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

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Appendix C Contributors and Sponsors The assessment of glass manufacturing in the United States has been made possible through the generous financial support of private corporations and government agencies. The value of this document has been greatly enhanced by the voluntary contribution of expertise, energy and time of scientists, engineers, managers and manufacturers in all segments of the glass community throughout the US and abroad. C.1. Principal Investigators C. Philip Ross began his 34-year career in the glass industry in 1965 after he received a BSc degree in ceramic engineering from the University of Illinois, where he studied under Prof. Fay Tooley, editor of “The Handbook of Glass Manufacture.” Ross brought over 27 years of first-hand experience in glass manufacturing to the project from employment at Kerr Glass Manufacturing Corporation (1977-1992) as divisional vice president for batch and furnace engineering; Glass Container Corporation (1968-1972) as area furnace engineer; Anchor Hocking Glass Co. (1965-1968). For over 12 years, he has consulted with glass manufacturers in the US and abroad on glass technology and furnace design through his company Glass Industry Consulting International. Gabe L. Tincher, economic assessments consultant on the project, worked for 30 years at Owens Corning as a group leader in strategic planning, technical planning, venture development, and businesstechnical analysis. As Leader of Strategic Planning, he conducted a broad assessment of Owens- Corning’s technology base, “Technology 2000.” That resulted in re-allocation of technology resources, new hires in critical technology areas, and creation of a corporate competitive technology intelligence capability. Tincher earned a BS degree in chemistry and mathematics from Western Kentucky University, a MS in chemistry from University of Kentucky, and a MSIA from Purdue University’s Krannert Graduate School of Management. C.2. GMIC Members 2001 to 2003 CertainTeed Corporation Corning Incorporated Fire and Light Originals L.P. Johns Manville Leone Industries Libbey Inc. Longhorn Glass Corp. Owens Corning Osram Sylvania PPG Industries–Fiberglass Saint-Gobain Containers Saint-Gobain Vetrotex America Schott Glass Technologies Inc. Society for Glass Science and Practices Techneglas Visteon–An Enterprise of Ford Motor Company (GMIC Members 2001 to 2003 continued) 245
Associate Members: Advanced Manufacturing Center Air Liquide America B.O.C. Center for Glass Research Eclipse Inc./Combustion Tec Gas Technology Institute Glass Service, Inc. Mississippi State University (Diagnostic Instrumentation & Analysis Laboratory) Pacific Northwest National Laboratory Praxair, Inc. Siemens Energy and Automation U.S. Borax C.3. GMIC Next Generation Melting System Task Force Members: Hamid Abbasi, GTI John Chumley, Techneglas Frank Dumoulin, Praxair Marv Gridley, Saint-Gobain Containers Eric Helin, Saint-Gobain Containers Aaron Huber, Johns Manville Moe Khaleel, PNNL Peter Krause, Siemens Christopher Jian, OC Robert Moore, UM-R Rand Murnane, Corning Incorporated Bob Newell, Siemens John Plodinec, DIAL Gene Ramsey, DIAL Cheryl Richards, PPG Fiberglass David Rue, GTI; Tom Seward, CGR Neil Simpson, BOC Gases Bill Snyder, Praxair Mike Soboroff, DOE Mariano Velez, UM(R) John Wells, Saint Gobain Vetrotex Carsten Weinhold, Schott Jim Williams, Techneglas Dan Wishnick, Eclipse/Combustion Tec Warren Wolf, Warren W. Wolf Jr. Services 246
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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
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and diverting funds from R&D and ot
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RR e c o m m e n d C o m p a n y s
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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 215 and 216: RR e c o m m e n d C o m p a n y s
Page 223 and 224: A u tt h o r // t i t l e / y e a r
Page 229 and 230: RR e c o m m e n d C o m p a n y s
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 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 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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