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

Chapter VI Vision for Glassmaking
VI.1. Future of Glassmaking
Given that the industry rate of growth has slowed, that fewer new glass plants have been
built, and that competition from global imports and other materials has intensified, a
vision that combines the economics with the technology is mandatory. For consideration
of new melting technologies, this study has defined the major priorities as quality of the
glass product; economic feasibility; and process compatibility.
Step-change efforts to improve melting technologies have been unsuccessful, or only
partially successful, to fully meet their design criteria. For example, oxy-fuel conversions
have been moderately successful, but still struggle with issues of refractory applications,
control strategies, and higher operating costs due to scrimping on technology funding.
Goals for the future of glass have already been established in the “Glass Industry
Roadmap,” which was developed under the auspices of the US Department of Energy—
Office of Industrial Technologies. For the year 2020, the set goals for economic and
technical advancements are aggressive and challenging. See Table VI.1.
Table VI.1. Objectives and Goals for 2020
Objective Goals for 2020
Production costs 20% below 1995 levels
Recycle all glass products in the
manufacturing process
Increase to 100%
Reduce process energy use 50% toward theoretical energy requirements
Reduce air/water emissions 20% below 1995 levels
Recover, recycle, and minimize available Increase to 100% where use exceeds 5lb. per capita
post-consumer glass products
Glass product quality Achieve Six Sigma quality
Broaden glass products in marketplace Create innovative glass products
Increase supplier/customer partnership In areas of raw materials, equipment, and energy
improvements
When envisioning a new approach to glassmaking, economic factors dominate technical
considerations. Capital costs of glass manufacturing must be reduced, preferably through
research and development of new melting technologies that substantially reduce required
investments; address the consumption of fossil fuel and cost of energy, both fossil and
electric; reduction of emissions; robotic and advanced automation that reduce labor costs;
and improve technical and aesthetic product quality. Yet any cost effective,
environmentally compliant technology developed must not create greater complexity in
processing methods or require greater expense of operation.
Business and technical industry leaders must develop a common view of the forces that
will drive the industry in the future and have a more visionary approach if the industry is
to survive. Glass manufacturers of all products can identify critical common areas that
could increase profit margins and market share to combat competition with alternative
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