81st Conference on Glass Problems E-Book
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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Serie: Ceramic Transaction Series
- Sprache: Englisch
The 81st Conference on Glass Problems (GPC) was organized by the Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, Alfred, NY 14802 and The Glass Manufacturing Industry Council (GMIC), Westerville, OH 43082. The Program Director was S. K. Sundaram, Inamori Professor of Materials Science and Engineering, Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, Alfred, NY 14802. The Conference Director was Bob Lipetz, Executive Director, Glass Manufacturing Industry Council (GMIC), Westerville, OH 43082. The GPC Advisory Board (AB) included the Program Director, the Conference Director, and several industry representatives. The Board assembled the technical program. Donna Banks of the GMIC coordinated the events and provided support. Due to world-wide COVID-19 pandemic, the conference was a virtual event. It started with a full-day plenary session followed by technical sessions.
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Table of Contents
Cover
Title Page
Copyright
Foreword
Preface
Acknowledgements
PLENARY
SURFACE VISCOSITY AND THE MELTING OF GLASS
ABSTRACT
GLASS FURNACE CORROSION
OBSERVED END OF LIFE FURNACE JOINT CORROSION
CORROSION AT THREE PHASE INTERFACES
SURFACE VISCOSITY
GLASS VISCOSITY
MODEL AND EQUATION
EQUATION DEVELOPMENT
STRUCTURAL RELAXATION
NETWORK BONDING
INTERNETWORK BONDING
FIT TO GLASS VISCOSITY
STRUCTURAL RELEVANCE OF PARAMETERS
SURFACE VISCOSITY
APPLICATION TO FURNACE CORROSION
CONCLUSIONS
ACKNOWLEDGEMENTS
REFERENCES
CONSTRUCTION AND REPAIR
SUPPORTING HOT AND COLD FURNACE REPAIRS
ABSTRACT
INTRODUCTION
EQUIPMENT USED
ADDITIONAL APPLICATIONS
REFERENCES
INFRASTRUCTURE AND PROCESS CONSIDERATIONS WHEN INCREASING THE SIZE OF YOUR FURNACE
ABSTRACT
INTRODUCTION
BUDGET ISSUES WITH LARGE CAPITAL PROJECTS
US GLASS MARKET CAPITAL EXPENDITURES
CAPITAL PROJECT SCENARIO
CONCLUSIONS AND RECOMMENDATIONS
REFERENCES
ANALYSIS OF EXPERIENCES IN RECURRING FURNACE CONSTRUCTION PROJECTS
ABSTRACT
INTRODUCTION
RESEARCH METHOD
RECOGNITION AND FIELD IMMERSION
DATA COLLECTION AND ANALYSIS
PHENOMENON DESCRIPTION
RFCP MANAGEMENT MODEL PROPOSAL
CONCLUSIONS
REFERENCES
MELTING
IMPROVED GLASS HOMOGENEITY AND HIGHER SUSTAINABILITY THROUGH TEXTURED EXPENDABLES TUBES IN CONTAINER GLASS FURNACE
ABSTRACT
TEXTURED EXPENDABLE TUBES – ROLE AND BENEFITS
INDUSTRIAL MEASUREMENTS OF GOBS PROPERTIES
CONCLUSION
EXTENDING CAMPAIGN LIFE IN AN ALL‐ELECTRIC MELTER USING HIGH LEVELS OF COMMERCIAL CULLET
ABSTRACT
INTRODUCTION
THE VALUE OF LONGER MELTER CAMPAIGNS
TECHNICAL APPROACH
CULLET TRIALS
RESULTS SUMMARY
SUMMARY
REFERENCES
CASE STUDY: COMPARISON OF AN AC IGBT CONTROLLED SYSTEM AND AC PHASE ANGLE SCR CONTROLLED SYSTEM IN A RESISTANCE HEATING APPLICATION
