41st Conference on Glass Problems

152 Pages·2008·7.64 MB·English

by  William Smothers

Proceedings of the
41st Conference on Problems
Glass
Charles H. Drummond
I11
Conference Director
A Collection of Papers Presented at the
41st Conference on Glass Problems
Sponsored by the
Departments of Ceramic Engineering
Ohio State University
and
University of Illinois
November 18-19, 1980
Ohio State University
Fawcett Center for Tomorrow
Columbus, Ohio
ISSN
0196-6219
Published by
The American Ceramic Society,
Inc.
65 Ceramic Drive
Columbus, Ohio
43214
0 The American Ceramic Society,
1980

Proceedings of the
41st Conference on Problems
Glass
Charles H. Drummond
I11
Conference Director
A Collection of Papers Presented at the
41st Conference on Glass Problems
Sponsored by the
Departments of Ceramic Engineering
Ohio State University
and
University of Illinois
November 18-19, 1980
Ohio State University
Fawcett Center for Tomorrow
Columbus, Ohio
ISSN
0196-6219
Published by
The American Ceramic Society,
Inc.
65 Ceramic Drive
Columbus, Ohio
43214
0 The American Ceramic Society,
1980
I t
Executive Director & Publisher Associate Editor
Arthur L. Friedberg Susan Stock Means
i
Director of Publications Graphic Production
Donald C. Snyder Carl M. Turner
Editor Circulation Manager
William J. Smothers Gary W. Panek
z
H. Kent Bowen; William C. Mohr; Richard M. Spriggs; Louis J. Trostel, Jr.,
ex oflcio; William J. Smothers, ex oflcio; Arthur L. Friedberg, ex oflcio.
Editorial Aduisory Board: L. J. Trostel, Jr., Chairman; R. L. Berger; W. G.
Coulter; R. T. Dirstine; R. A. Eppler; E. J. Friebele; F. A. Hummel; W. J.
Lackey; T. D. McGee; G. W. Phelps; D. W. Readey; and W. R. Walle.
Editorial and Subscription Oflces: 65 Ceramic Drive, Columbus, Ohio
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additional). Published bimonthly. Printed in the United States of America.
Allow six weeks for address changes. Missing copies will be replaced only if
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CESPDK Vol. 2. No. 1-2. 1-141. 1981
DD.
Introduction
The conference was sponsored by the Departments of Ceramic Engineering
of The Ohio State University and the University of Illinois at Urbana-
Champaign.
Director of the conference was Dr. Charles H. Drummond 111, Associate
Professor, Department of Ceramic Engineering, The Ohio State University.
Assistant Dean Richard Frasher of the College of Engineering, The Ohio
State University, gave the welcoming address, and Dr. William B. Shook,
chairman of the Department of Ceramic Engineering, gave the departmental
greetings.
The themes and chairmen of the three half-day sessions were:
Melting and Postforming
Beuther L. Schmidt
Anchor Hocking Corp.
Lancaster, Ohio
Refractories and Batching
Earl R. Smith
Ford Motor Co.
Lincoln Park, Mich.
Energy, Pollution, and Surface Cord
Everett A. Thomas
Didier Taylor Refractories Corp.
Cincinnati, Ohio
Presiding at the banquet was Professor Clifton Bergeron, Professor of
Ceramic Engineering, University of Illinois at Urbana-Champaign. The ban-
quet speaker was Coach Emeritus Woody Hayes, The Ohio State University.
His address was entitled “Looking Forward.”
The conference was held at the Fawcett Center for Tomorrow, The Ohio
State University, Columbus.
iii
Acknowledgments
It is a pleasure to acknowledge the assistance and advice provided by the
members of the Program Advisory Committee:
Clifton G. Bergeron
University of Illinois at Urbana-Champaign
John T. Brown
Corning Glass Works
M. Laird Froberg
Owens-Corning Fiberglas Corp.
Joe R. Monks
Owens-Illinois
Henry Moore
Stauffer Chemical Co.
Subhash H. Risbud
University of Illinois at Urbana-Champaign
Robert J. Ryder
Brockway Glass Co.
Beuther L. Schmidt
Anchor Hocking Co.
William B.
Shook
The Ohio State University
Earl R. Smith
Ford Motor Co.
Everett A. Thomas
Didier Taylor Refractories Corp.
Charles H. Drummond I11
Conference Director
iv
Preface
In the tradition of previous conferences, the papers presented at the 41st An-
nual Conference on Glass Problems have been collected and published. In
addition to the papers presented, there was a panel discussion on “Surface
Cord” chaired by Everett A. Thomas with panel members Gary A. Ander-
son, Allen D. Davis, Jr., John LeBlanc, Helmut Pieper, and Manfred
Weiler . Following presentations by the panel members, questions submitted
by the audience were discussed by the panelists.
After the conclusion of the conference, an informal discussion of topics
of interest was chaired by Beuther L. Schmidt.
The manuscripts are reproduced furnished by the authors with modest
as
editing by C. H. Drummond. The Ohio State University and the American
Ceramic Society are not responsible for the statements and opinions ex-
pressed in this publication.
Charles H. Drummond I11
Columbus, Ohio
January 1981
V
Ceramic Engineering and Science
Proceedings
The Six Issues for 1981 are:
41st Annual Cqnference on Glass Problems: This conference, alternately
sponsored by Ohio State University and the University of Illinois at Cham-
paign, has always focused on production operations. The November 1980
conference includes papers on melting and postforming, refractories, batch-
ing, energy and pollution, and surface cord. No. 1-2.
42nd Porcelain Enamel Institute Technical Forum: The PEI Technical
Forum continues to provide outstanding, down-to-earth coverage of
developments in the porcelain enamel field. Subjects covered include pro-
