In 2009 TECO presented a paper at the 70th Glass Problems Conference entitled “How Big is My Carbon Footprint”. In it, TECO compared the carbon dioxide emissions from an air-gas regenerative furnace, an oxy-gas furnace, and a cold-top electric furnace producing 300 ton/day of container glass. This chapter revisits the previous analysis in light of the current political and environmental climate. In 2009 about 50% of US electricity was generated in coal-fired plants, which resulted in a carbon dioxide emission of 1.34 lb./kWh. Since 2009, and more specifically the last couple of years, a third scenario now has to be investigated. This scenario involves replacing natural gas with hydrogen in fuel-fired furnaces. However, as is the case with electric melting, there is a difference in hydrogen's green credentials.
Chapter c10 HOW WILL THE ELECTRIFICATION OF GLASS FURNACES IMPACT REFRACTORIES? Isabelle Cabodi, Isabelle Cabodi Saint-Gobain Research ProvenceSearch for more papers by this authorIsabell Gross, Isabell Gross Cavaillon, FranceSearch for more papers by this authorPierrick Vespa, Pierrick Vespa Saint-Gobain SEFPROSearch for more papers by this authorMichel Gaubil, Michel Gaubil Le Pontet, FranceSearch for more papers by this authorStephane Schaller, Stephane Schaller Le Pontet, FranceSearch for more papers by this author Isabelle Cabodi, Isabelle Cabodi Saint-Gobain Research ProvenceSearch for more papers by this authorIsabell Gross, Isabell Gross Cavaillon, FranceSearch for more papers by this authorPierrick Vespa, Pierrick Vespa Saint-Gobain SEFPROSearch for more papers by this authorMichel Gaubil, Michel Gaubil Le Pontet, FranceSearch for more papers by this authorStephane Schaller, Stephane Schaller Le Pontet, FranceSearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch10Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary One of the main challenges for glass makers in the coming years will be to adapt their melting technology to achieve carbon neutrality. Currently most glass melting still uses fossil fuels, but with penalties for carbon emission and the rising demand for decarbonized glass, alternative energy sources are being investigated. While the electric melting technology has existed for over 100 years, it was less popular due to the high price of electricity and to restrictions in furnace design and cullet use. For a robust high-electrical boosting furnace, the choice of the right refractory materials is crucial to ensure smooth furnace operations and to optimize furnace lifetime. In this chapter, the authors discuss the consequences of the use of high-electrical energy input on bottom paving, electrode blocks and side wall blocks. 83rd Conference on Glass Problems: Ceramic Transactions RelatedInformation
Chapter c13 ADVANCES IN GLASS INDUSTRY ENERGY SAVINGS USING HEAT OXYCOMBUSTION James McAndrew, James McAndrewSearch for more papers by this authorKenneth Kaiser, Kenneth KaiserSearch for more papers by this authorBhupesh Dhungel, Bhupesh DhungelSearch for more papers by this authorJiefu Ma, Jiefu MaSearch for more papers by this authorChendhil Periasamy, Chendhil PeriasamySearch for more papers by this authorRémi Tsiava, Rémi TsiavaSearch for more papers by this authorAbou Ba, Abou BaSearch for more papers by this authorMohand Amirat, Mohand AmiratSearch for more papers by this authorNiomar Marcano, Niomar MarcanoSearch for more papers by this authorXavier Paubel, Xavier PaubelSearch for more papers by this authorTâm Lâm, Tâm LâmSearch for more papers by this authorLuc Jarry AIR LIQUIDE Emre Dumankaya, Luc Jarry AIR LIQUIDE Emre DumankayaSearch for more papers by this authorNeşet Arzan, Neşet ArzanSearch for more papers by this authorBahtiyar Dalgıç, Bahtiyar DalgıçSearch for more papers by this authorErdinç Şükrü ŞIŞECAM, Erdinç Şükrü ŞIŞECAMSearch for more papers by this author James McAndrew, James McAndrewSearch for more papers by this authorKenneth Kaiser, Kenneth KaiserSearch for more papers by this authorBhupesh Dhungel, Bhupesh DhungelSearch for more papers by this authorJiefu Ma, Jiefu MaSearch for more papers by this authorChendhil Periasamy, Chendhil PeriasamySearch for more papers by this authorRémi Tsiava, Rémi TsiavaSearch for more papers by this authorAbou Ba, Abou BaSearch for more papers by this authorMohand Amirat, Mohand