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

Tables
Table II.1. Key End-Use Markets by Segment 31
Table II.2. Estimated Cost of Manufacture by Cost Component (%) 31
Table II.3. Energy by Process Stage 32
Table II.4. Industry Segment Concentration 34
Table II.5. Trend in value of glass products shipped 1997–2001 ($ million) 34
Table II.6. Trend in Container Glass Shipments 35
Table II.7. US Flat Glass Production 1980 to 2000 36
Table II.8. Glass Fiber Insulation Demand by Market 1990-2010 38
Table II.9. US Value of Glass Shipments 39
Table II.10. Melter Rebuild Cost by Glass Industry Segment 40
Table II.11. Direct Container Glass Costs 41
Table II.12. Reduction in Energy Cost (%) Required to Earn 10% to 20% 45
Return on a $1Million Capital Investment per Glass Furnace
Table III.1. Advantages and Disadvantages of Electric Melting 57
Table IV.I. RAMAR compared to conventional melting systems 83
Table VI. Objectives and Goals for 2020 101
Table 2.1 Key Performance indicators (KPI) 138
Table A.1. Categorization of Liberature 189
Table A.2. Categorization of Patents 215
Figures
Figure I.1. Quality, Energy, Throughput Choices. 13
Figure I.2. Energy consumption of 123 glass furnaces globally, ranked low to high. 14
Figure I.3. Sankey diagram of energy flows in the most energy-efficient container glass 16
furnace—end port regenerative without electric boosting—normalized to 50% cullet,
without batch preheating.
Figure II.1. Trend in Flat Glass Sales for 25 years. 46
Figure III.1. End Port Melter 52
Figure III.2. Side Port Melter 53
Figure III.3. Unit Melter 54
Figure IV.1. PPG P-10 Primary Melter, Secondary Melter, and Vacuum Refining 62
Figure IV.2. GRI’s Advanced Glass Melter 69
Figure IV.3. BOC E-Batch Design 75
Figure IV.4. Rapid Melting and Refining (RAMAR) Owens-Illinois (pellet et al. 1973;
Barton, 1993). 82
Figure 1.1. General Flow of Glass Manufacture 113
Figure 3.A.1.. Submerged Combustion Melter Schematic. 153
Figure 3.B.1. High-Intensity Plasma Glass Melter Schematic 162
Figure 3.D.1. Schematic arrangement of sections of a segmented melter, with typical
temperature levels, residence times, and heating options. 178
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