grams for energy conservation and management, base metals and metal
fabrication, furnace improvements, advances in enamel application, low
cobaltho cobalt ground coats, nickelho pickle systems, materials utiliza-
no
tion and waste disposal, and porcelain enamel in microcircuitry. No. 3-4.
9th Automotive Materials Conference: Held in November 1980, this con-
ference was sponsored jointly by the Department of Materials and
Metallurgical Engineering of the University of Michigan, the American
Ceramic Society’s Michigan Section, and the Michigan Catalysis Society. It
was devoted to automotive exhaust catalysis and included papers on
monolithic and pelleted supports for automotive exhaust catalysis, three-way
catalysis, automobile emission testing and certification, and future directions
in automobile exhaust catalysis. 5-6.
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of Contents
Table
.......................
Design Considerations for All-Electric Glassmelters: 11 1
William R. Steitz and Carl W. Hibscher
...................
Forehearth Electric Heating Controlled by Conductance 14
James F. Stevenson
.................................................
Fuel Savings on Remodeled Lehrs 25
Melvin N. Roberts, Jr.
............................................
Asbestos Elimination in a Glass Plant 30
James C. Haney
...................
Problems Involving Spent-Chrome-Bearing Refractories 35
Warren Ferguson
S.
Chrome-Containing Basic Materials: Experience in the European
...........................................................................
Glass Industry 39
Paul P. Boggum
............
Longer Glass Furnace Life Using 38.1-cm-Thick Flux Material 51
J. J. Kersting, L. H. Kotacska, and L. K. Smith
Glass Batch Pelletizing and Pollution Capture Studies
............................................................................
in Pellet Beds 57
R. Raghavan, R. R. Thomas, R. Miller, and W. L. Wallding
E.
......................................
Fluidized Beds for Glass Batch Preheating 79
Ravi Sakhuja and William E. Cole
..........................................
An Energy Survey in the Glass Industry 88
Charles H. Allen
Environmental Regulation and Its Effect on the
...........................................................................
Glass Industry 95
George Teitelbaum
.....................................................
Surface Cord: A Case History 108
G. A. Anderson
.................................
Surface Cord Analysis and Potential Sources 112
Allen D. Davis, Jr.
............................................
General Comments on Surface Cord 120
John LeBlanc
Furnace Construction and Its Effect on Surface Cord
....................................................................
in Container Glass 133
Manfred Weiler
vii
Design Considerations for
All-Electric Glassmelters: I1 *
w.
WILLIAM STEITZ AND CARL HIBSCHER
R.
Toledo Engineering Co., Inc.
3001 Sylvania Ave., Toledo, Ohio 43613
The performance and operation of two different types electric melters, the
of
semicold top type and the cold top type, are discussed. The melting and operating
characteristics each type are described.
of
Glass resistivity and furnace resistance are very important considerations in
resolving the parameters of an electric melter, and these factors are best
determined by laboratory tests and models.
When the melting and electrical characteristics of the glass are deter-
mined, the selection of the type of electrical power system can be made. The
final shape and geometry of the melter are then coordinated with the
appropriate electrical scheme.
Single-phase application of power to an electric melter is normally used
for small melters up to about 27 t/d as a practical design limitation. Two-
phase and three-phase power is used for the larger capacity melters.
Multiphase melters can be either symmetrical or unsymmetrical from
both a geometric and an electrical aspect. The symmetrical system has a
uniform energy release that is conducive to vertical melting and utilizes a
distributor-type batch charger to create a uniform batch cover or blanket
over the entire melter surface. Symmetrical three-phase-type melters have
been used to about 80 t/d capacity, whereas the two-phase type has been used
up to 218 t/d capacity.
The unsymmetrical system has a nonuniform energy release pattern,
which creates zonal temperature differences in the melter. Unsymmetrical
furnaces usually have a length-to-width (L: W) ratio of more than one and are
generally associated with fixed-position batch chargers at the back wall. This
type of melter can have a broad turndown capability, but it will be at the ex-
pense of excessive power utilization when operating with a partial batch
cover. Further, the redox condition of the glass is dependent on pull rate and
percent batch cover.
Control of an unsymmetrical system is complex since generally no one
leg of the electrical power circuitry is truly representative of the resistance or
the condition of the body of glass.
The sidewall-entry-type electrode can be easily installed in operating fur-
naces without shutdown. The tip current density is normally high relative to
the body of the electrode, and accelerated erosion of the molybdenum rod is
encountered. The bottom-rod-type electrode has a very uniform current den-
sity over its full length, and electrodes usually last a campaign without the
1