THE CHALLENGE
BACKGROUND AND DEFINITIONS
SETUP
TESTING RESULTS
COMPARISON
RESULTS AND CONCLUSIONS
CONCLUSIONS
FROM LANDFILL TO RAW MATERIAL: OBTAINING HIGH QUALITY RECYCLED CULLET TO AVOID GLASS MANUFACTURING PROBLEMS
ABSTRACT
HISTORY OF GLASS RECYCLING IN THE NETHERLANDS
THE RECYCLING PROCESS
THE INSPECTION PROCESS
IMPROVEMENTS IN CULLET QUALITY
FURTHER DEVELOPMENTS
CONCLUSIONS
REFERENCES
QUALITY CONTROL AND SENSORS
GLASS MELT QUALITY OPTIMIZATION BY MATHEMATICAL MODELING OF REDOX AND BUBBLES IN THE GLASS MELT
ABSTRACT
INTRODUCTION
REDOX CHEMISTRY OF CONTAINER GLASSES WITH CHROMIUM
REDOX REACTIONS UNDER REDUCING CONDITIONS
REDOX REACTIONS IN THE FULL 3D MODEL
BUBBLE PREDICTION IN THE FULL 3D MODEL
APPLICATION OF THE MODEL IN AN INDUSTRIAL SITUATION
CONCLUSIONS
REFERENCES
THE DETECTION AND ROOT CAUSES OF CORD IN GLASS
ABSTRACT
INTRODUCTION
ROOT CAUSES OF CORD
CASE STUDIES
DETECTION OF CORD
ABRADED THERMAL SHOCK TESTING
CONCLUSION
ACKNOWLEDGEMENTS
REFERENCES
FLOAT GLASS FLATNESS: PROCESS CONSEQUENCES, AND HOW TO IMPROVE CONTROL
EFFICIENT FLOAT GLASS INSPECTION IN A MATTER OF SECONDS: 3D MEASUREMENT FOR TOP‐QUALITY LARGE GLASS
3D MEASUREMENT PROVIDES DATA FOR COMPREHENSIVE PROCESS OPTIMIZATION
POTENTIAL OF FLOAT GLASS INSPECTION FOR INNOVATIVE INDUSTRY SECTORS
CONCLUSION
ENVIRONMENT AND SUSTAINABILITY
WASTE HEAT RECOVERY IN OXY‐FUEL GLASS FURNACES –A PATH TO SUSTAINABILITY AND LOWER CO
2
EMISSIONS
INTRODUCTION
FUTURE OF OXY‐FUEL GLASS MELTING
BATCH AND/OR CULLET PREHEATING
THERMO‐CHEMICAL REGENERATOR SYSTEM (TCR) TECHNOLOGY
ACHIEVING FULL HEAT RECOVERY
BRIDGE TO FUTURE WITH GREEN H
2
SUMMARY
REFERENCES
End User License Agreement
List of Tables
Chapter 1
Table 1 Comparison of predictions
Chapter 2
Table 1 Target vs. actual temperatures
Chapter 3
Table 1 Typical Container Glass Process Fan Lineup
Chapter 4
Table 1 Study group
Table 2 Documents and analysis units count
Table 3 Coding syntaxis for analysis units
Table 4 Code list
Chapter 6
Table 1 Cost Effect of Extending Melter Campaign
Table 2 Manganese Dioxide Reactions and Oxygen Release2
Table 3 Project Glass Temperature Reductions
Chapter 10
Table 1 Comparing outcomes of stress birefringence measurements and abraded t...
Chapter 12
Table 1 List of commercial references for Batch and Cullet Preheating from Jo...
List of Illustrations
Chapter 1
Figure 1 Photo of AZS sidewall at furnace end of life
Figure 2 Image of furnace surface created from laser dot mapping. Left is fr...
Figure 3 Corrosion at the joints as seen from the back and bottom of the fur...
Figure 4 Expected convective currents
Figure 5 Observed corrosion shape at metal line.
Figure 6 Observed corrosion patterns for upward drilling, downward drilling,...
Figure 7 Glass transition temperature as a function of crosslinking in Ge‐Sb...
Figure 8 Silicon tetrahedra in a four coordinated state and in a two coordin...
