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

maintained as a process development and demonstration facility, which can be accessed by
clients either for Plasmelt funded demonstrations, or on a for-fee basis for process/product
testing programs.
The development and demonstration of the concept will require a minimum of 1 to 1.5 years at
the Boulder Lab. The initial target is the textile fiberglass segment, since we expect to
demonstrate throughputs that can quickly be put into commercial use within this segment (i.e.
500 lb/hr). AGY is our first target location.
Energy and Environmental Benefits:
The plasma melter benefits to the glass industry include:
FEATURE BENEFIT
Low melting energy- 4.1MM BTU/ton vs
Fiber sector average of 8.42 MM
Low cost melter
50-70% improvement in energy use vs. direct firing
Significant capital cost savings (melter, APC,
facility cost). Estimated system cost ~ $500to $700,000
Uses little or no refractory
Environmental gains / lower operating cost
No glass contact with refractories
Low melt volume allows 10 minute Rapid product changes with minimal waste
Startups Ability to turn melter on/off; energy efficiency
Modular design allows additional units
to be added
Production efficiency; match market demands
Ability to change products daily Increase market share for niche products
Uses inert plasma gas/electric arc
Reduce emissions; eliminate combustion products
Reduced exhaust abatement (APC) equipment
Very high melt temperatures achievable Ability to melt specialty glasses / refractories
Plasma anode and cathode
Eliminate glass contamination/electro-chemical
(non-submerged)
glass reactions caused by submerged electrodes
In addition to the batch melter features and benefits listed, the plasma melter has already been
proven in recycling scrap glass material. The same melter used for batch melting can accept a
very wide variety of scrap glass materials and can process these at temperatures high enough to
burn off all binders and yield a glass. The economic benefits can be further enhanced when the
same capital investment can be used for multiple functions.
The relative value of the benefits listed will vary for different applications. In many cases, just
one of the benefits can provide the financial return to justify the use of plasma technology. Two
or more of the benefits listed can provide a significant competitive advantage.
The plasma melter technology will reduce the emissions while providing the opportunity to
recycle scrap products that would have previously been buried in a landfill. In addition to
providing the financial competitive advantage gained from the improved capital productivity, the
environment will benefit from the advancement of this technology.
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