Technic
Page 3 and 4: Disclaimer This document was prepar
Page 6 and 7: Glass Melting Technology: A Technic
Page 8 and 9: cyclical economy. Specialty glass m
Page 12: CONTENTS Executive Summary v Prefac
Page 15 and 16: To compile this technical assessmen
Page 18 and 19: Introduction The goal of the projec
Page 20 and 21: environmental protection regulation
Page 22 and 23: Most glass manufacturers expect one
Page 24: Section A Technical and Economic As
Page 27 and 28: However, the challenges that face t
Page 29 and 30: I.3. Industry perspectives on curre
Page 31 and 32: consumption level was 5.5 GJ (6.9-7
Page 33 and 34: Special energy consumption, normali
Page 35 and 36: load, physical and thermal spalling
Page 37 and 38: have recently been converted to oxy
Page 39 and 40: needed to describe the batch layer
Page 41 and 42: have evolved with little risk and s
Page 44 and 45: Chapter II Economic Assessment of U
Page 46 and 47: survive by innovating new products.
Page 48 and 49: Table II.1. Key End-Use Markets by
Page 50 and 51: Therefore, technological improvemen
Page 52 and 53: Container glass The glass container
Page 54 and 55: Fiberglass: Insulation The health o
Page 56 and 57: scientific glassware, glass tubing,
Page 58 and 59: meeting business cycle demands and
Page 60 and 61:
When a glass corporation operates a
Page 62 and 63:
Table II.12. Reduction in Energy Co
Page 64 and 65:
Fiberglass insulation sales are exp
Page 66 and 67:
Chapter III Traditional Glass Melti
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periods. Natural gas is the preferr
Page 70 and 71:
of waste gas through a metal heat e
Page 72 and 73:
Although the volume of exhaust gase
Page 74 and 75:
Two shortcomings of electric furnac
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Chapter IV Innovations in Glass Tec
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various stages of the process. Each
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series of compartments heated and a
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or glass components, plasma technol
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output. If the technology were to b
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Development of the Submerged Combus
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Glass quality is the greatest conce
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IV.7.2. Refining zones for electric
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damper. The most stringent regulati
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• electrostatic collection is eff
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• soda-lime batch/cullet could be
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pioneered the RAMAR system of mecha
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limited power inputs and the unit t
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y the Advanced Glass Melter develop
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and PPG Inc. in the United States a
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As challenges to industry intensify
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.) Develop new products by coupling
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developing an innovative glass melt
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hazardous waste containment, recycl
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Workshop Participants The perspecti
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WARREN WOLF is currently a glass in
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materials. Perhaps partnering or ot
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expressed during interviews, discus
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Section Two Applied Glass Technolog
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Chapter 1 Primer for Glassmaking Co
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Figure A.1 Figure 1.1. General Flow
Page 132 and 133:
intimately in contact with each oth
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Dissolution of the more refractory
Page 136 and 137:
quartz. If limestone and sodium car
Page 138 and 139:
Primary-melt liquids usually wet an
Page 140 and 141:
The thickness of concentration laye
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distance to escape. If thermal curr
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ubbly or foamy layers under the bat
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Melt evaporation is more appropriat
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preparations are beneficial. These
Page 150 and 151:
The other common energy source for
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precipitator (EP) dust collected fr
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Chapter 2 Automation and Instrument
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lower glass weight and combustion c
Page 158 and 159:
In practice, electric boosters, wit
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Data control Data logging is requir
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If a glassmaking facility is engine
Page 164 and 165:
To ensure optimum combustion condit
Page 166 and 167:
Chapter 3 Developments in Glass Mel
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the overall goal of design, modelin
Page 170 and 171:
SCM was developed by the Gas Instit
Page 172 and 173:
membrane (OTM) technology. The OTM
Page 174 and 175:
melter. Detailed designs were to be
Page 176:
Project Team Elliott Levine Brad Ri
Page 179 and 180:
Figure 3.B.1. High-Intensity Plasma
Page 181 and 182:
Key innovative components of this p
Page 183 and 184:
glass fibers at a location operated
Page 185 and 186:
Environmental Impacts The plasma ar
Page 187 and 188:
• Pressed/Blown Glass Current Siz
Page 189 and 190:
The major goal of the plasma progra
Page 191 and 192:
operations with minimum capital cos
Page 193 and 194:
However, the fundamental question r
Page 195 and 196:
control per mixer will optimize the
Page 197 and 198:
A. Literature and Patent Review—G
Page 199 and 200:
A variety of products with differen
Page 201 and 202:
steel walls, minimizing pressure lo
Page 203 and 204:
Innovative refining concepts includ
Page 206 and 207:
Appendix A1 Categorization of Liter
Page 208 and 209:
A u tt h o r // t i t l e / y e a r
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RR e c o m m e n d C o m p a n y s
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RR ee c o m m e n d C o m p a n y s
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Page 216 and 217:
RR e c o m m e n d s e c oo n d l o
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Page 220 and 221:
Page 222 and 223:
Page 224 and 225:
Page 226 and 227:
Page 228 and 229:
A u t h o r / tt i t l e / y e a r
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R e cc o mm mm ee nn dd C o mm pp a
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RR ee cc o m m ee n d C o mm p a n
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R e c o m m e nn d C o m p a n y s
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R ee c o m m e n d C o m p a n y s
Page 241 and 242:
R ee c o m m ee n d C o m p a n yy
Page 243 and 244:
R e c o m m e nn d s e c o n d l o
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R e c o m m ee nn d C o m p a n yy
Page 247 and 248:
R e c o m m e nn d C o m p a n yy s
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R e c o m m e n d C o m p a n y s e
Page 251 and 252:
R e c o m m e nn d s e c o n d l o
Page 253 and 254:
R e c o m m e n d C o m p a n yy s
Page 255 and 256:
R e c o m m e n d C o m p a n yy s
Page 257 and 258:
cost of capital: Rate of return tha
Page 259 and 260:
Proportional-Integral-Derivative (P
Page 262 and 263:
Appendix C Contributors and Sponsor
Page 264 and 265:
C.4. Special Contributors Elliott L
Page 266:
Appendix D Technology Resource Dire
Page 269 and 270:
Bamford, C. R., Colour Generation a
Page 271 and 272:
Charles River Associates Incorporat
Page 273 and 274:
Gushchin, S. N., V. B. Kutin, and P
Page 275 and 276:
Krause, W., “Glass-melting Strate
Page 277 and 278:
Nemec, L., “Energy Consumption in
Page 279 and 280:
Richards, R. S., “Method and Appa
Page 281 and 282:
“Standard Terminology of Glass an
Page 283 and 284:
Wagnerova, S., S. Kasa, P. Jandacek
Page 286:
Tables Table II.1. Key End-Use Mark
Page 289 and 290:
Energy considerations for glassmaki
Page 291 and 292:
Segmentation of glass industry, 30-
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