Figure 9 Representation of Strength and Number of Ionic and Covalent Bonds a...
Figure 10 Region of Composition Studied. Al (+Fe) (not shown) varied from 0....
Figure 11 Prediction vs best fit values of To
Figure 12 Prediction vs best fit values for E
Figure 13 Bulk and estimated surface viscosity curves calculated for a SLS g...
Figure 14 Photo of downward drilling with a mixed metal droplet in contact w...
Figure 15 AZS coupon extending 9 mm above glass melt
Figure 16 AZS coupon extending 3 mm above glass melt
Chapter 2
Figure 1 200 Degree range for sharper image
Figure 2 B&W gives the highest “visible” contrast
Figure 3 Rainbow Palette shows the highest thermal contrast
Figure 4 1.5* Zoom for closer inspection
Figure 5 2* Zooms shows extent of the holes/damage
Figure 6 First ever view of welding
Figure 7 Utilising isotherms to see the port flame temperatures and correspo...
Figure 8 2*Zoon END R‐L same isotherms
Figure 9 4*zoom Re Range Isotherms
Figure 10 +45 minutes
Figure 11 +90 minutes
Figure 12 Slide from 2019 Glass Problems ‐ Comparison with static 5 Deg
Figure 13 Three weeks later – Drain started – Auto temp range
Figure 14 End firing L‐R – Manual temp range 1575‐1425°C
Figure 15 End firing R‐L – 1.5 Zoom on wall to be re‐used‐Manual temp range ...
Figure 16 End firing R‐L – 1.5 Zoom on wall to be re‐used‐Manual temp range ...
Figure 17 + 4 hours ‐ End firing R‐L – 1.5 Zoom on wall to be re‐used‐Manual...
Figure 18 + 4 hours ‐ End firing R‐L – 1.5 Zoom on wall to be re‐used‐Manual...
Figure 19 + 4 hours ‐ End firing R‐L – 1.5 Zoom on wall to be re‐used‐Manual...
Figure 20 + 8 hours ‐ End firing R‐L – Auto temp range Polygons of interest ...
Figure 21 + 8 hrs End firing R‐L – Manual temp range (‐160) 1415‐1265°C Poly...
Figure 22 + 20 hrs End firing R‐L – Auto temp range Polygons of Interest by ...
Figure 23 + 20 hrs End firing R‐L – Manual temp range (‐425) 1150‐1000°C Pol...
Figure 24 + 24 hrs End firing R‐L – Manual temp range (‐475) 1100‐1000°C Pol...
Figure 25 Additive at RHS peephole – Premix burner
Figure 26 The last port flame 1050‐1000°C
Figure 27 Next frame
Figure 28 +36 hrs – Below 1000°C Range
Figure 29 + 48 hrs
Figure 30 +60 hrs – Regenerator ports
Chapter 3
Figure 1 Core Sample From Testing of Mat Slab
Figure 2 New Mat Slab & Support Steel
Figure 3 Deteriorated Furnace Support Column
Figure 4 Existing Support Steel with 7 Layers of Beams
Chapter 4
Figure 1 Research method with an empirical phenomenological design
Figure 2 Selection of analysis units and coding in Atlas.ti
Figure 3 Additional work network
Chapter 5
Figure 1 Operating Vortex tube
Figure 2 Comparison between a standard tube after 6 months of operation (lef...
Figure 3 Gobs thermal signature acquired using a thermal camera (left) and p...
Figure 4 Evolution of front & back gobs average temperature in time.
Figure 5 Determination method for Feret diameters.
Figure 6 Evolution of front and back gobs dimensions in time.
Chapter 6
Figure 1 Sidewall temperature contour (top) and plotted temperatures (bottom...
Figure 2 Model predicted sidewall temperature correlated to refractory wear ...
Figure 3 Total PM
10
emissions vs. bottle cullet percentage
Figure 4 Total PM
10
emissions vs. bottle cullet percentage
Figure 5 FeO content vs. 1050 nm absorbance normalized to 1 cm glass sample ...
