192,99 €
The 83rd Conference on Glass Problems (GPC) was organized by the Kazuo Inamori School of Engineering, The New York State College of Ceramics, Alfred University, NY, and The Glass Manufacturing Industry Council (GMIC), Westerville, OH. 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. The Conference Director was Bob Lipetz, Executive Director, GMIC, Westerville, OH. 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. It started with a full-day plenary session followed by technical sessions.
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COVER
TITLE PAGE
COPYRIGHT
FOREWORD
PREFACE
ACKNOWLEDGEMENTS
PLENARY
EVOLUTION OF REFRACTORY IN THE GLASS INDUSTRY
ABSTRACT
INTRODUCTION
REFRACTORY EVOLUTION OF THE GLASS CONTACT AREA
REFRACTORY EVOLUTION OF THE MELTER CROWN
REFRACTORY EVOLUTION OF THE MELTER BOTTOM
REFRACTORY EVOLUTION OF THE REGENERATOR
SUMMARY AND LEARNINGS
REFERENCES
HOW BIG IS MY CARBON FOOTPRINT…REVISITED
ABSTRACT
INTRODUCTION
ELECTRICITY GENERATION BY SOURCE
HYDROGEN
CONCLUSION
REFERENCES
GLASS MELTING OF THE FUTURE
ABSTRACT
INTRODUCTON
CONCLUSION
REFERENCES
QUALITY
DIGITAL MEASUREMENT OF CORD STRESSES IN CONTAINER GLASS
ABSTRACT
CORD DETECTION
SAMPLE PREPARATION
MANUAL MEASUREMENT
DIGITAL MEASUREMENT
MEASUREMENT CHALLENGES
PERFORMANCE COMPARISON WITH GAGE R&R ANALYSIS
SAMPLE SELECTION
TEST PLANNING AND EXECUTION
MEASUREMENT RESULTS
MEASUREMENT TIMES
OBSERVATIONS
GAGE R&R ANALYSIS RESULTS
CONCLUSION
THE ELECTRICAL SYSTEMS WILL BECOME THE GAS SKITS OF THE FUTURE
INTRODUCTION
OUR PAST
OUR PRESENT
OUR ELECTRIC FUTURE
HOW CAN SCHNEIDER ELECTRIC CONTRIBUTE?
CONCLUSION
REFERENCES
MELTING AND CONTROL
ALL‐ELECTRIC‐FOREHEARTH DESIGN WITH ZERO EMISSIONS
INTRODUCTION
SPECIALLY DESIGNED PROFILED ROOF BLOCK
RADIANT HEATING ELEMENTS
CENTRE LINE RADIATION COOLING IN REAR ZONES
TARGETED INSULATION
LOW THERMAL MASS INSULATION
IN‐GLASS TEMPERATURE MEASUREMENT
AUTOMATED COOLING DAMPERS, FH DESIGNED READY FOR AUTOMATED CONTROL
EASY ACCESS GUARDING AND LOW MAINTENANCE
ZERO CO
2
EMISSION
ENERGY EFFICIENCY
THE FULLY COMPARTMENTALIZED GLASS FURNACE
INTRODUCTION
P‐10 PROCESS FLOW
10‐1 ROTARY KILN
10‐3 RECEIVER
10‐4 VACUUM COLUMN REFINER
10‐5 TRANSITION
PERSPECTIVE ON P‐10
REFERENCES
5‐YEAR OPERATING EXPERIENCE WITH THE OPTIMELT™ HEAT RECOVERY TECHNOLOGY ON A TABLEWARE FURNACE
ABSTRACT
INTRODUCTION
GENERAL PROJECT EXPERIENCE
GREEN GLASS ISSUE
BACKWALL‐PORT CONNECTION
BURNER PORT ISSUE
REFRACTORY WEAR DOWNCOMER PORT – DAMPER DOOR
REGENERATORS KEEP CLEAN WITH OPTIMELT TECHNOLOGY
OXYGEN SENSOR ISSUE
OPTIMELT IMPACT ON FLUE GAS SYSTEM
ENERGY EFFICIENCY
FURNACE EMISSIONS
CONCLUSION
MODERN CONTROLLER AND SENSOR TECHNOLOGY TO ACHIEVE OPTIMUM ENERGY EFFICIENCY
INTRODUCTION
COMBUSTION CONTROL
GLASS FURNACE SIMULATION
SUPPORT THE DESIGN OF THE FURNACE OF THE FUTURE
SUPPORT DAILY PRODUCTION
GLASS MELT CONTROL
REFERENCES
REFRACTORIES AND RAW MATERIALS
HOW WILL THE ELECTRIFICATION OF GLASS FURNACES IMPACT REFRACTORIES?
