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

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Figure A.1 Figure 1.1. General Flow of Glass Manufacture The amount of soda ash (Na2CO3) produced by the Solvay process has decreased, and most soda ash now comes from the Trona, WY, deposits (trona, Na2CO3 -NaHCO3- 2H2O). Caustic soda (NaOH) solutions may be used in wet batching processes as a source 113
of soda. Other raw materials include boron, generally from deposits in California or Turkey. Either anhydrous borax or boric acid is used, but their consumption is decreasing because of the energy required to produce them. Mineral ores such as colemanite, rasorite or ulexite are now used in addition to boric acid or penta-aquo borax (Na2B4O75H2O) when possible. Feldspar and nepheline syenite are common mineral sources of alumina. Litharge is used as a source of lead oxide for the manufacture of lead glasses. Sulfates or nitrates oxidize other oxides in the glass and control fining reactions. Powdered anthracite coal is a common reducing agent in glass manufacture. Fining agents remove the bubbles in the molten glass and include sulfates, halides, peroxides, chlorates, perchlorates, CeO2, MnO2, As2O3 and Sb2O3. They react by release of oxygen or sulfur trioxide, or by vaporization as in the case of halides. Controlled decomposition of sodium sulfate with powdered coal is used to fine many soda-lime compositions. Common colorants for glass include iron, chromium, cerium, cobalt, nickel and selenium. Small amounts of iron are sometimes desirable for color and controlled radiant heat transfer during melting. Ferrous sulfide or iron pyrites produce amber-colored glass used in the container industry. Iron chromite is a source of chromium for green container glasses, whereas small amounts of cobalt and nickel oxides added to flint glass decolorize the yellow-green color that results from iron contamination. Selenium with iron and cobalt yields a bronze color. Ceria is used to increase ultraviolet absorption in optical or colorless soda-lime glass and to protect glasses from x-ray browning. Cullet, or broken glass, is used as a batch material to enhance glass melting and to reduce the amount of dust and other particulate matter that often accompanies a batch made exclusively from raw materials. Some forming operations, for example, the ribbon machine, generate as much as 70% waste glass, which must be recycled as cullet. More efficient operations, such as those used in the container industry, may require the purchase of cullet from recycled glass distributors or other sources. Typically, 10–50% of a glass batch comprises cullet. Melting and fining depend on the batch materials interacting with each other at the proper time and in the proper order. Therefore, care must be taken to obtain materials of optimum grain size, to weigh them carefully, and to mix them together intimately. The efficiency of the melting operation and the uniformity and quality of the glass product are often determined by the batch preparation. Batch handling systems vary widely throughout the industry, ranging from manual to fully automatic. Each batch material is stored in its own bin and the correct amount, determined and controlled by a computer, is weighed directly from the bin onto a conveyor belt that feeds directly into a mixer. Alternatively, sometimes only the gross weighing is made automatically and the final dribble feed is controlled manually. For small tanks and pot furnaces where the composition changes frequently, the batches are sometimes weighed into a bin or hopper. Often the weighing step is the most crucial in small tank operations, which are the most sensitive to fluctuations and often melt the types of glasses that must meet the most rigid specifications. Wet mixing and batch agglomeration (pelletizing or briquetting) are coming into vogue for several reasons. A wet batch (3–4% water) prevents dusting, controls air pollution, and ensures homogeneity, therefore increasing melting efficiency and glass quality. Especially in batches with raw materials of varying grain size, a wet batch prevents particle segregation because of fine particles settling to the bottom of the bin. The homogeneous batch melts more efficiently because all of the batch materials are more 114
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Glass Melting Technology: A Technic
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Disclaimer This document was prepar
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Glass Melting Technology: A Technic
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cyclical economy. Specialty glass m
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Reference The report is supplemente
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Preface The glass industry is under
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While this section was not a major
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5. All traditional glass segments a
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• Energy issues Glass melting is
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The issue of funding for research a
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Chapter I Technical Assessment of G
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process when it introduced continuo
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Figure I.1. Quality, Energy, Throug
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credible forecasts that energy cost
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Capital-intensive manufacturing bus
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silica sand with a variety of indus
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I.4. Motivation to advance melting
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would be possible with a more detai
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efining, higher performance refract
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A major regional producer, the Unit
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continues to operate using technolo
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The percentage used for batch melti
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having fewer producers of major com
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Flat glass Forecasters predict an a
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glass fiber in some applications an
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With the high capital cost of new g
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The economic viability of electric
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development and capital investment
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investment of the traditional glass
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and increase cooperation on the hig
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The melting processes for silica-ba
