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

expressed during interviews, discussions and workshops conducted over the course of
this study.
New melting glass processes must also be explored. Development of an advanced glass
melting process could be economically feasible as evaluated by improvements in glass
quality, higher yields in downstream forming operations, reduced energy consumption,
lower capital costs, enhanced flexibility, and adherence to environmental regulations.
The total automation of glass melting systems with adaptations to the continued evolution
of existing technology could also enhance the economic picture of glassmaking.
The submerged combustion melter effort has been encouraging because the consortium,
brought together by their membership in the GMIC, consists of major glass companies:
CertainTeed Corp.; Corning Incorporated; Johns Manville, Berkshire Hathaway Co.; PPG
Industries Inc.; Owens-Corning Corporation; and Schott North America Inc. These
companies account for a major share of glass sold in the US and are major employers
within the industry. This is the first such effort concentrated on an industry “Grand
Challenge.” This is a technology area where every glass company is involved but each
company uses the same process pioneered 60 years ago with relatively minor variations.
Many individual efforts have been mounted to improve this technology but due to the
complexity of the process and economics, not many innovations have been successful.
This recent effort has the potential to radically alter the economics of glass melting by
substantially reducing cost of operation. This combination of government funding and an
industry consortium, with the Gas Technology Institute (GTI) and suppliers sets a good
precedent.
VI.4. Conclusion
For the future of glass manufacturing in the United States, the need to develop new
energy-efficient, capital efficient and environmentally compliant glass melting processes
is crucial. This is a huge undertaking that will not be accomplished overnight. By
confronting the challenges and establishing a strategy, the glass industry can move
toward this goal. Without changes in the approach and drivers within the glass industry,
the US glass industry could follow the US steel industry into decline within the twentyfirst
century. By its inherent nature as a conservative, risk-averting industry, glass
manufacturers have already waited too long to solve the major problems that they face.
Increased funding from government sources will be essential for resolving the challenges
that confront the glass industry today.
The US glass industry could benefit from a new business model that would involve
collaboration across all four segments of glass manufacturing. The new business model
envisioned as Glass Inc. would involve a neutral party to play a comprehensive role in
evaluating technologies and assessing them for capital investment. Common problems
could be identified and technology could be developed to solve these problems for the
benefit of the whole industry.
Technology could be standardized for all segments of the industry that would benefit
from economies of scale in purchase of raw materials, energy sources, capital equipment,
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