ABSTRACT
INTRODUCTION
EFFECT OF ELECTRICAL BOOSTING ON REFRACTORIES
SIDEWALL CORROSION
BOTTOM PAVING CORROSION
ELECTRODE BLOCK CORROSION
CONCLUSION
FUTURE‐PROOFING YOUR DUST COLLECTION SYSTEM BEST PRACTICES IN DUST COLLECTION FOR THE GLASS INDUSTRY
ABSTRACT
INTRODUCTION
STEP 1: UNDERSTAND YOUR DUST
STEP 3: CONTAIN DUST‐PRODUCING PROCESSES
STEP 4: CHOOSE A DUST COLLECTION APPROACH
STEP 5: DUST COLLECTOR SELECTION AND SYSTEM DESIGN
CONSIDERATIONS FOR FUTURE‐PROOF DUST COLLECTION SYSTEM DESIGN
CONCLUSION
REFERENCES
COMBUSTION AND SUSTAINABILITY
PARTIAL OXY-FUEL CONVERSION OF GLASS FOREHEARTHS: A COST-EFFECTIVE WAY TO REDUCE CO2 EMISSIONS BY 50%
ABSTRACT
INTRODUCTION
LINDE’S PARTIAL OXY‐FUEL FOREHEARTH SOLUTION
CFD MODELLING
SINGLE‐ZONE BETA TEST
FULL FOREHEARTH CONVERSION
CONCLUSION
ADVANCES IN GLASS INDUSTRY ENERGY SAVINGS USING HEAT OXYCOMBUSTION
ABSTRACT
INTRODUCTION: ENERGY EFFICIENCY IMPROVEMENT
RADIATIVE HEAT EXCHANGE
CHALLENGES OF IMPLEMENTING HEATOX R
COMPUTATIONAL FLUID DYNAMICS (CFD)
COMPARISON OF EXPERIENCE VS. CFD
CONCLUSIONS ON THE PILOT SYSTEM & NEXT STEPS
REFERENCES
BLUE AND GREEN HYDROGEN PRODUCTION, DISTRIBUTION, AND SUPPLY FOR THE GLASS INDUSTRY AND THE POTENTIAL IMPACT OF HYDROGEN FUEL BLENDING IN GLASS FURNACES
INTRODUCTION
BLUE AND GREEN HYDROGEN FOR THE GLASS INDUSTRY
THE POTENTIAL IMPACT ON HYDROGEN FUEL BLENDING IN GLASS FURNACES
CONCLUSION
REFERENCES
DESIGN AND IMPLEMENTATION OF OPTIFIRE™ FLEX BURNER FOR FOAM REDUCTION IN OXY‐FUEL GLASS FURNACES
ABSTRACT
INTRODUCTION
PRIMARY FOAM
SECONDARY FOAM
EFFECT OF FURNACE ATMOSPHERE ON FOAM STABILITY
STAGED COMBUSTION
FOAM MITIGATION APPROACH WITH FLEX BURNER
BURNER ATTRIBUTES AND INSTALLATION
FOAM MITIGATION TRIAL AT CUSTOMER SITE
FIELD RESULTS
IN FURNACE GAS ANALYSIS DURING FLEX BURNER TRIAL
CURRENT STATUS OF FLEX BURNERS
SUMMARY OF FLEX BURNER TEST RESULTS IN 500 TPD CONTAINER GLASS FURNACE
REFERENCES
END USER LICENSE AGREEMENT
Chapter 4
Table I Gage R&R % Study Var
Table II Bottle Ring Samples Used in the Gage R&R Study
Table III. All Measurement Results
Table IV. Measurement Results Separated by Measuring Device and Operator
Table V Gage R&R Analysis Results
Chapter 8
Table I. Emission under various conditions
Chapter 11
Table 1 Exposure Limits for Respirable Crystalline and Amorphous Silica Dust...
