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

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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 Richards, R.S., and Jain, V. X Stir-Melter Yes Glassification of radioactive Rapid Stirred Melting of Simulated West wastes Valley High Level Waste pp. 229-38 in Ceramic Transactions, Vol. 39, Environmental and Waste Management Issues in the Ceramic Industry, ed., G.B. Mellinger, American Ceramic Society, Westerville, OH (1994) Roberts, D. X X X Vitrix Ltd Yes Asbestos destruction with Vitrifix Process “portable furnace” Conf. Rec. – IAS Annu. Mtg., 222 1032-50 (1987) Rokhlin X X X Up-to-date Methods of Manufacturing Glass Containers 1974 Ross Consultant Yes Detailed study of glass Energy Benchmarking for the Glass Industry industry energy consumption 1997 Ruiz, R., Wayman, S., Jurcik, B., Philippe, L., and Latrides, J.-Y. Oxy-Fuel Furnace Design Considerations Ceram. Eng. Sci. proc., 16[2] 179-89 (1995) Ruslov, V.N. X X Yes - ideas Comparative analysis of several Improving the Fuel Efficiency of Glassmaking furnaces Furnaces Glass Ceram. (Eng. Trans.), 550[5-6] 239-41 (1993) Sahvina X X Study of Manufacture Characteristics of Granulated Hydrothermal Batch Prepared from Either Burned or Natural Dolomite 1984 Samokhvalov, V.S., Torlopov, A.A., Zub, M.P., X X Yes - ideas Results from steam Kravets, S.M., and Novoselov, V.E. superheater in flue Operating a Steam Superheater on a Glass- Melting Furnace Glass Ceram. (Eng. Trans.), 48[9-10 479 (1991) 207
RR e c o m m e n d s e c oo n d l oo o k ? Commentts by Walt Scott No Model of flat glass furnace waist design C o m p a n y a f f i l i a t e A u t h oo r / t i t l e / yy ee a r 1 2 3 4 5 6 7 8 99 11 0 11 1 1 2 1 33 1 44 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 22 X X X X X German Yes - ideas Treatise on German glass industry; recycling X X X X X X German Yes - ideas Indirect cullet preheating; Batch and cullet - effects humidity X X X X Netherlands Yes - ideas Preheat with low NOx and particulates; power generation Savina, I.M., Bespalov, V.P., Ya, Levitin L., and Popov, O.N. Effect of the Design of the Separating Unit on the Heat and Mass Transfer of the Glass Mass Glass Ceram. (Eng. Trans.), 446[1-2] 16-9 (1989) Scarfe, F. Electric Melting — A Review Glass Technol., 21[1] 37-50 (1980) Schaeffer, H.A. Scientific and Technological Challenges of Industrial Glass Melting Solid State Ionics, 105 [1-4] 265-70 (1998) Schmalhorst, E. PLM’s Success with Indirect Batch and Cullet Preheating Glass (London), 71[1] 21-2 (1994) Scholz, U. Batch preheating with Simultaneous Nitric Oxide Reduction in a Container Glassworks Ind. Ceram., 9669 208-14 (2001) Schroeder, R.W., Kwamya, J.D., Leone, P., and Barrickman, L. Batch and Cullet Preheating and Emissions Control on Oxy-Fuel Furnaces Ceram. Eng. Sci. Proc., 21[1] 207-19 (2000) Schulz, R.L., Fathi, Z., Clark, D.E., and Wicks, G.G. Microwave Processing of Simulated Nuclear Waste Glass pp. 451-8 in Ceramic Transactions, Vol. 21, Microwaves: Theory & Applications in Materials Processing. ed. D.E. Clark, F.D. Gac, and W.H. Sutton, American Ceramic Society, Westerville, OH (1991) Schwalbe, F.G. Twenty Years of Progress in Glass Melting Glass Ind., 211 169-70, 202 (1940) Senior, D. From Deep Refiner Technology to Mathematical Modelling Glass (London), 78[3] 86-7 (2001) 208 X X X X Batch and cullet preheat — results of test in New Jersey X X Univ.FLA Yes - ideas Microwave melting of radioactive frit TECO No Treatise on glass from 1920 to 1940 X X X X Zedlec Eng No Forehearth design development via model and software
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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
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elative to a defined zero with prec
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glassmaking have proven to be more
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• Fuzzy Control Automation soluti
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• Oxygen furnace (MPC) • Refine
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3.A. Submerged Combustion Melting N
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• The Year 1 go-no-go decision po
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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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Page 223: A u tt h o r // t i t l e / y e a r
Page 232 and 233: Appendix A2 Categorization of Paten
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Page 236 and 237: RR e c oo mm m e n dd C o m p a n y
Page 238 and 239: R e c o m m e nn d C o m p a nn y s
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Page 256 and 257: Appendix B Glossary amortization: A
Page 258 and 259: eduction costs could purchase exces
Page 260: Seg-Melt: Glass melting furnace tha
Page 263 and 264: Associate Members: Advanced Manufac
Page 265 and 266: (C.6. Resource Contacts - Continued
Page 268 and 269: BIBLIOGRAPHY Abbott, E., “Compari
Page 270 and 271: Bezborodov, M. A., “The Effect of
Page 272 and 273: 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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