Figure 6 Improved redox control with fewer formulation changes (FeO results ...
Figure 7 Glass Temperature Decreases with High Cullet Use
Chapter 7
Figure 1 SCR Control and Transformer Schematic
Figure 2 Full Sine Wave
Figure 3 75% of Sine Wave
Figure 4 50% of Sine Wave
Figure 5 IGBT Control and Transformer Schematic
Figure 6 IGBT Waveforms (shown with a 480 Volt System)
Figure 7 Impedance Triangle
Figure 8 Power Triangle
Figure 9 Transformer Schematic for Primary Turns
Figure 10 Transformer Taps Highlighted are Used for Testing
Figure 11 SCR Application Schematic
Figure 12 IGBT Application Setup
Chapter 8
Figure 1 Examples of cullet related inclusions from left to right: Pottery, ...
Figure 2 Typical recycling process (1)
Figure 3 (a) Result of color distribution inspection and (b) Result of findi...
Figure 4 (a) Glass Melting test and (b) COD measurements.
Figure 5 Top: Trend on cullet quality improvements; Bottom: Trend on cullet ...
Figure 6 One of the inspection buses used
Chapter 9
Figure 1 Picture of bubbles in a glass melt. There are billions of bubbles b...
Figure 2 Relative concentrations of Fe and Cr in different valences as a fun...
Figure 3 Products of sodium sulphate chemical reactions in the glass melt
Figure 4 Speciation of iron and redox in the glass tank
Figure 5 Speciation of chromium oxide in the glass tank
Figure 6 Partial pressures of gasses released by the fining reactions the to...
Figure 7 Calculation of the amount of bubbles per kilo of glass melt on two ...
Figure 8 Industrial problem model including temperature validation
Figure 9 Bubble count prediction in two forehearths calculated for the base ...
Chapter 10
Figure 1 Samples demonstrating optical distortion created by cord or straie...
Figure 2 (A) Examination of the bottom of a glass container in a polariscope...
Figure 3 Stress birefringence effect that allows stress in glass to be quant...
Figure 4 The Michel‐Levy birefringence chart, with approximately levels of s...
Figure 5 Abraded thermal shock tests performed at increasing temperatures un...
Chapter 11
Figure 1 Within seconds, precise data on flatness, waviness and reflection o...
Figure 2 The three‐dimensional full surface optical measurement offers fast ...
Figure 3 With the P2‐3D, glass manufacturers ensure their products are suita...
Chapter 12
Figure 1 Flue gas heat recovery systems on commercial furnaces ‐ Cullet Preh...
Figure 2 Historical trend of specific electric power consumption to make VPS...
Figure 3 Potential improvements in fuel consumption for a 300t/d container f...
Figure 4 Schematic Representation of Batch Cullet Preheating System
Figure 5 Schematic representation of OPTIMELT TCR Process
Figure 6 OPTIMELT
TM
TCR System Arrangement in End‐fired Configuration at Lib...
Figure 7 Combining different waste heat recovery technologies to maximize he...
Guide
Cover
Table of Contents
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81st Conference on Glass Problems
Ceramic Transactions, Volume 269
A Collection of Papers Presented at the 81st Conference on Glass Problems October 26‐30, 2020
Edited by
S. K. Sundaram
This edition first published 2021
© 2021 The American Ceramic Society
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by law. Advice on how to obtain permission to reuse material from this title is available at http://www.wiley.com/go/permissions .
