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

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Appendix A2 Categorization of Patents Patents Reviewed and Categorized, July–September 2002 Categories developed to characterize the literature and patents for glass science and engineering for reference purposes Include technical data (1-15), financial/economic data (16-18), applications (19-22). Item Category TECHNICAL 1 Glass Quality Improvement 2 Manufacturing Flexibility 3 Raw Material Oxide Source Selection 4 Raw Material Beneficiation 5 Recycled Cullet Use 6 Batch preparation/Agglomeration 7 Batch/Cullet Preheating (or Pre-reacting) 8 Enhanced Heat Transfer 9 Waste Heat Recovery 10 Fusion (Sand Solution) Process 11 Zonal Separation 12 Refining (Seed Removal) 13 Chemical and Thermal Conditioning 14 Process Controls (Sensors, Analytical/Predictive, Process Analysis and Control) 15 Environmental Compliance FINANCIAL/ECONOMIC 16 Lower Capital Cost 17 Lower Operating Cost 18 Lower Environmental Compliance Cost APPLICATIONS 19 All-Electric Melter 20 Total Oxygen and Fuel-Fired Furnace 21 Combination Fuel and Electric Furnace 22 Can Apply to the General Glass Industry 215
R e cc o mm mm ee nn dd C o mm pp a n y ss e c o n d Paatteent no.. T i t l ee / i n v e n t oo rr / d a t e 1 2 3 44 5 6 77 8 9 1 0 1 1 1 2 11 3 1 4 11 5 1 6 1 7 1 8 1 99 2 0 2 1 2 2 a ff ff i l i a t e l o o k ? Coommmenntts byy WWaltter Scotttt 1,863,708 Melting glass in a rotary furnace X X X X German Inclined drum melter G. Zotos June 21, 1929 1,885,722 Melting glass by passing an electric X X PPG Yes Electric current through the material H. F. Hitner November 1, 1933 1,906,594 Melting glass by electric heating (with a X PPG Yes Electric reduced wall wear high-frequency induction coil) H. F. Hitner May 2, 1933 1,980,373 Rotary furnace for melting glass and X X Hazel Atl. Rotary kiln melter associated apparatus suitable for tilting the furnace, etc. S. B. Bowman and F. C. Flint November 13, 1935 2,127,087 Weir for use under molten glass in X X Hart. Emp Furnace weir with gas cooling glass-making tanks V. Mulholland August 16, 1938 2,330,343 Apparatus for fining molten glass by a X X PPG Stirrer /bubbler "bubbling operation" J. G. Frantz September 28, 1943 3,048,640 Melting and feeding heat-softenable X X X X OCF Marble melter mineral material, such as glass H. I. Glaser August 7, 1962 3,321,289 Rotatable current baffle in glass flow X X X X St. Gobain Graphite return flow baffle furnace R. Touvay May 23, 1967 3,811,859 Apparatus and method for X X PPG Oxygen bubble generator — electrolyically generating stirring cathode/anode bubbles in a glass melt F. M. Ernsberger May 21, 1974 3,938,976 Processes and apparatus for feeding X X X X PB-Float material to a glass melting tank N. I. W. Walker February 17, 1976 3,942,968 Method and apparatus for melting and X X X X X X X X X Sorg Yes subsequently refining glass H. Pieper March 9, 1976 216
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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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and has proved highly reliable. The
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The project team has agreed to form
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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
Page 207 and 208: RR e c o m m e n d C o m p a n y s
Page 209 and 210: RR ee c o m m e n d s e c oo n dd l
Page 211 and 212: RR ee c o m m e n d C o m p a n y s
Page 213 and 214: RR e c o m m e n d s e c oo n d l o
Page 223 and 224: A u tt h o r // t i t l e / y e a r
Page 234 and 235: R ee cc o m mm e nn dd C o m pp a n
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
Page 240 and 241: R ee c o m m ee n d C o m p a n yy
Page 242 and 243: R e c o m m e nn d C o m p a n y s
Page 244 and 245: R ee c o m m ee n d C o m p a n yy
Page 246 and 247: R e c o m m e nn d C o m p a n y s
Page 248 and 249: R e c o m m e n d C o m p a n yy s
Page 250 and 251: R e c oo m m e n d s e c o n d l o
Page 252 and 253: R ee c o m m ee nn d s e c o nn d l
Page 254 and 255: R e c o m m e n d s e c o n d l o o
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
Page 274 and 275: Kawachi, S., M. Kato, and Y. Kawase
Page 276 and 277: McCauley, R. A., “Evolution of Fl
Page 278 and 279: Pieper, H., “Flexible Melting Fur
Page 280 and 281: 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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