Chapter 12
Table I Maximum flame and refractory temperatures predicted by CFD modelling
Chapter 13
Table I Comparison of Test Data with CFD Results
Chapter 14
Table I Typical H
2
and O
2
supply quantities by glass type and assumed furna...
Chapter 15
Table I Example of Flex Burner Switching Pattern (24 Hour Cycle)
Table II Flex burner periodically switching between Heat and Foam Mode
Chapter 1
Figure 1. Historic development of furnace lifetime and specific melter load...
Figure 2. Historic development of crown temperatures in glass furnaces
Figure 3. a‐c. Impressions from tank block production in 1960
Figure 4. a‐c. Jebsen‐Marwedel’s explanation of upward‐drilling
Figure 5. Description of rat hole formation process
Figure 6. Silica insulation concepts
Figure 7. Silica bricks with honeycomb structure
Figure 8. Improved efficiency with honeycomb structure in melter crowns
Figure 9. Installation of lime‐free‐Silica (Stella® GNL) in stressed areas o...
Figure 10. Different bottom concepts. No insulation (a), one layer (b), thre...
Figure 11. Typical bottom concept
Figure 12. Different checker systems
Chapter 2
Figure 1. Carbon Dioxide Emission by Furnace Type (Local).
Figure 2. Carbon Dioxide Emission by Furnace Type (National) based on 2009 e...
Figure 3. USA Electricity Generation by Source. Data from US EIA (2022).
Figure 4. Carbon Dioxide Emissions by Electricity Generation Method. Data fr...
Figure 5. Carbon Dioxide Emission by Furnace Type (National) based on 2020 e...
Figure 6. Carbon Dioxide Emission by Furnace Type and Cullet Level. Source: ...
Figure 7. Global Production of Hydrogen (US Department of Energy, 2020).
Figure 8. Current Hydrogen Cost Ranges and Averages by Technology (US Depart...
Chapter 3
Figure 1. Turning down CO
2
Figure 2. CO
2
reduction is a must to rescue your profit
Figure 3. Biofuel has potential (glass futures)
Figure 4. Successful biofuel trials during 2015‐2016 in Germany
Figure 5. Additional successful biofuel trials in 2021 and 2022
Figure 6. Development of renewable energy in the EU
Figure 7. Wind turbines offshore
Figure 8. Solar panels
Figure 9. Oil pumping station using renewable energy
Figure 10. Renewable electric powerFigure 11. Gas peaked at €178/MWh
Figure 11. Renewable electric power Gas peaked at €178/MWh
Figures 12 and 13. Renewable energy dominates electricity pricing in some ar...
Figure 14. Forecast on hydrogen
Figure 15. Hydrogen costs and distribution
Figure 16. Hydrogen costs and distribution
Figure 17. Energy storage versus amount and time
Figure 18. Transport of hydrogen as methane or ammonia
Figure 19. Electric heat transfer efficiency
Figure 20. Electrification of automobiles
Figure 21. Glass melting furnace technology
Figure 22. Most common end‐fired container glass furnace with a specific ene...
Figure 23. Melting costs 2020, NG 0.25 €/Nm
3
, E 0.10/kWh, CO
2
25 €/Ton
Figure 24. Melting Costs 2022, NG 0.55 €/Nm
3
, E 0.15/kWh, CO
2
85 €/Ton
Figure 25. Expected melting costs 2023, NG 0.6 €/Nm
3
, E 0.05/kWh, CO
2
100 €/...
