Modeling of Glass Making Processes for Improved Efficiency Page: 3 of 77
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DE-FG07--96EE41262 Page 3
Final Report
March 31, 2003
1.7 Project Participants: The New York State College of Ceramics (NYSCC)
The NSF Industry-University Center for Glass Research
The New York State College of Ceramics at Alfred University was the official project recipient and
administered the contract through its Office of Sponsored Programs, Dr. Vasantha Amarakoon,
Acting Director, (607) 871-2486.
The CGR provided oversight for the project and, as cost sharing, funded eight (8) additional
research projects in direct support of this DOE/OIT grant as described in Sections 2.1, 3.4 and 5.3
below.
In addition to direct CGR cost sharing, individual CGR member companies provided technical
assistance and sample quantities (25 - 50 Lbs.) of the six commercial glasses employed in the
study.
1.8 DOE Project Team: DOE-OIT Glass Team Leader - Elliott Levine
DOE Program Manager -Elliott Levine
DOE Project Manager - Matae H. McCray
Grant Administrator - Marshall Garr
Industry Contact - Industrial Liaison Board of the NSF
Industry/University Center for Glass Research at Alfred
University
1.9 Date Project Initiated: September 15, 1996
1.10 Completion Date: December 31, 2002 (database reported here)
December 31, 2003 (estimate for validation of models by
CGR member companies)
1.11 Introduction and Background
Glass manufacturing is a capital-intensive industry. In 1996, the cost of a new float glass facility
was estimated to be about $150 million. The corresponding figures for fiberglass, container glass
and color TV tube bulbs were $80, $100 and $300 million, respectively [2]. Furnace rebuilding
costs run into millions of dollars. It is imperative that any proposed changes in furnace design have
near 100% assurance of success. Lost production resulting from a poor furnace design can
ultimately cost far more than the construction. Radical changes in design are almost always
considered "high risk." On the positive side, design changes that improve production yields or
result in even a 5% decrease in fuel consumption per ton of glass melted would have important
economic and environmental benefits for the industry. Consequently modeling of the glass-melting
process to predict performance has become a necessity for any new furnace design.
In July 1996, the U.S. Department of Energy (DOE) and the NSF Industry/University Center for
Glass Research (CGR) conducted a workshop at Alfred University on "Modeling in the Glass
Industry." Two of the primary needs identified for virtually all modeling of the glass melting
process are 1) reliable data on high-temperature melt properties and 2) improved sensors for in-line
measurement of process variables. Also deemed important is an "improved understanding" of the
fundamental principles of combustion and the fluid flow models themselves.
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III, Thomas P. Seward. Modeling of Glass Making Processes for Improved Efficiency, report, March 31, 2003; United States. (https://digital.library.unt.edu/ark:/67531/metadc740906/m1/3/: accessed April 25, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.