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

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CONTENTS Executive Summary v Preface xiii Introduction 1 Section One Technical and Economic Assessment Report I. Technical Assessment of Glass Melting 9 II. Economic Assessment of US Glass Manufacturing 27 III. Traditional Glass Melting 49 IV. Innovations in Glass Technology 59 V. Industry Perspective on Melting Technology 89 VI. Vision for Glassmaking 101 Section Two Applied Glass Technology Introduction 109 1. Primer for Glassmaking 111 2. Automation and Instrumentation for Glass Manufacturing 137 3. Developments in Glass Melting Technology 149 Submerged Combustion Melting: 150 (Next Generation Melting System (NGMS) High-Intensity Plasma Glass Melter 161 Advanced Oxy-Fuel Fired Front End 173 Segmented Melting System 175 Appendices A. Literature and Patent Review—Glass Technology 180 1. Categorization of Literature 2. Categorization of Patents B. Glossary 239 C. Contributors and Sponsors 245 D. Technology Resource Directory 249 Bibliography 251 Figures and Tables 269 Index 271
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 10: Reference The report is supplemente
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
Page 68 and 69:
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
Page 76 and 77:
Chapter IV Innovations in Glass Tec
Page 78 and 79:
various stages of the process. Each
Page 80 and 81:
series of compartments heated and a
Page 82 and 83:
or glass components, plasma technol
Page 84 and 85:
output. If the technology were to b
Page 86 and 87:
Development of the Submerged Combus
Page 88 and 89:
Glass quality is the greatest conce
Page 90 and 91:
IV.7.2. Refining zones for electric
Page 92 and 93:
damper. The most stringent regulati
Page 94 and 95:
• electrostatic collection is eff
Page 96 and 97:
• soda-lime batch/cullet could be
Page 98 and 99:
pioneered the RAMAR system of mecha
Page 100 and 101:
limited power inputs and the unit t
Page 102 and 103:
y the Advanced Glass Melter develop
Page 104:
and PPG Inc. in the United States a
Page 107 and 108:
As challenges to industry intensify
Page 109 and 110:
.) Develop new products by coupling
Page 111 and 112:
developing an innovative glass melt
Page 113 and 114:
hazardous waste containment, recycl
Page 115 and 116:
Workshop Participants The perspecti
Page 117 and 118:
WARREN WOLF is currently a glass in
Page 119 and 120:
materials. Perhaps partnering or ot
Page 121 and 122:
expressed during interviews, discus
Page 124:
Section Two Applied Glass Technolog
Page 128 and 129:
Chapter 1 Primer for Glassmaking Co
Page 130 and 131:
Figure A.1 Figure 1.1. General Flow
Page 132 and 133:
intimately in contact with each oth
Page 134 and 135:
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
Page 142 and 143:
distance to escape. If thermal curr
Page 144 and 145:
ubbly or foamy layers under the bat
Page 146 and 147:
Melt evaporation is more appropriat
Page 148 and 149:
preparations are beneficial. These
Page 150 and 151:
The other common energy source for
Page 152 and 153:
precipitator (EP) dust collected fr
Page 154 and 155:
Chapter 2 Automation and Instrument
Page 156 and 157:
lower glass weight and combustion c
Page 158 and 159:
In practice, electric boosters, wit
Page 160 and 161:
Data control Data logging is requir
Page 162 and 163:
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
Page 168 and 169:
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
Page 210 and 211:
RR e c o m m e n d C o m p a n y s
Page 212 and 213:
RR ee c o m m e n d C o m p a n y s
Page 214 and 215:
Page 216 and 217:
RR e c o m m e n d s e c oo n d l o
Page 218 and 219:
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
Page 230:
Page 233 and 234:
R e cc o mm mm ee nn dd C o mm pp a
Page 235 and 236:
RR ee cc o m m ee n d C o mm p a n
Page 237 and 238:
R e c o m m e nn d C o m p a n y s
Page 239 and 240:
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
Page 245 and 246:
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
Page 249 and 250:
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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