AmiratSearch for more papers by this authorNiomar Marcano, Niomar MarcanoSearch for more papers by this authorXavier Paubel, Xavier PaubelSearch for more papers by this authorTâm Lâm, Tâm LâmSearch for more papers by this authorLuc Jarry AIR LIQUIDE Emre Dumankaya, Luc Jarry AIR LIQUIDE Emre DumankayaSearch for more papers by this authorNeşet Arzan, Neşet ArzanSearch for more papers by this authorBahtiyar Dalgıç, Bahtiyar DalgıçSearch for more papers by this authorErdinç Şükrü ŞIŞECAM, Erdinç Şükrü ŞIŞECAMSearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch13Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary Improving energy efficiency, always important in glass manufacturing, has become urgent in the current context of climate change and restricted availability of fuels due to conflict. Oxy-combustion reduces energy consumption by reducing the volume of flue gas, and reduces NO x emissions. Increasing costs of fuel, especially natural gas, have made oxy-combustion particularly interesting recently. Nonetheless, it remains important to further optimize oxy-combustion, where possible, by integrating additional energy-saving technologies. "Heat Oxy-Combustion" abbreviated as "HeatOx" is such a technology, which combines the benefits of oxy-combustion with heat recovery. In this chapter, the authors describe the installation and start-up of a pilot Radiative Heat Exchanger system at the Paşabahçe Glass plant in Targovishte, Bulgaria, by Air Liquide and Şişecam, supported by the LIFE European Program. REFERENCES Air Liquide's Heat Oxy-combustion: An Innovative Energy Saving Solution for Glass Industry , Taekyu Kang , Kenneth Kaiser , Scott Liedel , Luc Jarry , Xavier Paubel , Youssef Joumani and L. Kaya , 76th Conference on Glass Problems , Columbus, Ohio, Nov. 4. 2015 Google Scholar Oxy-fuel tableware furnace with novel oxygen and natural gas preheating system , Tunc Görüney , Neset Arzan Süleyman Koc, Osman Öztürk , Hakan Sahin , Hwanho Kim , Taekyu Kang , Xavier Paubel Youssef and Luc Jarry , 77th Conference on Glass Problems , Columbus, Ohio Nov. 2016 Google Scholar HeatOx makes major efficiency strides , Chloé Caumont-Prim , Xavier Paubel , Tâm Lâm , Sarah Juma and Luc Jarry , Glass Worldwide • May / June 2018 pp. 78 - 80 Google Scholar 83rd Conference on Glass Problems: Ceramic Transactions ReferencesRelatedInformation
Chapter c15 Design and Implementation of Optifire™ Flex Burner for Foam Reduction in OXY-FUEL Glass Furnaces Robert L. Bell, Robert L. Bell Linde Inc., Danbury, CT, USASearch for more papers by this authorGeert Cnossen, Geert Cnossen Linde Inc., Danbury, CT, USASearch for more papers by this authorRobert Miller, Robert Miller Linde Inc., Danbury, CT, USASearch for more papers by this authorGaurav Kulkarni, Gaurav Kulkarni Linde Inc., Danbury, CT, USASearch for more papers by this authorHisashi Kobayashi, Hisashi Kobayashi Linde Inc., Danbury, CT, USASearch for more papers by this author Robert L. Bell, Robert L. Bell Linde Inc., Danbury, CT, USASearch for more papers by this authorGeert Cnossen, Geert Cnossen Linde Inc., Danbury, CT, USASearch for more papers by this authorRobert Miller, Robert Miller Linde Inc., Danbury, CT, USASearch for more papers by this authorGaurav Kulkarni, Gaurav Kulkarni Linde Inc., Danbury, CT, USASearch for more papers by this authorHisashi Kobayashi, Hisashi Kobayashi Linde Inc., Danbury, CT, USASearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch15Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary Foam is generated in a glass furnace because of complex chemical reactions happening within the glass forming batch materials as well as the molten glass. The foam layer acts as insulation and negatively affect heat transfer to the glass-melt, which would subsequently lead to higher fuel consumption and increased crown temperature. The foam can be formed either from the raw batch materials, or from the fining process which is called secondary foaming. Linde's OPTIFIRE™ FLEX burner is designed to mitigate the secondary foam formation. This chapter summarizes the technology development of the FLEX burner and presents the authors' experiences in its implementation and performance on the commercial container glass furnace. Oxy-fuel furnaces using sodium sulfate as a refining agent are prone to secondary foaming due to the high concentration of water vapor. Staged combustion is used in oxy-fuel furnaces to reduce NOx generation and emissions. REFERENCES P.R. Laimbock , PhD thesis Technical University of Eindhoven 1998 . Google Scholar R.G.C. Beerkens , P. Laimbock , in; J Kieffer (Ed.) 60th Conference of Glass Problems-Urban IL , American Ceramic Society , October 19-20, 1999 Google Scholar M. Cable , C.G. Rasul , J. Savage , Glass Technol. 