Figure 26. – Melting costs comparison, hydrogen gas, 0.1 EUR/Nm
3
Figure 27. Examples of large known cold top AEM and Hybrid for container gla...
Figure 28. Different examples of cold top AEM designs
Figure 29. AEM doctor
Figure 30. A detailed batch model is important, using the latest technology ...
Figure 31. Center electrodes creating cross spiral recirculation now with mo...
Figure 32. Furnace of the past (80’s) and future?
Figure 33. Horizontal hot top electric melter (H
2
EM) concept
Chapter 4
Figure 1. Prepared Glass Ring Sample
Figure 2. Polarizing Microscope with Berek Tilting Compensator
Figure 3. StrainScope Cord Tester Apparatus
Figure 4. StrainScope Cord Tester User Interface
Figure 5. Selected Bottle Ring Samples #1 to #8 (from top left to bottom rig...
Figure 6. Mean Measurement Values of the Selected Samples
Figure 7. Average Result Values and Standard Deviations Across Both Measurin...
Figure 8. Average Result Values by Measuring Device
Figure 9. Average Standard Deviations by Measuring Device
Figure 10. Average Result Values for the Polarizing Microscope
Figure 11. Average Result Values for the StrainScope Cord Tester
Figure 12. Average Testing Times
Figure 13. Individual Testing Times
Figure 14. Gage R&R Contributions for the Polarizing Microscope
Figure 15. Gage R&R Contributions for the StrainScope Cord Tester
Chapter 7
Figure 1. P‐10 Process Schematic
Figure 2. Rotary Ablative Melter (from US Patent 4,521,238)
Figure 3. Close Up Schematic of 10‐3, 10‐4, and 10‐5
Chapter 8
Figure 1. OPTIMELT TCR Process
Figure 2. Optimelt implementation table ware furnace l1 leerdamcrisal glass ...
Figure 3. Damper rebuild
Figure 4. A view of bottom generator
Figure 5. Specific Energy Consumption versus Furnace Production
Chapter 9
Figure 1. Flame velocity versus the velocity of the batch piles in a glass f...
Figure 2. Measured CO concentrations versus measured O
2
concentration during...
Figure 3. Schematic view of a laser sensor positioned in the flue gas exhaus...
Figure 4. The cold top furnace experiment in CelSian’s laboratory
Figure 5. Example of a hybrid furnace design (courtesy of Fives Stein).
Figure 6. Modeling and validation of hydrogen combustion
Figure 7. Time transient modeling of a color change and the impact on temper...
Figure 8. Using a detailed furnace simulation to generate a fast and accurat...
Chapter 10
Figure 1. a) shows the modeling of the sidewall corrosion under two differen...
Figure 2. Bottom paving blocks will be influenced by higher bottom temperatu...
Figure 3. Different wear mechanisms that influence the electrode block syste...
Chapter 12
Figure 1. Schematic of common premixed air‐fuel forehearth (left) vs. Linde ...
Figure 2. Theoretical calculation of fuel savings vs. oxygen enrichment
Figure 3. Temperature profile comparison from CFD modelling for a single zon...
Figure 4. Fuel and oxygen nozzle configuration for the distributor section
Figure 5. Oxygen and air/fuel manifolds, partial oxy‐fuel system
Chapter 13
Figure 1. NOx emissions reduction with oxy‐combustion ("ColdOx") and HeatOx...
Figure 2. Energy savings as a function of oxygen and natural gas temperature...
Figure 3a. HeatOx with air as heat transfer fluid
Figure 3b. HeatOx with Radiative Heat Transfer paper, we present the first r...
Figure 4. Flue gas bypass with HeatOx R HX. Perspective view on the left, to...
Figure 5. Installation of HeatOxR): Top right: HX Transport into the plant. ...
Figure 6. HeatOx R heat exchanger model for CFD simulations. Left: overall g...
