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

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Chapter 3 Developments in Glass Melting Technology Research projects with potential to meet the need for a new glassmaking process Have been launched due to the efforts of the US DOE-Office of Industrial Technologies and the Glass Manufacturing Industry Council. Initial developments on these projects are reported here for further study: • Submerged Combustion Melting (Next Generation Melting System) Gas Technology Institute (David Rue) with A.C. Leadbetter and Son Inc., Fluent Inc., Praxair Inc NYSERDA DE-FC36-03G013092 USDOE • High-Intensity Plasma Glass Melter Plasmelt Glass Technologies, LCC Ron Gonterman and Michael Weinstein with James K. Hayward, InnovaTech Services Inc., N.Sight Partners LLC, Laboratory of Glass Properties LCC, Tooley Design Services, Advanced Glassfiber Yarns, Johns Manville • Oxy-Fuel Fired Front End Owens Corning (Steve Mighton) With Osram-Sylvania, Inc., BOC, Combustion Tec/Eclipse • Segmented Melting System Ruud Beerkens, TNO, the Netherlands 149
3.A. Submerged Combustion Melting Next Generation Melting System (NGMS) The Project Energy-Efficient Glass MeltingThe Next Generation Melter System (Report for 4 th quarter 2003) Gas Technology Institute with A.C. Leadbetter and Son Inc., Fluent Inc., Praxair Inc and NYSERDA USDOE award (DE-FC36-03GO13092) Objective The objective of this project is to demonstrate a high intensity glass melter, based on the submerged combustion melting technology. This melter will serve as the melting and homogenization section of a segmented, lower-capital cost, energy-efficient Next Generation Glass Melting System (NGMS). After this project, the melter will be ready to move toward commercial trials for some glasses needing little refining (fiberglass, etc.). For other glasses, a second project Phase or glass industry research is anticipated to develop the fining stage of the NGMS process. Overall goals of this project are: • Design and fabrication of a 1 ton/h pilot-scale submerged combustion glass melter, • Extensive melting of container, fiber, flat, and specialty glass formulations, • Detailed analysis of the product glasses, • Preparation of a Fluent-supported CFD model of the melter to be used in parallel with further development of the NGMS technology, • Physical modeling of the NGMS process to determine energy savings, cost savings, environmental improvements, and use of waste heat for production of needed oxygen, • Development of a commercialization plan and timeline for further, needed components and integration of the NGMS technology. The project team recognizes that further work will be needed after this project to bring the critically-needed NGMS into industrial use. To expedite that development, the work in this project is focusing in three areas needed to demonstrate the melting and homogenization steps of the NGMS technology and to prepare for further work to commercialize NGMS. These work areas are: • Design, fabrication, and operation of a pilot-scale melter with analysis of product glass, • Supported Computational Fluid Dynamics (CFD) modeling on the melter that is available to all users, • Physical modeling and energy balances for the full NGMS with specific planning for further steps leading to commercial implementation. Work in each project year is divided into tasks with milestones at the end of many of the Tasks. The integrated Task Schedule enables project team members to assign labor appropriately and to follow a critical path to reach all milestones and objectives toward 150
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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
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Figure IV.1. PPG P-10 Primary Melte
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system. Applications for the techno
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stable and controlled operating pro
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Four test series using oxy-gas burn
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In the AGM melting process, mixed b
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Melter controls are extremely sophi
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simplify heat exchange technique th
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square or rectangular hopper locate
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After operating for over 12 years,
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The modular design of the device ma
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A single-phase 600-KW saturable rea
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IV.9.2. Fusion et Affinage Rapide (
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gases leave this compartment and gi
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Chapter V Industry Perspective on M
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problems that confront the entire i
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and port structures. Fuel savings o
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Glass manufacturers of all products
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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
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Page 126: Introduction In the course of gener
Page 129 and 130: totally replaced by barium, zinc or
Page 131 and 132: of soda. Other raw materials includ
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
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Page 163 and 164: • Fuzzy Control Automation soluti
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Page 169 and 170: • The Year 1 go-no-go decision po
Page 171 and 172: splitting the fuel-oxidant mixture
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Page 175 and 176: The project team has agreed to form
Page 178 and 179: 3.B. High-Intensity Plasma Glass Me
Page 180 and 181: Plasmelt will utilize a full-scale
Page 182 and 183: Plasmelt has assembled a world-clas
Page 184 and 185: maintained as a process development
Page 186 and 187: entrainment by reducing melter size
Page 188 and 189: Glass melting began two weeks befor
Page 190 and 191: 3.C. Advanced Oxy-Fuel Fired Front-
Page 192 and 193: 3.D. Segmented Melting System Ruud
Page 194 and 195: supplemental energy input in a form
Page 196 and 197: Appendix A. Literature Review Glass
Page 198 and 199: A.2. Manufacturing flexibility Plac
Page 200 and 201: A.5. Recycled cullet use Increased
Page 202 and 203: Technology for direct heating withi
Page 204: and diverting funds from R&D and ot
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A u tt h o r // t i t l e / y e a r
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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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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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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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