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

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R e c o m m e n d s e c o n d l o o k ? Comments byy Walteer Scottt C o m p a n y a f ff i l i a t e PPattent no. T i t l e / i n v e n t o rr / d a tt e 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 88 1 9 2 0 2 1 2 2 X X X X GlasTec See 5273576 X X X X X Praxair See 5807418 X X X X Praxair See 5922097 X X X X Praxair See 5922097 - steam bubbling X X Asahi Yes Methods to dissolve foam - organic metal inject with gas X X X X X X BOC Yes Roof mounted oxy-fuel burners over batch in conv. Tank 00574537/EP B1 High shear mixer and glass melting apparatus and method R. S. Richards October 20, 1999 00808806/EP A1 Method for recovering energy in oxygen-fired glass melting furnaces R. P. Chamberland and H. Kobayashi November 26, 1997 00812809/EP A2 Method to reduce toxic emissions from glass melting furnaces by water enhanced fining process H. Koyabashi and R. G. C. Beerkens November 25, 1998 00884287/EP A1 Water enhanced fining process a method to reduce toxic emissions from glass melting furnaces H. Kobayashi and R. Beerkens December 16, 1998 01046618/EP A1 Method for melting glass Y. Takei and K. Oda October 25, 2000 01077201/EP A2 Method of boosting the heating in a glass melting furnace using a roof-mounted oxygen-fuel burner N. G. Simpson, G. F. Prusia, S. M. Carney, T. G. Clayton, A. P. Richardson and J. R. Leblanc February 21, 2001 01078892/EP A2 Process and furnace for melting glass using oxy-fuel burners R. Alchalabi, D. Satchell and S. V. Krishnan February 28, 2001 01136451/EP A2 Glass melting process and furnace therefor with oxy-fuel combustion over melting zone and air-fuel combustion over fining zone B. C. Hoke, K. A. Lievre, A. G. Slavejkov, J. L. Inskip, R. D. Marchiando and R. M. Eng September 26, 2001 00128702 WO Processing of contaminated river sediment in a glass melting furnace T. J. Baudhuin April 26, 2001 237 X X X X X X BOC Yes Roof burners with alternate lean and rich firing X X X X X X X Air Prod Furnace config. For oxy-fuel melting, air-fuel refining X X Min-Ergy Conversion of contaminated river slug to glass
R e c o m m e n d C o m p a n yy s e c o nn d PPattentt nno. T i tt l e / i n v e n t o r / d a t e 1 2 3 4 5 6 7 88 9 1 0 11 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 22 0 22 1 2 2 a f f i l i a tt e l o o k ?? Comments by Walter Scottt 09736134 WO Glass melting furnace X X X X CombTec NOx control with in-line burners in M. L. Joshi and P. J. Mohr firing ports October 2, 1997 09855411 WO Glass induction melting furnace X X X X X X X OCF Yes See 5979191 using a cold crucible C. Q. Jian December 10, 1998 09923050 WO Method and apparatus for melting X JohnMathy Platinum coating to refractories of glass batch materials D. R. Coupland, M. L. Doyle, R. Herts and P. M. Williams May 14, 1999 RE29,622 Apparatus and process for pellet X X X X X Pullman Batch and cullet pellet preheating preheating and volatile recycling in a glass making furnace K. H. Lange May 2, 1978 RE32,317 Glass batch liquefaction X X X X X X PPG Yes Rotary ablative melter to do first G. E. Kunkle and J. M. Matesa stage melting December 30, 1986 238
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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
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Plasmelt will utilize a full-scale
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Plasmelt has assembled a world-clas
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maintained as a process development
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entrainment by reducing melter size
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Glass melting began two weeks befor
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3.C. Advanced Oxy-Fuel Fired Front-
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3.D. Segmented Melting System Ruud
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supplemental energy input in a form
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Appendix A. Literature Review Glass
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A.2. Manufacturing flexibility Plac
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A.5. Recycled cullet use Increased
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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 232 and 233: Appendix A2 Categorization of Paten
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 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
Page 282 and 283: Tooley, F. V., Handbook of Glass Ma
Page 284: contributed by Nancy Lemon, Knowled
Page 288 and 289: INDEX Accelerated melting, 66-69, 9
Page 290 and 291: 71-72; Successes, 11; PPG P-10 Proc
Page 292: ISBN: 0-9761283-0-6 Printed in the
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