Figure 7. Qualitative temperature profiles. Left: One side of flue gas enclo...
Chapter 14
Figure 1. Description of Grey, Blue, and Green Hydrogen color classification...
Figure 2. Combustion images of various H
2
blends using the HR
x
burner. Blend...
Figure 3. Oxygen staging allows for control of properties including flame le...
Figure 4. Flame emission spectra measure between 200‐1000 nm with various H
2
Figure 5. Spectral emission measurement of the Hydroxyl (OH) radical using t...
Figure 6. Four thermocouples embedded in furnace breast wall show an increas...
Figure 7. Percent change in NOx emissions levels. Only 6% increase when tran...
Chapter 15
Figure 1. OPTIFIRE™ XD burner showing no signs of buildup
Figure 2. The Flex Burner (right) is seen installed in the commercial trial ...
Figure 3. Outdoor test FLEX burner in Heat and Foam modes at 7 MMBTU/h (~2.1...
Figure 4. The highly startified oxidative and reductive localized layers wer...
Figure 5. The heated fuel port generates soot. The heated oxygen port preven...
Figure 6. Overnight reduction of UVA Green glass foam layer from FLEX burner...
Figure 7. The reflection of the flame is seen the glass surface throughout t...
Figure 8. Water cooled probe and analyzer used to measure glass surface in F...
Figure 9. Furnace in‐situ gas measurement above glass bed in Foam Mode confi...
Figure 10. The metallic section and refractory block were in excellent condi...
Cover
Table of Contents
Title Page
Copyright
Foreword
Preface
Acknowledgements
Begin Reading
End User License Agreement
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A Collection of Papers Presented at the 83rd Conference on Glass Problems
Greater Columbus Convention Center, Columbus, Ohio October 31–November 3, 2022
Edited byS. K. Sundaram
Copyright © 2023 by The American Ceramic Society. All rights reserved.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.Published simultaneously in Canada.
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Library of Congress Cataloging-in-Publication Data Applied for:
ISBN: 9781394200276
Cover Design: Wiley
The 83rd 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, 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. It started with a full‐day plenary session followed by technical sessions. The themes and chairs of four technical sessions were as follows:
QualityChris Tournour, Corning Incorporated, Corning, NYKenneth Bratton, Bucher Emhart Glass, Windsor, CT
Melting & ControlsJim Uhlik, TECO, Toledo, OHShrikar Chakravarti, Linde Inc., Peachtree City, GA
Refractory & Raw MaterialErik Helin, Johns Manville, Windsor, CTEric Dirlam, SSOE Group, Toledo, OH
Combustion & SustainabilityGlenn Neff, Glass Service USA, Inc., Stuart, FLJan Schep – Owens‐Illinois, Inc., Perrysburg, OH
This volume is a collection of papers presented at the 83rd year of the Glass Problems Conference (GPC) in 2022. 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 83nd GPC. This year’s meeting was a winner on a positive trajectory of recovering and approaching pre‐COVID 19 attendance level. We had a total of ~ 425 registered attendees including 10 students from across the country this year.
I truly appreciate all the support from the members of Advisory Board. Their volunteering sprit, generosity, profes‐sionalism, and commitment were critical to the high‐quality technical program at this Conference. I am indebted to the outgoing Conference Director, Mr. Bob Lipetz, Executive Director of GMIC for his excellent unwavering leadership and support. I welcome Mr. Kerry Ward on board as new Conference Director and Executive Director of GMIC. I also appreciate continuing excellent support from Ms. Donna Banks of GMIC in organizing the GPC.
Please note that the American Ceramic Society and I edited and formatted these papers. Neither Alfred University nor GMIC is responsible for the statements and opinions expressed in this volume.