9 ( 2 ) ( 1968 ) Google Scholar R.G.C. Beerkens , Glastech Ber. 71 ( 4 ) ( 1998 ) 111 . Google Scholar R.G.C. Beerkens , P. Laimbock , Ceram. Eng. Sci. Proc. 21 ( 1 ) ( 2000 ) 41 CASGoogle Scholar Kulkarni , G. , De Deigo , J. , Cnossen , G. , Cates , J. , Francis , A. ( 2014 , September 29). " Design Considerations and Emission Performance of Oxy-fuel Burners for Glass Furnaces ". Paper presented at XXIV ICF-EDG Technical Exchange Conference. Google Scholar [7] Kulkarni , G. , Iyoha , U. , Chakravarti , S. , Diggins III , P. , Francis , A. , Panuccio , G. , 2018 . " Staged, Oxy-Fuel Wide Flame Burners to Mitigate Refractory Port Fouling and Foaming in Glass Furnaces ." 78th Glass Problems Conference Google Scholar 83rd Conference on Glass Problems: Ceramic Transactions ReferencesRelatedInformation
Chapter 6 All-Electric-Forehearth Design with Zero Emissions Christoph Jatzwauk, Christoph Jatzwauk F.I.C. Germany GmbH, Mühlweg 48, 92637 WEIDEN, GermanySearch for more papers by this authorStuart Hakes, Stuart Hakes F.I.C. Germany GmbH, Mühlweg 48, 92637 WEIDEN, GermanySearch for more papers by this authorHans Mahrenholtz, Hans Mahrenholtz F.I.C. Germany GmbH, Mühlweg 48, 92637 WEIDEN, GermanySearch for more papers by this author Christoph Jatzwauk, Christoph Jatzwauk F.I.C. Germany GmbH, Mühlweg 48, 92637 WEIDEN, GermanySearch for more papers by this authorStuart Hakes, Stuart Hakes F.I.C. Germany GmbH, Mühlweg 48, 92637 WEIDEN, GermanySearch for more papers by this authorHans Mahrenholtz, Hans Mahrenholtz F.I.C. Germany GmbH, Mühlweg 48, 92637 WEIDEN, GermanySearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch6Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary Gas fired forehearths being by far the most popular design, have been studied and developed in great depth over the decades with numerous variations, all now following the same basic principle of separating the cooling and heating zones in the superstructure to effect better control of the glass conditioning process. F.I.C. has analyzed deeply all common forehearth designs available on the glass market, has further used the competence of their mother company GS, and developed based on this an ALL-ELECTRIC-FOREHEARTH-Design. That new 'FIC-AE-FH' system uses special key feature of a profiled roof block design, which is a perfect feature of almost all good gas fired forehearth designs. FIC-design is using a special heating element. Due to the use of electricity as the sole source of energy there are no CO 2 emissions associated with the use of gas. 83rd Conference on Glass Problems: Ceramic Transactions RelatedInformation
Chapter 8 5-Year Operating Experience with the Optimelt™ Heat Recovery Technology on a Tableware Furnace M. van Valburg, M. van Valburg LCGlass, Lingedijk 8,4142LD, Leerdam, The Netherlands *Linde Inc., Danbury, CT, USASearch for more papers by this authorH. Kobayashi, H. Kobayashi LCGlass, Lingedijk 8,4142LD, Leerdam, The Netherlands *Linde Inc., Danbury, CT, USASearch for more papers by this authorA. Aluri, Corresponding Author A. Aluri LCGlass, Lingedijk 8,4142LD, Leerdam, The Netherlands *Linde Inc., Danbury, CT, USASearch for more papers by this author M. van Valburg, M. van Valburg LCGlass, Lingedijk 8,4142LD, Leerdam, The Netherlands *Linde Inc., Danbury, CT, USASearch for more papers by this authorH. Kobayashi, H. Kobayashi LCGlass, Lingedijk 8,4142LD, Leerdam, The Netherlands *Linde Inc., Danbury, CT, USASearch for more papers by this authorA. Aluri, Corresponding Author A. Aluri LCGlass, Lingedijk 8,4142LD, Leerdam, The Netherlands *Linde Inc., Danbury, CT, USASearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch8Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary The OPTIMELT™ Thermochemical Regenerator (TCR) system has been in successful commercial operation on an oxyfuel fired tableware glass furnace at Leerdam Crisal