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

entrainment by reducing melter size (i.e. surface area reduced over 90%), gas flow, impingement
and turbulence.
Volatiles: The melt rate of the plasma arc melter system is anticipated to be 10-20 times greater
per unit surface area than conventional fuel fired melter systems. The reduction in surface area
per ton, and the presence of unmelted batch on the melt surface, are expected to reduce the
volatilization of boron and fluorine, as well as volatile alkaline species. The amount of
improvement will be a function of the batch composition, melt rate (i.e. kinetics), and the
localized melt surface temperatures. .
The following is a summary of data referenced in OIT’s Energy and Environmental Profile (April
2002), and anticipated improvements that are expected from the demonstration. Where available,
the technical basis or logic behind the improvement has been provided.
Furnace/
segment
Particulate
(lb/ton)
SOx
(lb/ton)
NOx
(lb/ton)
CO
(lb/ton)
Fluoride
(lb/ton)
Insulation Fiber Glass
Regen/Recup 0.02-1.08 10 1.7-5 0.25 0.11-0.12
Gas-Direct 9 0.6 0.3 0.25 0.12
Textile Fiber Glass
Regen/Recup 2-16 3-30 20 0.5-1.0 2
Gas-Direct 6 ND 20 0.9 2
Pressed/Blown Glass (Uncontrolled)
All 17.4 5.6 16.8-27.2 0.2 ND
Plasma Improvement Estimates
Improvement >50% 25-50% >90% 100% 25-50% 100%
Reference Textile Textile Textile All Textile All
Basis Notes 1 2, 4 3 4 2 4
H2O, CO2
(combustion)
(lb/ton)
1) 90-95% reduction in gas flow relative to gas firing combustion product emissions
2) Surface area for equivalent melt rate is 75-90% less than conventional melters of similar
throughput (Plasma at < 1 sf/ton/day, versus 4-15 sf/ton/day for conventional melters)
3) Argon torch gas, limited reaction volume, high temperature gradients
4) No partial combustion or other combustion products due to elimination of carbon based fuel
sources; no sulfur contamination in fuels
Also, many experts agree that the ability to use gas-fired melters will be compromised in the 10- to
20-year time frame. Plasma technology is a natural alternative to gas-fired melters. Investment in
plasma technology now will provide the technology required in the future.
Economic Benefits
High Priority Target Markets for this plasma melting system (size shown in tons per year*):
169