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

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• soda-lime batch/cullet could be preheated successfully to greater than 1000˚ F (538˚C); • a 1300 ˚ F (704 ˚ C) gas inlet and 280–380 ˚ F (138–193 ˚ C) gas outlet; • the system could be integrated in association with an operating glass furnace; • particulate loss from the preheater exhaust cyclone was
The modular design of the device makes for easy access to condensates for cleaning, but caused problems during operation. The Zippe indirect preheating device is in operation on furnaces in Europe, particularly in glass container furnaces in Germany, Switzerland and the Netherlands. (Barton, 1993) (Zippe B-H, Glass, 67[5] (1990) IV.8.6. Electrified Cullet Bed (Edmeston, Sweden, 1990) The Electrified Granulate Bed (EGB), a hybrid filter system, uses the cullet bed as a filter for waste gases. The system combines an electrostatic precipitator that removes dust with a direct cullet preheater. The hot waste gas enters the top of the system and passes through an ionizing stage, imparting an electrical charge to the dust particles. The gas then passes into a bed of granular cullet, which is polarized by a high-voltage electrode immersed in the cullet bed. The charged dust particles are attracted to the cullet, where they are deposited. The cullet is constantly being added at the top of a shaft from which it is removed at the bottom. The preheated cullet (up to 752 ˚ F [400 ˚ C]) and the attached particulates are charged into the furnace. In 1994, the Irish Glass Bottle Co., along with the British Glass Manufacturers Confederation and Edmeston GmbH, received a Thermie grant from the European Commission to develop this innovative cullet preheating process. The system developed by this group incorporated an electrostatic principle to collect furnace particulate onto the cullet that was fed to the furnace. Like the Zippe system, this device requires a separate cullet bin. Since the exhaust gases must be passed through a bed of cullet about 12 to 18 in. thick, the cullet must be of a reasonable size to minimize the pressure drop through the bed. Cullet preheat temperatures above 1292 ˚F (700 ˚C) have been realized, and particulate is recaptured with the system. A second unit installed on a new oxy-fuel furnace at Leone Industries in the United States has met New Source Performance Standards (NSPS) standards for particulate control. (McGrath, J.M., “Preheating cullet while using the cullet ed as a filter for waste gases in the Edmeston heat transfer/emission control system,” Glass Technology, 37[5], 146-150 (1996)) IV.9. Non-conventional melting systems Methods of combining melting and refining in non-conventional melting systems have been explored extensively both in the United States and Europe. Attempts to design innovative glass melting processes for melting and refining have generally segmented the melting process into distinct steps that incorporate driven systems to increase dissolution of sand particles and initial gaseous evolution from raw materials. Combined melting-refining systems explored over the past 25 years include the Rapid Melting and Refining (RAMAR) by Owens Illinois; Fusion et Affinage Rapide (FAR) system by Saint- Gobain; Fusion et Affinage Rapide Electrique (FARE) system by Saint-Gobain; and the PPG P- 10 system. (See details of these technologies below.) Since traditional glass melters rely on natural convection for internal melt movement, the melters are very “fragile.” Critical convection patterns are strongly affected by minor changes in inputs, largely changing product quality. More robust melters are needed to allow a stirred chemical reactor in which convection is controlled directly. Controlled stirring forces can counteract the forces created by thermal and compositional gradients and by release of gases. Owens-Illinois 80
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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
Page 45 and 46: A major regional producer, the Unit
Page 47 and 48: continues to operate using technolo
Page 49 and 50: The percentage used for batch melti
Page 51 and 52: having fewer producers of major com
Page 53 and 54: Flat glass Forecasters predict an a
Page 55 and 56: glass fiber in some applications an
Page 57 and 58: With the high capital cost of new g
Page 59 and 60: The economic viability of electric
Page 61 and 62: development and capital investment
Page 63 and 64: investment of the traditional glass
Page 65 and 66: and increase cooperation on the hig
Page 67 and 68: The melting processes for silica-ba
Page 69 and 70: In the regenerative furnace, two re
Page 71 and 72: • Unit melter The unit melter is
Page 73 and 74: Furnace emissions are reduced and t
Page 75 and 76: glass. Electric boost is often used
Page 77 and 78: materials, state-of-the-art equipme
Page 79 and 80: Figure IV.1. PPG P-10 Primary Melte
Page 81 and 82: system. Applications for the techno
Page 83 and 84: stable and controlled operating pro
Page 85 and 86: Four test series using oxy-gas burn
Page 87 and 88: In the AGM melting process, mixed b
Page 89 and 90: Melter controls are extremely sophi
Page 91 and 92: simplify heat exchange technique th
Page 93 and 94: square or rectangular hopper locate
Page 95: After operating for over 12 years,
Page 99 and 100: A single-phase 600-KW saturable rea
Page 101 and 102: IV.9.2. Fusion et Affinage Rapide (
Page 103 and 104: gases leave this compartment and gi
Page 106 and 107: Chapter V Industry Perspective on M
Page 108 and 109: problems that confront the entire i
Page 110 and 111: and port structures. Fuel savings o
Page 112 and 113: Glass manufacturers of all products
Page 114 and 115: here. To remain vigorous and compet
Page 116 and 117: RAY RICHARDS holds a BS in chemistr
Page 118 and 119: Chapter VI Vision for Glassmaking V
Page 120 and 121: VI.3. Economic perspective The majo
Page 122: and facility construction and plant
Page 126: Introduction In the course of gener
Page 129 and 130: totally replaced by barium, zinc or
Page 131 and 132: of soda. Other raw materials includ
Page 133 and 134: Batch melting in combustion furnace
Page 135 and 136: 1.3. Detailed description of the fu
Page 137 and 138: increase reactions in soda-lime-sil
Page 139 and 140: promoted by the addition of fine-gr
Page 141 and 142: The presence of some distinct solid
Page 143 and 144: surface and escape from the melt. S
Page 145 and 146: 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
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RR e c o m m e n d s e c oo n d l o
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A u tt h o r // t i t l e / y e a r
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Appendix A2 Categorization of Paten
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R ee cc o m mm e nn dd C o m pp a n
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RR e c oo mm m e n dd C o m p a n y
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R e c o m m e nn d C o m p a nn y s
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R ee c o m m ee n d C o m p a n yy
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R e c o m m e nn d C o m p a n y s
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R ee c o m m ee n d C o m p a n yy
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R e c o m m e nn d C o m p a n y s
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R e c o m m e n d C o m p a n yy s
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R e c oo m m e n d s e c o n d l o
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R ee c o m m ee nn d s e c o nn d l
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R e c o m m e n d s e c o n d l o o
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Appendix B Glossary amortization: A
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eduction costs could purchase exces
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Seg-Melt: Glass melting furnace tha
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Associate Members: Advanced Manufac
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(C.6. Resource Contacts - Continued
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BIBLIOGRAPHY Abbott, E., “Compari
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Bezborodov, M. A., “The Effect of
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Enninga, G., K. Dytrych, and H. Bar
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Kawachi, S., M. Kato, and Y. Kawase
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McCauley, R. A., “Evolution of Fl
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Pieper, H., “Flexible Melting Fur
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Schulz, R. L., Z. Fathi, D. E. Clar
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Tooley, F. V., Handbook of Glass Ma
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contributed by Nancy Lemon, Knowled
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INDEX Accelerated melting, 66-69, 9
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71-72; Successes, 11; PPG P-10 Proc
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ISBN: 0-9761283-0-6 Printed in the
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