Table Of Content47th Conference on Glass Problems
Proceedings of the
47th Conference on Glass Problems
Charles H. Drummond 111
Editor
A Collection of Papers Presented at the
47th Conference on Glass Problems
Sponsored by the
Departments of Ceramic Engineering
The Ohio State University
and
The University of Illinois at Urbana-Champaign
November 19-20, 1986
The Ohio State University
Fawcett Center for Tomorrow
Columbus, Ohio
ISSN 0196-6219
Published by
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@The American Ceramic Society, Inc., 1987
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CESPDK Vol. 8, NO. 3-4, pp. 111-297, 1987
I
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Foreword
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, Associ-
ate Professor, Department of Ceramic Engineering, The Ohio State
University.
Dr. Thomas L. Sweeney, Associate Vice-president for Research Adminis-
tration, The Ohio State University gave the welcoming address, and Profes-
sor Dennis W. Keadey, Chairman of the Department of Ceramic Engineering,
gave the departmental greetings.
The themes and chairmen of the three half-day sessions were:
Computer Control and Modeling in the Glass Industry
C. Philip Ross, Jr.
Kerr Glass Manufacturing
Santa Ana, California
Furnace Operation
Harry N. Mills
Owens-Illinois
Toledo, Ohio
Combustion
John F. McConnell
PPCi Industries
Pittsburgh, Pennsylvania
Hef ract ories
Edward R. Begley
Corhart Refractories
Louisville, Kentucky
Presiding at the banquct was professor Clifton Bergeron, Professor of
Ceramic Engineering, The University of Illinois at Urbana-Champaign. The
banquet 5peaker was Professor Roger D. Blackwell, Department of Market-
ing, The Ohio State University, Columbus, Ohio. His address was entitled
“Changing Life Styles: Implications for Glass Markets in the Future”.
The conferencc was held at the Fawcett Center for Tomorrow, The Ohio
State University, Columbus, Ohio.
...
111
Preface
In the tradition of previous conferences, the papers presented at the 47th
Annual Conference on Glass Problems have been collected and published
as the 1986 edition of The Collected Papers.
The manuscripts are reproduced as furnished by the authors but were
reviewed prior to presentation by the respective session chairmen. Editing
was done by C. H. Drummond. The Ohio State University is not responsible
for the statements and opinions expressed in this publication.
Charles H. Drummond I11
Columbus, Ohio
December 1986
iv
Acknowledgments
It
is a pleasure to acknowledge the assistance and advice provided by the
members of the Program Advisory Committee:
Edward R. Begley
Corhart Refractories
Clifton G. Bergeron
University of Illinois at Urbana-Champaign
John F. Blumenfeld
Emhart
Douglas H. Davies
Manville
Carl W. Hibscher
Toledo Engineering
William E. Horsfall
Corning Glass Works
John F. McConnell
PPG Industries
Harry N. Mills
Owens-Illinois
Dennis W. Readey
The Ohio State University
C. Philip Ross, Jr.
Kerr Glass Manufacturing
Charles H. Drummond 111
Conference Director
V
Each issue of Ceramic Engirlrering 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 hased on the proceedings of a conference. Both Society and non-Society
conferences provide these technical articles. Each issue is organized by an editor who
selects and edits material from the conference. There is no other review prior to
publication.
vi
Table of Contents
......................
Computer Control in the Glass Industry 111
Theodore J. Williams
Computer Modeling of Glass Thermal Characteristics in
.............................................
Spout Bowl 123
Stephen A. Austin and Michael J. Stankosky
.........................
Maximum Glass Melter Performance 142
Warren H. Turner
................
Lightweighting in the Glass Container Industry 156
Helmut Griffel
..................
Fluidized Bed Glass Batch Preheater, Part I1 171
R. De Saro, L. W. Donaldson, and C. W. Hibscher
.................
Other Opportunities for Waste Heat Recovery 181
Timothy W. Ottie
...............
Electric Furnace Application for Container Glass 188
R. Douglas Moore and R. Eugene Davis
The Effect of Amber Cullet Additions on Amber Glass
............................................
Transmission 200
Steven M. Weiser
A Hot-end Cullet Collection and Quench-clarifying System. ...... 208
Stephen B. Parker and T. 0. Dutaud
...........................
Batch-Cullet Segregation Studies 217
Albert J. Werner
.........................
Combustion Characteristics of Fuels 222
Richard J. Reed
........................................
Fuel Procurement 233
Samson J. McMahon
Engineering Development and Economic Analyses of An
....................
Advanced Gas-fired Glass Melting System 237
L. F. Westra, L. W. Donaldson, and J. G. Hnat
............
State-of-the-art of Hot Cullet Recycling in Europe.. 256
Bernd-Holger Zippe and Horst Moser
.................
A Regulatory Update for the Glass Industry.. 260
Robert Drake
vii
. . . . . . . . . . . . . . . . . .
Integrating the Laboratory into Glassmaking 268
Wayne Wallding
. . . .
