48th Conference on Glass Problems

Transcription

1 48th Conference on Glass Problems Proceedings of the 48th Conference on Glass Problems Clifton G. Bergeron Editor A Collection of Papers Presented at the 48th Conference on Glass Problems Sponsored by the Departments of Ceramic Engineering The University of Illinois at Urbana-Champaign and The Ohio State University November 10-11, 1987 The University of Illinois at Urbana-Champaign Mini Union Building Urbana. 1L ISSN Published by The American Ceramic Society, Inc. 757 Brooksedge Plaza Drive Westerville, OH Copyright@ 1988, The American Ceramic Society, Inc.

2 I Executive Director & Publisher W. Paul Holbrook Director of Publications Linda S. Lakemacher Editor William J. Smothers Production Manager Alan Hirtle Committee on Publications: Victor A. Greenhut, chair; David W. Johnson, Jr.; Ronald E. Loehman; Cameron G. Harman, Jr., exofficio; W. Paul Holbrook, ex officio; William H. Payne, ex offcio; William J. Smothers, ex officio. Editorial Advisory Board: Cameron G. Harman, Jr., chair; Waltraud M. Kriven, chair elect; Uma Chowdhry; Ellis Gartner; George Gehringer; Carol M. Jantzen; Ronald E. Loehman; David B. Marshall; William J. Rice; Thomas F. Root; Gary S. Sheffield; James E. Shelby, Jr.; Karl E. Spear; Mark A. Stett; Russell K. Wood. Editorial and Subscription Offices: 757 Brooksedge Plaza Drive, Westerville, Ohio, Subscription $60 a year; single copies $15 (postage outside U.S. $5 additional). Published bimonthly. Printed in the United States of America. Allow four weeks for address changes. Missing copies will be replaced only if valid claims are received within four months from date of mailing. Replacements will not be allowed if the subscriber fails to notify the Society of a change of address. CESPDK Vol. 9, NO. 3-4, pp , 1988 I 1 The American Ceramic Society assumes no responsibility for the statements and opinions advanced by the contributors to its publications, or by the speakers at its programs. Copyright@ 1988, by the American Ceramic Society. Permission to photocopy for personal or internal use beyond the limits of Sections 107 and 108 of the U.S. Copyight Law is granted by the American Ceramic Society for libraries and other users registered with the Copyright Clearance Center, provided that the fee of $2.00 per copy of each article is paid directly to CCC, 21 Congress Street, Salem, MA The fee for articles published before 1988 is also $2.00 per copy. This consent does not extend to other kinds of copying, such as copying for general distribution, for advertising or promotional purposes, or for creating new collective works. Requests for special permission and reprint requests should be addressed to the Technical Editor, the American Ceramic Society (01%-6219/87 $2.00). Each issue of Ceramic Engineering and Science Proceedings includes a collection of technical articles in a general area of interest, such as glass, engineering ceramics, and refractories. These articles are of practical value for the ceramic industries. The issues are based on the proceedings of a conference. Both The American Ceramic Society, Inc.. and non-society conferences provide these technical articles. Each issue is organized by an editor who selects and edits material from the conference. Some issues may not be complete representations of the conference proceedings. There is no other review prior to publication.

3 Foreword The conference was sponsored by the Departments of Ceramic Engineering of the University of Illinois at Urbana-Champaign (UIUC) and the Ohio State University. C. G. Bergeron, Professor, Department of Ceramic Engineering, was Director of the Conference. Local arrangements and conference operations were handled by G. W. Conlee, Assistant Director of the Glass Conference, also of the Department of Ceramic Engineering, UIUC. Anthony F. Graziano, Associate Dean of the College of Engineering, UIUC, gave the welcoming address. David A. Payne, Acting Head, Department of Materials Science and Engineering, UIUC, gave the Departmental Greeting. Themes and chairmen of the conference sessions were as follows: Environmental Considerations John F. McConnell PPG Industries, Pittsburgh, PA Computer Control and Modeling Carl W. Hibscher Toledo Engineering Company, Toledo, Ohio Furnace Operation C. Philip Ross, Jr. Kerr Glass Company, Santa Ana, CA Charles H. Drummond 111, Associate Professor of Ceramic Engineering, the Ohio State University, presided at the banquet. Entertainment was provided by the University of Illinois Jazz Band. The Conference was held in the Illini Union Building, Urbana, IL

4 Preface In keeping with the precedent established by the previous glass conferences, the papers from the 48th Annual Conference on Glass Problems have been brought together for the 1987 edition of The Collected Papers. These proceedings were prepared in the Department of Ceramic Engineering at UIUC. Manuscripts are reproduced largely as furnished by the authors but were reviewed prior to presentation by the respective session chairmen. A modest amount of editing or correction was also done by C. G. Bergeron. The University of Illinois at Urbana-Champaign is not responsible, as a body, for the statements and opinions expressed in this publication. C. G. Bergeron Urbana, IL December 1987 iv

