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

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RR e c o m m e n d C o m p a n y s e c oo n d A u t h oo r / t i t l e / yy ee a r 11 2 3 4 5 6 7 8 9 1 00 1 1 1 22 1 3 1 44 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 22 a f f i l i a t e l oo o k ? Commentts by Walt Scott Browning, R., and Nabors, J. X X MG Ind Yes Oxygen preheat systems and Regenerative Oxygen Heat Recovery for advantages Improved Oxy-Fuel Glass Melter Efficiency Ceram. Eng. Sci. Proc., 188[1] 251-65 (1997) Buhdov X Intensification of Manufacturing Methods is the Principal Way to Make Production More Effective 1975 Byburt X Obtaining Glass from Gels by Lowtemperature Synthesis 1982 Cable, M.J. UnivShef Yes Revolutionary improvements in Possibilities of Progress in Glassmelting melting unlikely' J. Non-Cryst. Solids, 73[1-3] 451-61 (1985) Cable, M.J. UnivShef Yes Wide-ranging article; possible Challenge to Improve Large-Scale ideas Glassmelting Silikaty (Prague), 300[2] 155-68 (1986) Cable, M.J. UnivShef Yes Wide-ranging article; possible Century of Developments in Glassmelting ideas Research J. Am. Ceram. Soc., 811[5] 1083-94 (1998) Cable, M., and Siddiqui, M. Replacement of Soda Ash by Caustic Soda in Laboratory Glass Melting Trials Glass Technol., 21[4] 193-8 (1980) Carroll, H.R., and Angelo, J.J. Adding Lithium Can Improve Melting- Forming Performance Glass Ind., 64[11] 14-16 (1983) Carvalho, M.G. and Nogueira, M. Improvement of Energy Efficiency in Glass- Melting Furnaces, Cement Kilns and Baking Ovens Appl. Therm. Eng., 17[8/10] 921 (1997) Cerchez, M., Elena, T., and Spurcaciu, C. X X X X X Rumania Yes Future batching possibilities Kinetic Assessment of the Raw Materials Glass Batch Reactivity When Using Melting Acids or Pellets Sprechsaal, 118[9] 755-6, 8 (1985) 193
RR ee c o m m e n d C o m p a n y s e c o n d A u tt h o r // t i t l e / y e a r 1 2 3 4 5 6 7 88 99 11 0 11 1 1 2 1 33 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 11 2 2 a f f i l i a t e l o o k ? Comments by Walt Scott Chapman, C. X X X X Battelle Yes Several melting technologies State-of-the-Art of Waste Glass Melters for waste vitrification pp. 485-93 in Ceramic Transactions 229, Advances in Fusion and Processing of Glass, ed., Varshneya, A.K., Bickford, D.F., Bihuniak, P. American Ceramic Society, Westerville, OH 1993 Choubinidze X Granulating of Sodium Silicate Batch 1987 Choubinidze X X Main Directions in Creating of Novel Glass Manufacture Equipment 1980 Choubinidze X Melt Motion in Reception Bay of Cyclone Furnace 1980 Clark, T.P. X X Inex Yes Ideas for use of coal to fire Glass Furnace Direct Coal Firing glass Can. Clay Ceram. Q., 499[2] 8, 11 (1976) Conradt, R. X X X X GR - Univ Yes Practical look at furnace Some Fundamental Aspects of the Relation Operations vs quality/yields between Pull Rate and Energy Consumption of Glass Furnaces Int. Glass J., 200[108] 22-6 (2000) Cozzi, C., Blanchet, P. and Segond, J. Design of a Glass Furnace Throat by Means of a Single Mathematical Model Glass Technol., 24[2] 62-6 (1983) Di Bello, P.M. X X X X Ansac Yes Prereaction occuring in Time to Rethink Batch Prereactions preheated batch Glass (London), 69[3] 113-4 (1992) Ducharme, R., Scarfe, F., Kapadia, P., and X X England Yes Technical look at induction Dowden, J. heating The Induction Melting of Glass J. Phys. D: Appl. Phys., 24[5] 658-63(6) (1991) Ehrig, R., Wiegand, J., and Neubauer, E. X X X Sorg Yes LoNOx Melter results and Five Years of Operational Experience with rebuild plans the Sorg LoNOx Melter Glastech. Ber. Glass Sci. and Technol., 688[2] 73-8 (1995) 194
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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
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RAY RICHARDS holds a BS in chemistr
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Chapter VI Vision for Glassmaking V
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VI.3. Economic perspective The majo
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and facility construction and plant
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Introduction In the course of gener
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totally replaced by barium, zinc or
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of soda. Other raw materials includ
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Batch melting in combustion furnace
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1.3. Detailed description of the fu
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increase reactions in soda-lime-sil
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promoted by the addition of fine-gr
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The presence of some distinct solid
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surface and escape from the melt. S
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Homogenization can also be aided by
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Batch melting strongly depends on t
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downstream operations, these bubble
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furnaces generally have better spec
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fundamental change in heat transfer
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or long-term trends and judges the
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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
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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Page 232 and 233: Appendix A2 Categorization of Paten
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Page 256 and 257: Appendix B Glossary amortization: A
Page 258 and 259: 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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