Glass in The Netherlands since November 2017. This chapter introduces the implementation of the Linde OPTIMELT TCR heat recovery system at Leerdam and highlights the operating experience over the past 5 year of operation. The energy savings performance, furnace emissions and glass quality results of TCR operation will be summarized and compared to the results of the conventional oxy-fuel furnace without the TCR. Two unique features of the system will be reviewed – ability to switch between TCR and oxy-fuel modes as well as the self-cleaning mechanism that minimizes sulfates deposit build-up in the regenerators. The chapter concludes with a brief discussion of H2-readiness of the TCR technology. 83rd Conference on Glass Problems: Ceramic Transactions RelatedInformation
Since the nineteen-fifties, the performance of glass furnaces has improved significantly. This chapter describes important refractory developments and leads 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. The chapter also describes how the lining concepts had been changed over the decades and how the refractories contributed to the improvements in glass melting technology. The glass contact area is one of the most critical parts of a glass furnace as it is holding the entire glass melt and it has a direct impact on the glass quality. It's been at least 70 years that silica is in use for melter crown construction.
Chapter c12 PARTIAL OXY-FUEL CONVERSION OF GLASS FOREHEARTHS: A COST-EFFECTIVE WAY TO REDUCE CO2 EMISSIONS BY 50% J. Pedel, J. Pedel Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this authorG. Kulkarni1, G. Kulkarni1 Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this authorS. Vijayan, S. Vijayan Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this authorR. Nath, R. Nath Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this author J. Pedel, J. Pedel Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this authorG. Kulkarni1, G. Kulkarni1 Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this authorS. Vijayan, S. Vijayan Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this authorR. Nath, R. Nath Linde, Inc., Tonawanda, NY, USA, Linde, SA, Services Pvt. Ltd, IndiaSearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch12Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary Typical glass forehearths use a premixed mixture of gas and air for combustion, but numerous problems exist with this approach. The flame luminosity is low and since there is no flue gas heat recovery and the air is not preheated, the thermal efficiency is poor, typically around 25%. Oxy-fuel combustion can address these problems by improving fuel efficiency, reducing emissions, and improving the heat transfer to the glass to achieve better temperature homogeneity. Linde has developed a cost effective partial oxy-fuel solution that can be retrofitted on existing air-gas forehearths and addresses the common issues associated with the high flame temperature while maintaining the fuel savings benefits. The chapter also presents a computational fluid dynamics comparison between the air-fuel system and the partial oxy-fuel retrofit and then discusses the implementation at the customer site and the operating results. Linde partial oxy-fuel solution was first tested on a single commercial forehearth in 2017. 83rd Conference on Glass Problems: Ceramic Transactions RelatedInformation
Chapter c11 FUTURE-PROOFING YOUR DUST COLLECTION SYSTEM BEST PRACTICES IN DUST COLLECTION FOR THE GLASS INDUSTRY Alysha Yinger, Alysha Yinger RoboVent Sterling Heights, MI, USASearch for more papers by this authorKyle Billie, Kyle Billie RoboVent Sterling Heights, MI, USASearch for more papers by this author Alysha Yinger, Alysha Yinger RoboVent Sterling Heights, MI, USASearch for more papers by this authorKyle Billie, Kyle Billie RoboVent Sterling Heights, MI, USASearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch11Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary A dust collection system is a major capital expenditure for glass and ceramic manufacturers. It is also essential for worker health and safety and regulatory compliance. Glass manufacturers can take proactive steps to ensure that their dust collection systems are ready for the future. This chapter outlines five important steps for efficient