5 Acknowledgments It is a pleasure to acknowledge the assistance and advice provided by the Program Advisory Committee whose members are listed below: Edward R. Begley Corhart Refractories Corporation John F. Blumenfeld Consultant Douglas H. Davis Manville Corporation Charles H. Drummond, 111 The Ohio State University Carl W. Hibscher Toledo Engineering Company J. Jerry Kersting Corning Glass Works John F. McConnell PPG Industries Harry N. Mills Owens-Illinois Inc. Dennis W. Readey The Ohio State University C. Philip Ross, Jr. Kerr Glass Manufacturing Company C. G. Bergeron Conference Director V

6 OPENING REMARKS-48TH GLASS PROBLEMS CONFERENCE The papers this morning and the majority of the papers throughout the conference will deal with various aspects of environmental concerns and from different viewpoints. Therefore, to start off the 48th Glass Problems Conference and this morning's session in particular, I would like to present some information pertaining to the environmental aspects of a recent float furnace cold repair. The numbers I present are real and are the result of a dedicated effort by our company to identify areas where additional resource concentration is required. One thing we can say with a degree of certainty is that the environmental costs of a cold repair are going to increase in the future. These costs do nothing to improve the product but only add cost. On an analysis of a cold repair of one of our float furnaces in early 1987, 9.6% of the total furnace tear out and rebuild cost were direct environmental costs. Indirect costs such as loss of efficiency and increased furnace downtime were not included but if included, would make the number even higher. To establish a trend or direction as to where these costs are going, this same 9.6% would have been 3.6% approximately 2 years ago. For our analysis, we choose to divide the 9.6% into 3 general categories: 1. Disposal other than Asbestos 2. Asbestos Disposal 3. Safety and Health The major category-disposal other than Asbestos-accounted for 65.5% of the 9.6%. Hazardous waste materials, namely chrome refractories or chrome contaminated materials, made up a little over two-thirds of the 65.5%. The second category-asbestos Disposal-accounted for approximately 18.6%. In our operations, this number is headed to zero at a fast rate through very successful company-backed programs. In only a few remaining facilities like this example does asbestos exist in the furnace area. The third category-safety and Health-accounted for the remaining 15.9% of the 9.6%. For this particular repair, 430 employees were given respirator qualification testing. As a point of interest, 9% of the 430 employees failed to get medical approval, and another 5% had to shave to qualify for respirator usage. Also included in this category was employee protective equipment (coveralls, respirators, ear plugs, etc.) as well as the cost of enclosures and various barriers. One can see from the numbers just presented that the environmental aspects of a float furnace cold repair are significant-10% of the total cost now-and will become even larger in the future. The proximity of both hazardous and non-hazardous waste sites to the plant will have a major impact on the cost of transportation. Other than for the cost of transportation, I would say the percents I have mentioned would be very close for any float furnace currently operating in the U. S. Anything we can do to lower these costs will be a benefit both to the employee and the company. John F. McConnell PPG Industries, Inc. November 10, 1987 vi

7 Table of Contents Environmental and Health Aspects of Glass Furnace Repairs, IV Bradley Q. Kinsman and John L. Cherill Combustion Modifications for Control of NO, Emissions from Glass Melting Furnaces Hamid A. Abbasi and Donald K. Fleming Cullet Processor Design and Operation Donald H. Schendel Wet Sand Handling System for Float Glass Manufacturing Christopher R. Cording, Stephen B. Parker, and Bruce A. Wallace Analysis of Glass Process Problems Using Three-Dimensional Computer Modeling R. A. Murnane and N. J. Moreland State-of-Art Numerical Simulation of Glass Melting Furnaces A. Ungan and R. Viskanta Glass Melting with Pure Oxygen Combustion: Modeling of Convective and Radiative Heat Transfer Dominique Jouvaud, Jean-Franqois I Huissier, and Bernard Genies Experiences in Operating Computer-Controlled Furnaces and Forehearths J. P. Hartley Refiner Temperature Control and Its Influence on Forehearths Operation John P. Theisen First Campaign of a Lead Crystal Glass Electric Furnace in Poland G. A. Warren, T. Stasiak, and R. E. Davis Results of Scaled Testing and Analytical Investigations of a Cullet Preheater R. De Saro, L. Donaldson, S. Panahe, G. Ridderbusch, and J. Pagliarini High Zirconia Glass Refractories: An Overview A. D. Davis, Jr. and T. M. Wehrenberg vii

8 Optimizing Batch Composition, Redox. and Furnace Operation R. Hulrne Gaseous Inclusions in Float Glass R. R. Snow and D. R. Sendi Glass Furnace Bottom Construction-Trends, Facts, and Myths-A Review E. R. Begley Interim Study of a Chrome-Free, High-Efficiency Checker Setting in a Container Glass Furnace W. John Kivala and H. Edward Wolfe... VIII