The right of S K Sundaram to be identified as the author of the editorial material in this work have been asserted in accordance with law
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Library of Congress Cataloging‐in‐Publication Data applied for:
ISBN: 9781119822998
Foreword
The 81st Conference on Glass Problems (GPC) was organized by the Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, Alfred, NY 14802 and The Glass Manufacturing Industry Council (GMIC), Westerville, OH 43082. The Program Director was S. K. Sundaram, Inamori Professor of Materials Science and Engineering, Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, Alfred, NY 14802. The Conference Director was Bob Lipetz, Executive Director, Glass Manufacturing Industry Council (GMIC), Westerville, OH 43082. The GPC Advisory Board (AB) included the Program Director, the Conference Director, and several industry representatives. The Board assembled the technical program. Donna Banks of the GMIC coordinated the events and provided support. Due to world‐wide COVID‐19 pandemic, the conference was a virtual event. It started with a full‐day plenary session followed by technical sessions. The themes and chairs of four technical sessions were as follows:
Construction/Repair
Larry McCloskey, Anchor Acquisition, LLC, Lancaster, OH
Melting
Uyi Iyoha, Linde Inc., Peachtree City, GA
Quality Control & Sensors
Kenneth Bratton, Bucher Emhart Glass, Windsor, CT
Environmental and Sustainability
Adam Polycn, Vitro Architectural Glass, Cheswick, PA
In addition, one session entitled, “In‐Furnace Thermal Imaging for Survey and Operations Optimization,” was held at the end Monday October 26th sponsored by Land Ametek. Two sessions entitled, “New Technology Spotlight Webminar: Synchronized Oxy‐Fuel Boost Burners for Zero‐Port Performance Optimization,” sponsored by Air Products and “Current and Future Melting & Conditioning Solutions for All Glassmakers,” sponsored by fives were held at the end of Tuesday 27th.
Preface
This volume is a collection of papers presented at the 81st year of the Glass Problems Conference (GPC) in 2020. The GPC continues the tradition of publishing the papers that goes back to 1934. The manuscripts included in this volume are reproduced as furnished by the presenting authors but were reviewed prior to the presentation and submission by the respective session chairs. These chairs are also the members of the GPC Advisory Board.
As the Program Director of the GPC, I am thankful to all the presenters at the 80th GPC. This year’s meeting was record breaking in many senses. We had a total of 570 registered attendees including 40 students from across the country. I appreciate all the support from the members of Advisory Board. Their volunteering sprit, generosity, professionalism, and commitment through an unprecedented world‐wide pandemic were critical to the high‐quality technical program at this Conference. I also appreciate continuing support and strong leadership from the Conference Director, Mr. Bob Lipetz, Executive Director of GMIC and excellent support from Ms. Donna Banks of GMIC in organizing the GPC. I look forward to continuing our work with the entire team in the future.
Please note that The American Ceramic Society and myself did minor editing and formatting of these papers. Neither Alfred University nor GMIC is responsible for the statements and opinions expressed in this volume.
S. K. SundaramAlfred, NYNovember 2020
Acknowledgements
It is my great pleasure to acknowledge the dedicated service, advice, and team spirit of the members of the GPC AB in planning this Conference, inviting key speakers, reviewing technical presentations, chairing technical sessions, and reviewing manuscripts for this publication:
Kenneth Bratton ‐
Bucher Emhart Glass, Windsor, CT
Chris Bloom ‐
Owens Corning, Granville, OH
Weijian Chen ‐
Libbey Glass, Toledo, OH
Eric Dirlam ‐
Ardagh Glass, Muncie, IN
Uyi Iyoha –
Linde Inc., Peachtree City, GA
Bob Lipetz ‐
Glass Manufacturing Industry Council, Westerville, OH
Larry McCloskey –
Anchor Acquisition, LLC, Lancaster, OH
Glenn Neff ‐
Glass Service USA, Inc., Stuart, FL
Adam Polcyn –
Vitro Architectural Glass, Cheswick, PA
Jan Schep –
Owens‐Illinois, Inc., Perrysburg, OH
Christopher Tournour –
Corning Incorporated, Corning, NY
Phillip Tucker ‐
Johns Manville, Littleton, CO
James Uhlik –
Toledo Engineering Co., Inc., Toledo, OH
Justin Wang –
Guardian Industries, Auburn Hills, MI
I am indebted to Donna Banks, GMIC for her patience, support, and attention to detail in making this conference a big success and this Proceedings possible.
Finally, the whole team has worked tirelessly against all odds of the ongoing world‐wide pandemic making this a successful conference. The determination and enthusiasm are enduring and inspiring.