dust collection system design, including understanding the dust, determining exposure levels and permissible exposure limits, containing dust-producing processes, choosing the right dust collection approach, and sizing and designing the system for efficient dust capture. It introduces specific considerations in designing a system that will meet future needs, including energy efficiency, maintenance requirements, the regulatory environment, business needs and industry best practices. Dust collectors are sized primarily by airflow, measured in cubic feet per minute. Dust collector filters are rated according to their ability to filter out contaminants of different sizes. REFERENCES NIOSH , Crystalline Silica: Health Risks of Exposure, accessed September 2022 from https://www.cdc.gov/niosh/topics/silica/risks.html#:~:text=Silica%20dust%20particles%20b ecome%20trapped,debilitating%2C%20and%20sometimes%20fatal%20disease Google Scholar OSHA , Standard Number 1910.1000, Table Z-3 Mineral Dusts , accessed September 2022 from https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.1000TABLEZ3 Google Scholar OSHA , Occupational Exposure to Respirable Crystalline Silica , 29 C.F.R. 1910.1053 Google Scholar OSHA , Occupational Exposure to Respirable Crystalline Silica , 29 C.F.R. 1910.1053 Google Scholar NIOSH , NIOSH Pocket Guide to Chemical Hazards , 3rd Printing, Publication Number 2005-149 Google Scholar ACGIH , Silica, Crystalline: alpha-Quartz and Cristobalite: TLC(R) Chemical; Substances 8th Edition Documentation Google Scholar 83rd Conference on Glass Problems: Ceramic Transactions ReferencesRelatedInformation
Chapter 7 The Fully Compartmentalized Glass Furnace Adam Polcyn, Adam Polcyn Vitro Architectural Glass, Cheswick, PA, USASearch for more papers by this author Adam Polcyn, Adam Polcyn Vitro Architectural Glass, Cheswick, PA, USASearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch7Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary In the late 1970's, PPG Industries (now Vitro Architectural Glass), embarked on a program to develop a "leapfrog" glass melting technology by 1986. Originally called "Project 86", and later renamed to "Project 10" or simply "P-10", the objectives of the project included: reducing the capital cost of the melter by half; reducing the amount of energy needed to melt the glass to a fraction of its typical value at the time; and eliminating any need for pollutant post-treatments. In this chapter, the author provides an overview of the basic structure, function, and some of the issues encountered with each of the P-10 compartments. The 10-2 Rotary Ablative Melter was one of the most innovative, and complex, compartments of the P-10 process. The partially melted material exiting the 10-2 then free-fell into the 10-3 Receiver compartment. REFERENCES Glass Manufacturing Industry Council , " Glass Melting Technology: A Technical and Economic Assessment ," 2004 . Google Scholar S. Chakravarti , " Technical and Economic Investigation of Next Generation Fuels for Glass Melters ," in 82nd Glass Problems Conference , Columbus, 2021 . Google Scholar S. Hakes , " The Future of Glass Melting in a World Where Stringent Reductions of Carbon Dioxide and NOX, SOX Require 600 tpd All-Electric Furnaces and/or the Role of Super Boosting ," in 79th Conference on Glass Problems , Columbus, 2018 . Google Scholar E. Muijsenberg , " Economic and Sustainability Considerations of All Electric and Hybrid Glass Melters ," in Glass Manufacturing Industry Council Symposium on Sustainability in Glass Manufacturing , Columbus , 2019 . Google Scholar W. Trier , Glass Furnaces: Design, Construction, and Operation, Sheffield , UK : Society of Glass Technology , 1987 . Google Scholar R. Beerkens , " Trends in Glass Production ," in 1st Joint Meeting DGG – ACerS GOMD , Aachen , 2014 . Google Scholar R. Schwenninger , Interviewee, Private Communication . [Interview]. 27 October 2022 . Google Scholar R. Heithoff , " Method and Apparatus for Controlling an Ablation Liquifaction Process ". United States of America Patent 4,521,238, 4 June 1985 . Google Scholar R. Schwenninger , " Metering Device for Molten Glass and the Like ". United States of America Patent 4,600,426, 15 July 1986 . Google Scholar World Resources Institute; World Business Council for Sustainable Development , " The Greenhouse Gas Protocol ," World Resources Institute , Washington, D.C. , 2015 . Google Scholar 83rd Conference on Glass Problems: Ceramic Transactions ReferencesRelatedInformation
