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

problems that confront the entire industry rather than diluting efforts by solving problems
for individual companies or market segments.
• Educate plant engineers and operators
Widespread knowledge about glass technology is prevalent within the industry among
plant engineers and operators. GMIC might update the “Handbook for Self Study” by
Fay Tooley for distribution within the industry. Glass technology manufacturing
workshops could be sponsored in conjunction with conferences and workshops.
3. Process design (segmented melting, vacuum refining, waste heat utilization).
• Melter size.
Consider small versus large melters. While large melters are more energy efficient, small
melters provide greater flexibility and faster changeovers. Smaller melters are easier to
service and reconfigure. They provide higher profit margins by quickly adjusting to
market demands for a variety of products.
• Automation and control systems.
Technologies with increased automation and process control should be designed to save
energy, reduce pollutant emissions, enhance product quality and increase productivity.
They could be based on process and equipment that can feed forward from melter to
production equipment and back to batch house. To drive the melting process and produce
consistent quality products, intelligent control systems should be a feature of all glass
melters. Apply intelligent control systems to drive the melting process and insure product
consistency. Revisit on-the-shelf projects and technology that was technically successful
but economically challenged.
• Accelerated melting.
For highly driven melting processes, high shear is easily induced in glass melts and shear
attenuating silica cords by a factor of several thousand has been far more effective than
an extra 100˚F in melting temperature. Likewise, ordinary glass melting uses gravity
(1G) to cause bubbles to rise out of the melt. Centrifuges easily generate hundreds of Gs.
(This technique was used in experiments at Owens Illinois to melt and refine soda-lime
glass at 1950˚F.)
4. Technology base development (instrumental and controls, “central” industry lab,
industry and government relationship).
The technology should be advanced to meet the challenge of the three E’s—energy
consumption, environmental regulation compliance and economic viability.
• Value-added methods
Industry should work together on innovations that create value-added products in two
directions.
a.) Develop new products within the glass industry by changes within the total
melting system: higher glass quality; higher durability and strength made from higher
temperature melting systems; changes within the conditioning and refining atmosphere or
immediately downstream of final glass delivery to fabrication.
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