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

awarded, and a forum convened to tap hundreds of years of experience and knowledge of
expert glass industry scientists and engineers provided the data for this document. As an
industry reference, “Glass Melting Technology: A Technical and Economic Assessment”
should enhance the viability of the glass industry in the nation’s economy by creating a
broad based understanding of glass melting technology research and development;
economic challenges and potential; current glass melting practice; past innovations with
potential for future development; the perspective of experienced glass manufacturers;
and activity in cutting edge melting research. To expand this document’s value,
appendices include a primer on the glass fusion process; review of technical literature
and patents; and an analysis of automation systems and instrumentation to improve the
melting process.
Technology Assessment
The technical dimensions of the current glass melting process must be addressed if the
industry is to meet the increasing demands of the 21st century. Development for all four
segments of the industry will be affected by the following factors: higher quality
requirements; stricter environmental regulations; cost and availability of fuel; capital
intensity; capital productivity; improved flexibility of operation; reduced product costs;
development of new glass compositions; improved worker ergonomics; and better
methods to recycle waste glass. Competition from other materials and imported glass
products intensifies the need for advanced melting technology.
Development of a new glass melting process will not be easy. Energy efficiency of the
glass melting process is approaching practical limits. Further environmental regulations
and glassmaking technology must be compatible. The four glassmaking segments must
identify common areas for improvement, pool their resources, and share the risks.
Profitability must be improved to allow appropriate funding for research and to provide
capital investment opportunities.
Under the auspices of the US DOE Office of Industrial Technologies and the Glass
Manufacturing Industry Council (GMIC), research efforts are already underway to
enhance the viability of this important US industry. Among the research projects funded
are Submerged Combustion Melting (Next Generation Melting System/NGMS);
Segmented Melting System; High-Intensity Plasma Glass Melter; and Advanced Oxy-
Fuel Fired Front End Melting. Members of the GMIC are making a concerted
cooperative effort to advance glass-melting technology.
Economic Assessment
Despite economic challenges, most segments of the multi-billion dollar glass industry
have maintained reasonable operating margins and have generated positive cash flow.
Container glass, although threatened by substitution of plastics and aluminum, has
experienced an upsurge in the past few years due to increased use for alcoholic
beverages. Flat glass has fluctuated with the economy, yet sales have remained positive
over the past 25 years. Fiberglass insulation has slowed slightly in recent years but is
expected to surge with new construction due to lower interest rates and with concern for
energy consumption. Fiberglass textiles and reinforcements sales have also reflected a
vi