Chapter 5 THE ELECTRICAL SYSTEMS WILL BECOME THE GAS SKITS OF THE FUTURE René Meuleman, René MeulemanSearch for more papers by this authorChristian Collombet, Christian CollombetSearch for more papers by this authorSchneider Electric, Schneider ElectricSearch for more papers by this author Baarn, BaarnSearch for more papers by this authorThe Netherlands, The NetherlandsSearch for more papers by this author René Meuleman, René MeulemanSearch for more papers by this authorChristian Collombet, Christian CollombetSearch for more papers by this authorSchneider Electric, Schneider ElectricSearch for more papers by this author Baarn, BaarnSearch for more papers by this authorThe Netherlands, The NetherlandsSearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch5Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary The world's first commercially successful regenerative furnace was built for a small glass making company at Rotherham, South Yorkshire, in 1860. Today, the glass industry has come to a point in time in where, instead of using fossil fuels, it has started to consider alternative, renewable heat sources to run energy-intensive melting, fining and conditioning processes. One goal is a reduced carbon footprint to maintain a social licence to operate. The obvious choices seem to be electrical energy or the use of hydrogen. It ultimately changes the energy mix of glass sites: electricity being the major power; a significant portion being fully reliable; and all electric supply being produced from sustainable sources. The requirement for more electrical boosting power will lead to more and bigger electrodes running higher currents. Size and number of electrodes are limited but nevertheless, power control systems will need to move up in current and input voltage. References " Glass Technology " – European Journal of Glass Science and Technology Part A , Volume 54 , Number 3 , June 2013 , pp. 93 – 99 Google Scholar https://science.anu.edu.au/news-events/news/how-we-discovered-climate-problem; https://www.bbc.com/news/science-environment-15093234 Google Scholar 83rd Conference on Glass Problems: Ceramic Transactions ReferencesRelatedInformation
Chapter 4 DIGITAL MEASUREMENT OF CORD STRESSES IN CONTAINER GLASS Henning Katteilis, Henning Katteilis ilis gmbh, Erlangen, GermanySearch for more papers by this author Henning Katteilis, Henning Katteilis ilis gmbh, Erlangen, GermanySearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch4Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary The presence of so-called cord stresses (also known as striae) in glass products indicates local variations in the glass composition due to problems in the batch preparation (mixing) or glass conditioning. Facing the ever-increasing pressure to reduce costs and use low-grade raw materials and recycled glass, the challenging task of measuring cord stresses in container glass has become increasingly important. For decades, measurements have been carried out in a manual/visual way using conventional polarization microscopes. To prepare a sample for measurement, a glass ring must be cut from the cylindrical part of the glass container. The simplest setup to visualize cord stresses is a polariscope with two crossed polarizers. Manual measurement of cord stresses with a polarizing microscope is a complex two-step process. Digital measurement enables documentation of the measurement process and thus traceability of measurement results. 83rd Conference on Glass Problems: Ceramic Transactions RelatedInformation