Start-up and Surface Blistering of Fusion-Cast Refractories.. 276
Allen D. Davis, Jr., and Lurleen L. Cureton
Establishment of Specifications for Glass Melting
Refractory Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
L. H. Kotacska
viii
Ceramic Engineering and Science Proceedings
Charles H. Drummond Ill
copyright @The American Ceramic Society, 1987
Cerarn. Eng. Sci. Proc., 8 (3-41 pp. 111-122 (1987)
Computer Control in the Glass Industry
THEOIIOKJE. WILLIAMS
Purdue Laboratory for Applied Industrial Control
West Lafayettc, IN 47907
This paper calls attention to some of the wide-ranging increased capabilities for
dynamic control of glass industry and other processes which will be available as
soon as recent deuelopments in low cost but veryfast computers with large memories
are made available in the microprocessor-based, distributed control systems cur-
rently produced by all process-control vendor companies. It may require a new
generation of these control systems to supply these capabilities since their incor-
poration directly into the current oersions may be difficult.
Introduction
p
urdue University through its Laboratory for Applied Industrial Control has had
the opportunity of reviewing with the glass industry their basic problems in proc-
ess control in glass manufacture (in 1970 and 1979) and developed on each occa-
sion what they and we felt were the most important areas of process control research
in the industry at that time. Table I presents this list. Unfortunately, the list re-
I,2
mained the same over that period of time and we have seen no indication that there
has been much change in the interim period to the present time. Thus these prob-
lems are sure to continue to remain with us because of their inherent difficulty.
Perhaps some of the ideas presented here as near-future potentialities will finally
offer a path out of these difficulties.
Purduc University also had the opportunity of hosting the international sym-
posium on Automatic Control in Glass in September, 1973. This symposium, under
the sponsorship of the International Federation of Automatic Control, was chaired
by Mr. R. J. Moulys and remains the classic collection of papers in the field as
of that date. In addition this author had the further opportunity of addressing the
12th International Glass Conference in Albuquerque, New Mexico, in July 1980,
on a topic6 similar to the present one. Thus this paper can be considered as an
updated report on progress in the computer control field and in the glass industry’s
use of these techniques.
Process control in the glass industry has been reported today’ as being mixed;
i.e., some systems use conventional (that is, analog) instrumentation; a few have
IBM-1800 type systems which are now being phased out; still others have more
current models of minicomputer based DDC systems; while a few are using the
distributed microprocessor based systems to be discussed here. Most new installa-
tions today use the distributed system. In terms of computers, most systems in the
glass industry like most others are DEC-based. Many of these are programmed
in assembler or related languages and are cumbersome to use from a software point
of view. The trend. as everywhere, is toward user-friendly systems and high-level
languages.
Even if we are somewhat disappointed in our ability to have solved the basic
underlying process control difficulties which have plagued our industry in the past,
we can take some heart in the spectacular advances which have occurred in proc-
ess control hardware and applications techniques over the past few years and in
the prospects these offer to present a solution to the basic difficulties which face us.
The major developments can be categorized into two areas: the distributed.
microprocessor-based, computer control system; and the potential application of
on-line process simulation to industrial process control. Let us look at the distributed
control systems first.
Distributed, Microprocessor-based Systems
The current offerings of the leading process control equipment manufacturers
in the world all comprise a set of distributed, microprocessor-based, digital con-
trollers connected together and to other parts of the plant control system with a
high-speed, serial communications link and utilizing color CRT-based, operator’s
consoles for human interfacing with the process being controlled. While much work
remains in developing these systems, particularly in establishing standards for their
interconnectability , they have achieved a remarkable level of sophistication and
ease of usc in the relatively few short years since their initial development in the
middle 1970s. The microprocessor (so well known to us all through its use in small
personal computers) has made practical the direct digital control techniques
developed over the 15 yr previous to that time (1960-75). As the primary result,
every major process control vendor in the world now has as his major product
line (as just noted above)-a microprocessor-based, digital control system including
a data-highway , data transmission capability and a color CRT-based, man-machine
interface facility.
Besides their major benefits in improved controllability of thc process, these
new systems have also brought with them a much increased reliability and ease
of installation and use when compared to early models of equipment of these same
vendors.
The developments of the digital computer field are far from over. Thus we
can expect microprocessors to continue to provide ever faster computation, with
much larger allowable memory sizes and greatly increased reliabilities. These will
also be provided at ever lowering costs as mass production and competition force
such lower prices.
Figures 1 and 2 show dramatically the effect which these microprocessor-based
control system designs have had on industrial control systems. As presently
marketed, these systems can cover the first two levels of the overall hierarchical,
computer-based, control systems currently proposed for industrial as in
Figs. 3 and 4. A further discussion of the gains the microprocessor based systems
have made is evident from the material of Table I1 and a comparison of Fig. 5
with Fig. 4.
These problem areas (Figs. 1 and 5) have all been corrected by the
microcomputer-based, distributed, digital control systems discussed in this paper
(Figs. 2 and 4).
Features of the New Direct Digital Control Systems
The control systems vendors are all actively engaged in major developments
in this area. Almost universally the new systems proposed by them feature the
following attributes and capabilities:
lo
( 1) A modular, building block, system development capability which should
he extremely easy for the user to employ particularly with the configuration aids
available from the vendor.
(2) A color CRT-based operator interface system which is mainly
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