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

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C.4. Special Contributors Elliott Levine, Department of Energy Keith Jamison, Energetics Josef Chmelar, Glass Service L. David Pye, Dean and Professor of Glass Science Emeritus, Alfred University Frederic Quan, Corning Incorporated Ronald Gonterman, Plasmelt William Prindle, glass industry consultant David Rue, Gas Technology Institute Phillip Sanger, Cleveland State University Saint-Gobain SEFPRO (formerly Corhart) for furnace cut-away drawings C.5. Automation Specialists Dan Base, Encompass Automation & Engineering Technologies LLC Josef Chmelar, Glass Services Peter W. Krause, Siemens Energy and Automation Inc. William K. Pollock, Optimation Technology Inc. Michael V. Triassi, Optimation Technology Inc. Mark Weihs, Encompass Automation & Engineering Technologies LLC C.6. Resource Contacts Many academic centers, R&D organizations, engineering firms, consultants, and manufacturers listed below assisted in the development of this report. AEI Air Liquide Air Products Alfred University Arc International Asahi Glass ATC BOC Gases British Glass BSN CGR (NSF Industry-University Center for Glass Research) Corning Czech Institute of Inorganic Chemistry Eclipse/Combustion Tec Frazier Simplex Gas Technical Institute GE Lighting German Glass Society, HVG Glass Service, Inc. Glass Technology Services Ltd. GMIC Gas Technical Institute Library Guardian H. F. Teichman 247
(C.6. Resource Contacts - Continued) ICG TC-13 (Environmental Committee) ISORCA Kumgand Korea Chemical Kyoto Institute of Technology Leone Industries Libbey Glass Maxon Nienburger Glas Nippon Electric Glass Co., Ltd. Owens Corning Owens-Illinois Perrier Philips Display Pilkington PPG PQ Corp. Saint Gobain (France) Saint Gobain Containers Scholes Library Science Production Enterprise (Armenia) Sorg Stazione Sperimentale del Vetro (Italy) St. George Crystal Techneglas TECO Thomson Multimedia Ultramax Vitro Vortec, Inc. Zippe C.7. Editorial and Reference Assistance Pat LaCourse, Scholes Library, New York State College of Ceramics at Alfred University Lori Kozey, Editing Services Nancy Lemon, Librarian, Owens Corning 248
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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
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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 219 and 220: RR ee 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 263: Associate Members: Advanced Manufac
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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