Chapter c14 Blue and Green Hydrogen Production, Distribution, and Supply for the Glass Industry and the Potential Impact of Hydrogen Fuel Blending in Glass Furnaces Michael J. Gallagher, Michael J. Gallagher Dewing Air Products & Chemicals Allentown, PA, USASearch for more papers by this authorAshwin Vinod, Ashwin Vinod Dewing Air Products & Chemicals Allentown, PA, USASearch for more papers by this authorA. Roger, A. Roger Dewing Air Products & Chemicals Allentown, PA, USASearch for more papers by this author Michael J. Gallagher, Michael J. Gallagher Dewing Air Products & Chemicals Allentown, PA, USASearch for more papers by this authorAshwin Vinod, Ashwin Vinod Dewing Air Products & Chemicals Allentown, PA, USASearch for more papers by this authorA. Roger, A. Roger Dewing Air Products & Chemicals Allentown, PA, USASearch for more papers by this author Book Editor(s):S. K. Sundaram, S. K. SundaramSearch for more papers by this author First published: 08 August 2023 https://doi.org/10.1002/9781394200306.ch14Book Series:Ceramic Transactions Series AboutPDFPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShareShare a linkShare onEmailFacebookTwitterLinkedInRedditWechat Summary The global movement towards decarbonization spans across all industries, including Glass manufacturing. Hydrogen is expected to play a key role in decarbonizing industry. To make it easy to differentiate between the different hydrogen production methods/carbon intensities, industry has adopted the practice of referring to hydrogen using various colors. The most used colors are grey, blue, and green. Blue hydrogen is made from a hydrocarbon source. Green hydrogen is produced from a renewable energy source. Air Products has made significant investments in blue and green hydrogen and ammonia production. Currently, there are three major projects in the Middle East, Canada, and the United States in various stages of completion. The chapter also discusses some aspects of these projects including production, distribution, and supply methods. In addition, results using hydrogen as a fuel to replace natural gas combustion with existing oxy-fuel burner technology are presented. REFERENCES Kearney Energy Transition Institute , Hydrogen applications and business models , June 2020 . https://www.energy-transition-institute.com/insights/hydrogen Google Scholar Air Products , ACWA Power and NEOM Sign Agreement for $5 Billion Production Facility in NEOM Powered by Renewable Energy for Production and Export of Green Hydrogen to Global Markets. Air Products, ACWA Power and NEOM Sign Agreement for $5 Billion Production Facility in NEOM Powered by Renewable Energy for Production and Export of Green Hydrogen to Global Markets . Google Scholar Report from the Commission to the European Parliament and the Council on the Functioning of the European Carbon Market . 2020 . https://ec.europa.eu/clima/system/files/2021-10/com_2021_962_en.pdf Google Scholar A. Keeley . Hydrogen Combustion on a Float Glass Furnace. 26 th International Congress on Glass . Berlin, Germany , 3-8 July 2022 . Google Scholar 83rd Conference on Glass Problems: Ceramic Transactions ReferencesRelatedInformation
CelSian has developed a new method for predicting the presence of bubbles in the glass melt and the resulting bubble count in the final product by means of a bubble size distribution model (BSM). With the bubble size distribution model, the transport of bubbles in the glass melt is simulated in a continuous way. By continuous we mean that the presence of bubbles is calculated as the number of bubbles in the entire glass melt per volume during the normal simulation (not as a post processing step after the simulation). This allows for interaction between bubbles, chemistry, and the actual glass properties in the melt (density, heat absorption, viscosity, etc.). On each location in the melt, it is calculated how many bubbles per kg of glass it contains, what the typical size distribution of those bubbles is and what the gas content inside the bubbles is. The BSM is combined with chemistry (redox) calculations in the glass melt, in which case we also keep track of the gas species’ concentrations in the bubbles. These gases can react with each other in the bubble and/or they can react with the species in the surrounding glass through a surface reaction on the bubble-melt interface. Thus, the bubble growth due to fining as well as the bubble rise due to buoyancy and bubble release on the melt surface is calculated accurately and in detail. In this paper, modeling of industrial furnaces will be presented, and the result of the bubble and chemistry calculations will be compared for different situations. The impact on furnace design and furnace operation will be discussed as well as the value for a glass producer to have the capability to accurately predict the number, size and content of bubbles on every location in the melt.
