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

If a glassmaking facility is engineered for an integrated development environment, the operator interfaces,
controllers, I/Os, drives, and communications are configured and programmed as one comprehensive system.
This allows for a more intuitive and clearer overview of the whole glassmaking process and standardizes the
engineering and facility configuration. When a system is tightly integrated, it can be designed, configured,
programmed and tested to allow faster delivery of products.
A push button plant operates automatically within limits established by knowledgeable process engineers,
who constantly require better target set points of a multiple set point control process. Technology is
available for model multiple set point changes that can be used until a strategy for process change is selected
with statistically predicted performance. This new set of process set points adjust for an aging furnace,
outside temperature or humidity changes. Changes in pull to accommodate job changes and cullet changes
are well within today’s control technology capability.
Batch delivery systems can be computerized to prevent deposit of raw materials in the wrong silos and to
assure on-time delivery of materials as needed.
An integrated automated system for glass melting obtains a continuous flow of information across the entire
operation of the plant from raw materials delivery to final glass product shipment. All business
administration within a company is handled through these systems: finances, order processing, production,
logistics.
Specific devices
• DeNOx technology is based on an increase of energy transfer from the flames to the batch and glass
directly, which results in a 50°C drop in exhaust temperature and a corresponding lowering of crown and
flame temperature. Developed by STG GmbH Cottbus, this technology has been designed to save energy
required to heat glass tank furnaces and reduce NOx emissions by 50 to 70 percent, down to 350-800
NOx/m 3 of air, compared to 0°C and 8 percent excess oxygen. An energy savings of 5-plus percent is
accompanied by increased melting capacity. Reduction of energy consumption and increased glass pull pays
for NOx emission reduction and provides a return of investment of less than a year. This intensified direct
energy transfer results from the design of oil and gas burners for improved heat exchange.
Any parasite air infiltration is minimized and compensated for, providing precisely controlled low-excess air
at the flame, thus extending furnace life and lowering capital cost. This assumes that the flux blocks and tuck
stones are protected against block cooling fan air that enters the furnace, as well as sealed sidewall burner
blocks.
• Optical Melting Control (OMC) provides better control for real melting conditions, optimizing these effects
and avoiding risk from increased heat transfer to glass and batch. OMC is based on computer processing of
information related to open glass surfaces, batch cover and hot spot conditions, as well as standards for
stable glass quality. Optical Melting Control, or imaging devices, optimizes glass melting within a furnace,
reducing energy consumption. Capital cost is relatively low, and life of the furnace is extended.
• Machine Cooling Automation. The use of this technology on the IS machine optimizes operation for
container glass. Production is increased, product quality is stable, and capital cost is relatively low.
• Viscosity Automation manages and sustains viscosity in container glass production. Production is
increased, product quality is stable and capital cost is relatively low.
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