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In the regenerative furnace, two re
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• Unit melter The unit melter is
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Furnace emissions are reduced and t
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glass. Electric boost is often used
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materials, state-of-the-art equipme
Page 79 and 80: Figure IV.1. PPG P-10 Primary Melte
Page 81 and 82: system. Applications for the techno
Page 83 and 84: stable and controlled operating pro
Page 85 and 86: Four test series using oxy-gas burn
Page 87 and 88: In the AGM melting process, mixed b
Page 89 and 90: Melter controls are extremely sophi
Page 91 and 92: simplify heat exchange technique th
Page 93 and 94: square or rectangular hopper locate
Page 95 and 96: After operating for over 12 years,
Page 97 and 98: The modular design of the device ma
Page 99 and 100: A single-phase 600-KW saturable rea
Page 101 and 102: IV.9.2. Fusion et Affinage Rapide (
Page 103 and 104: gases leave this compartment and gi
Page 106 and 107: Chapter V Industry Perspective on M
Page 108 and 109: problems that confront the entire i
Page 110 and 111: and port structures. Fuel savings o
Page 112 and 113: Glass manufacturers of all products
Page 114 and 115: here. To remain vigorous and compet
Page 116 and 117: RAY RICHARDS holds a BS in chemistr
Page 118 and 119: Chapter VI Vision for Glassmaking V
Page 120 and 121: VI.3. Economic perspective The majo
Page 122: and facility construction and plant
Page 126: Introduction In the course of gener
Page 129: totally replaced by barium, zinc or
Page 133 and 134: Batch melting in combustion furnace
Page 135 and 136: 1.3. Detailed description of the fu
Page 137 and 138: increase reactions in soda-lime-sil
Page 139 and 140: promoted by the addition of fine-gr
Page 141 and 142: The presence of some distinct solid
Page 143 and 144: surface and escape from the melt. S
Page 145 and 146: Homogenization can also be aided by
Page 147 and 148: Batch melting strongly depends on t
Page 149 and 150: downstream operations, these bubble
Page 151 and 152: furnaces generally have better spec
Page 153 and 154: fundamental change in heat transfer
Page 155 and 156: or long-term trends and judges the
Page 157 and 158: Thermal momentum Thermal momentum i
Page 159 and 160: elative to a defined zero with prec
Page 161 and 162: glassmaking have proven to be more
Page 163 and 164: • Fuzzy Control Automation soluti
Page 165 and 166: • Oxygen furnace (MPC) • Refine
Page 167 and 168: 3.A. Submerged Combustion Melting N
Page 169 and 170: • The Year 1 go-no-go decision po
Page 171 and 172: splitting the fuel-oxidant mixture
Page 173 and 174: and has proved highly reliable. The
Page 175 and 176: The project team has agreed to form
Page 178 and 179: 3.B. High-Intensity Plasma Glass Me
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Plasmelt will utilize a full-scale
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Plasmelt has assembled a world-clas
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maintained as a process development
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entrainment by reducing melter size
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Glass melting began two weeks befor
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3.C. Advanced Oxy-Fuel Fired Front-
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3.D. Segmented Melting System Ruud
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supplemental energy input in a form
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Appendix A. Literature Review Glass
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A.2. Manufacturing flexibility Plac
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A.5. Recycled cullet use Increased
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Technology for direct heating withi
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and diverting funds from R&D and ot
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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 s e c oo n dd l
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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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RR e c o m m e n d s e c oo n d l o
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A u tt h o r // t i t l e / y e a r
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Appendix A2 Categorization of Paten
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R ee cc o m mm e nn dd C o m pp a n
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RR e c oo mm m e n dd C o m p a n y
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R e c o m m e nn d C o m p a nn y s
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R ee c o m m ee n d C o m p a n yy
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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 ee n d C o m p a n yy
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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 e c o m m e n d C o m p a n yy s
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R e c oo m m e n d s e c o n d l o
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R ee c o m m ee nn d s e c o nn d l
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R e c o m m e n d s e c o n d l o o
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Appendix B Glossary amortization: A
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eduction costs could purchase exces
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Seg-Melt: Glass melting furnace tha
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Associate Members: Advanced Manufac
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(C.6. Resource Contacts - Continued
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BIBLIOGRAPHY Abbott, E., “Compari
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Bezborodov, M. A., “The Effect of
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Enninga, G., K. Dytrych, and H. Bar
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Kawachi, S., M. Kato, and Y. Kawase
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McCauley, R. A., “Evolution of Fl
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Pieper, H., “Flexible Melting Fur
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Schulz, R. L., Z. Fathi, D. E. Clar
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Tooley, F. V., Handbook of Glass Ma
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contributed by Nancy Lemon, Knowled
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INDEX Accelerated melting, 66-69, 9
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71-72; Successes, 11; PPG P-10 Proc
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ISBN: 0-9761283-0-6 Printed in the
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