Refractory manufacturers can and do select from a large menu of different ingredients to arrive at the same bulk chemistry in their final product. Chief among these are zircon or zirconia for the ZrO 2 source and kaolin/clay, andalusite, mullite, fused mullite, calcined alumina, tabular alumina or electro-fused alumina grain for the Al 2 O 3 source; and usually two or three different aluminous raw materials are used in a single product. Silica is added by default as a natural ingredient of zircon, kaolin/clay, andalusite and mullite but it is sometimes also added as quartz, colloidal silica, or sodium silicate to aid in the binding process. Another ingredient finding increased use in bonded AZS products is recycled or scrap fused cast AZS grain as “grog” added to the product. These ingredients and the combinations thereof all behave differently when exposed to alkali vapors or in glass contact situations inside the hot glass furnace. The bonded AZS materials also includes similar products used in patch, mortars and hot bottom repairs. Certain ingredients such as the clay and siliceous phases will corrode or dissolve faster than others. Zircon usually dissociates to silica glass phase and crystalline fish egg, nodular or acicular ZrO 2 , sometimes even dendritic ZrO 2 . Mullite and the finer-grained calcined alumina can partially dissolve and re-crystallize as secondary mullite needles or secondary hexagonal plates of α-Al 2 O 3 . Alkali-rich vapors of sodium and to a lesser extent, potassium, will react with the alumina and silica enriched glassy phase to form nepheline, carnegieite or perhaps a leucitic-nepheline solid solution phase if there is enough potassium. The fused cast AZS grain additive, zirconia phase and larger fused mullite, tabular alumina and/or electro-fused alumina aggregates have a greater propensity to survive intact and be seen in stone defects. The laboratory technician, scientist or process engineer responsible for daily petrographic analysis of stone defects coming off the line must know the entire list of refractories used in the construction of the furnace as well as what those refractories look like under the polarized light microscope. This paper will include example photomicrographs of several stones originating from different bonded AZS refractory materials and include photomicrographs of some thin-sectioned AZS brick and castable products to show the wide range of base ingredients and microtextures that characterize these products in their original state.
With the realities of global warming and plans for CO 2 reduction, the interest in alternative furnace designs such as hybrid electric melting is getting more attention. The generation of electricity by renewable energy sources is, of course, a great help as it brings costs of electricity finally down and will be CO 2 free. In Europe the average generation of electricity by renewable resources is already above 40% coming from wind, solar, hydro and bio. Electricity storage however is complex and expensive, while transporting energy in the form of a gas via pipes is cheaper than via electric wires. An alternative renewable energy carrier is hydrogen. Hydrogen can be generated via electrolysis using electricity: this conversion, however, is only in the effective range of 65%. After this, hydrogen can be burned in a glass melting furnace with a typical efficiency of 50%. This paper will present Glass Service a.s. (GS) thermal efficiency studies showing if the future will be more likely using electric heating or hydrogen combustion. Results of mathematical modeling show the efficiency of the different technologies.
When an independent float glass manufacturer had an environmental emission challenge using through-port gas burners, they initially approached Simpson Combustion and Energy Limited. There was a marginal improvement following several site visits and basic furnace optimisation, but no adjustment could change the flame shape for one burner. A new gas nozzle design was manufactured, and in parallel, a five-day AMETEK Land in-furnace near infrared thermal imaging survey was performed. It is believed that this paper will be the first presentation of in-furnace thermal imaging in a float furnace. It is also believed that this is the first presentation of in-furnace thermal imaging with the inclusion of regenerators. Three days were allowed for the baseline survey; however, the on-site customer support enabled the task to be completed in two days, allowing for an additional day to undertake the burner and furnace optimisation. The regenerator thermal imaging survey highlighted a strange phenomenon whereby on the port, the flame could not be adjusted, as the checker pack had lifted defying gravity! Bizarrely and coincidentally the lifting had created an internal regenerator by-pass flue which enabled a path of least resistance for cold combustion air in such quantities that the burner adjustments were ineffective! A conventional photographic survey confirmed the lifting of the refractory but could not indicate the formation of the by-pass flue. The twin nozzle through-port flat flame gas burner was first developed in the early 90s and helped facilitate the conversion of float furnaces from oil to natural gas. Two impacting jets create a flat flame. This paper will show examples of the nozzles tested and developed as a result of this study. The in-furnace thermal imaging survey camera was positioned at the waist and port target wall for both the firing and exhaust side, generating four thermal images of one flame. This paper will demonstrate how this thermal survey method can be used as a furnace optimisation and a combustion development tool. The final formal report and presentation to the float manufacturer and their local environmental authority justified continued work on primary emission reduction methods.