S. K. SundaramAlfred, NYDecember 2022
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, CTJong Han – Owens Corning, Granville, OHShrikar Chakravarti – Linde Inc., Peachtree City, GADaniel Johnson – Libbey Glass, Toledo, OHEric Dirlam – SSOE Group, Toledo, OHDavid Girvan – Vitro Architectural Glass, Cheswick, PAErik Helin – Johns Manville, Littleton, COBob Lipetz – Glass Manufacturing Industry Council, Westerville, OHLarry McCloskey – Anchor Acquisition, LLC, Lancaster, OHGlenn Neff – Glass Service USA, Inc., Stuart, FLAdam Polcyn – Vitro Architectural Glass, Cheswick, PAJan Schep – Owens‐Illinois, Inc., Perrysburg, OHChristopher Tournour – Corning Incorporated, Corning, NYPhillip Tucker – Johns Manville, Littleton, COJames Uhlik – Toledo Engineering Co., Inc., Toledo, OHJustin Wang – Guardian Industries, Auburn Hills, MIKerry Ward – Glass Manufacturing Industry Council, Westerville, OH
I appreciate excellent leadership of Bob Lipetz, GMIC in making the GPC a big success this year. I am excited about an opportunity to work with Kerry Ward in supporting future GPCs. I am thankful to Donna Banks, GMIC for her patience, support, and attention to detail through the whole process.
Stefan Postrach, Ignacio Ramirez
RHI MagnesitaKranichberggasse 61120 Wien, AT
Since the nineteen‐fifties, the performance of glass furnaces has improved significantly. We have seen a significant improvement in furnace life. There has been an increase in output while energy demand for the process has been reduced. Factors like improved furnace design, construction, and refractory lining concepts, including the quality of refractories, have contributed heavily to this development. A very important step was of course the invention of fused cast products in the 1920s. However, it took decades to implement fused cast products in different areas of the glass furnace; for example, to replace traditionally used alumina‐based bonded products in glass contact areas. In addition, several incremental improvements contributed to the evolution process, but hardly any new product line has been invented. Silica, high‐alumina, zircon‐based and basic products still determine the lining concepts in which case huge improvements were achieved regarding quality, quality assurance and by optimizing the combination of different materials. An important precondition for such improvements is a clear understanding of the processes that influence refractory corrosion.
This paper will describe important refractory developments and will lead through the evolution of refractory for glass furnaces. In addition to the most important developments of fused cast products, examples for certain furnace assemblies will be given, e.g., melter bottom, melter crown including the development of the insulation concepts, regenerator checker pack and casing. These examples show nicely that the development was driven by evolution: once a problem was solved, another aspect ‐which was not consequently in the minds before became the problem. Present day trends will also be mentioned, as these trends may give a glance to the future.
As mentioned above, a key aspect that led to the improvements was by clearly understanding the complex conditions in a glass furnace and the influence on refractories. These important lessons that we have learned in the past 70 plus years can help us solve new challenges that come ahead.
The glass production process experienced huge improvements over the last decades, proven by KPIs like furnace lifetime and specific furnace load [1], see Figure 1, but also observable on the quality of glass products. During this evolution the operation conditions changed permanently and heavily. The most important aspect was of course the temperature increase in the glass melting process [2] (Figure 2). Higher furnace temperatures increased corrosion effects and even new and unexpected mechanism became evident.
Figure 1. Historic development of furnace lifetime and specific melter load
Figure 2. Historic development of crown temperatures in glass furnaces
This paper describes how the lining concepts had been changed over the decades and how the refractories contributed to the improvements in glass melting technology. However, it should not be ignored that other factors supported the improvements as well:
Furnace and refractory design
Installation accuracy
Heat‐up processes
Improved raw material quality including cullet
And improved equipment’s, e.g., the combustion technology and level of automation.
Latest push to prolong the furnace lifetime further resulted out of the development of various hot repair techniques in the last ten years. But now let’s focus on the question how refractories could contribute and even influence the development of furnace design. In total there are four general aspects that are of course connected to each other:
Understanding the refractory behavior: like in every other application of refractories it is of upmost importance to understand the operation conditions and the influence on the corrosion mechanism. Academic