Overview of Energy Efficiency

for Glass Furnace

April 3, 2006

Organised by:
Energy Systems Engineering, IIT Bombay
&
Petroleum Conservation Research Association (PCRA)
Lecture delivered at One day workshop Energy Efficiency & Benchmarking of Glass Furnace, 3rd April, 2006 at IIT Bombay
 Purpose of Workshop
To obtain feedback from industry on
glass furnace energy modelling tool
To disseminate results /approach
To encourage industry to use the
energy performance tool
To plan future course of action

3 April, 2006 2
 Need for Energy Efficiency
Energy significant percentage of
manufacturing cost
Energy cost increasing
Energy shortages
Emission reduction GHG (CO2), NOx,
SOx,Particulates (Environmental norms)
Global competitiveness

3 April, 2006 3
 Crude Oil Price

3 April, 2006 Source: www.oilnergy.com 4

 Natural Gas Price

3 April, 2006 Source: www.oilnergy.com 5

Carbon Dioxide Concentrations

3 April, 2006 6
Glass Manufacturing Process

Mixed Raw Melting Glass

Material Furnace Forming Annealing

Inspection Storage or
Finishing
and Testing Packing Shipping
Operations
(Optional)

3 April, 2006 7
 Energy Consumption in Glass Plant

Melting
75%

Other
10%
Forehearth
Anneling Printing and Lehr
7%
4% 4%

3 April, 2006 8
 Indian Glass Industry
Particular Value
Container Glass Industry 89 %

Flat Glass 8%

Fiber Glass 2%

Other 1%

3 April, 2006 Source: TERI Manual on Glass Industry 9

 Specific Energy Consumption
Specific Energy Consumption (SEC) Energy
Consumption per unit of product output
Units kJ/ kg of glass, kcal/kg of glass
SEC Varies with capacity, process,
operating parameters, ambient temperature
Zero Based Target Setting (thermodynamics)
Retrofit/ Improvement targets

3 April, 2006 10
 Benchmarking
Benchmarking comparing the performance
with the best possible, setting targets
Approaches a)Data Analysis regression
pooled cross-sectional and time series data,
best practice, average data
b) Minimum thermodynamic energy required
Internal within plant, time series
External- with other plants

3 April, 2006 11
Minimum Thermodynamic Energy
Particular Value Remark
(kJ/kg)

Heat of reaction of glass 487 Endothermic heat of reaction

Glass enthalpy at outlet 1886 From temperature of 20 oC to

of tank 1500 oC

Batch gas enthalpy 289 From temperature of 20 oC to

1500 oC

Total thermodynamic 2671

minimum energy

3 April, 2006 12
 SEC for Furnaces
Energy balance for 123 Operating Glass Furnaces*
Specific Energy Consumption (kJ/kg)

Furnace Number
*Rund G. C., Energy Efficiency Benchmarking of Glass Furnace,
62ed Conference on Glass Problems, University of Illinois , Urbana Champaign , 2001
3 April, 2006 13
 SEC for Indian Furnaces
12000.0
Sp. Energy Consumption (kJ/kg)

10000.0

8000.0

6000.0

4000.0

2000.0

0.0
0 5 10 15 20

Furnace Number
3 April, 2006 14
 IITB-PCRA Project
Started April 2005 September 2006
Objective- Develop simulation tool for energy
analysis of glass furnace
Usages of tool
Bench marking energy consumption of existing
glass furnaces
Study the effect of retrofit on existing furnace
Setting operating parameters
Provide useful input for new furnace design

3 April, 2006 15
 Need for Model
Furnace processes
- Glass Melting
- Combustion
-Heat Transfer (Radiation & Convection)
Empirical/ Experience based
Interlinkages between operating & design
parameter- complicated
Experimentation difficult, Trial & error costly

3 April, 2006 16
 Glass Furnace
Exhaust

Combustion Regenerator
blower

Melting area

Flue gas
Fuel supply
Chimney Batch feeding
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 Furnace Experimental Work
Collection of operating data
Furnace Air Balance
Air supplied from blower
Oxygen percentage in flue gas
Regenerator Outlet Temperature
Furnace Wall Temperature
Furnace observations

3 April, 2006 18
 Instrumentation Used for
Experimentation
Measured Parameter Instrumentation used

Oxygen at furnace outlet Oxygen analyzer

Oxygen at furnace outlet Oxygen analyzer

Moisture in batch Lab testing in moisture meter

Glass surface temperature at hotspot Radiation pyrometer

Flue gas outlet temperature from regenerator K- type Thermocouple

Furnace wall temperature Infrared camera

Velocity at suction of combustion blower Hot wire anemometer

3 April, 2006 19
 Measurement of Furnace
Wall temperature profile of Crown using infrared thermal imager

0-50 50-100 100-150

150-200 200-250 250-300
300-350 350-400 400-450

3 April, 2006 20
 Measurement of Regenerator

Initial stabilizing period 52 67

650 54 61
600 55
Temperature (deg C)

550 62
56
500
450 62 67 111
106
400
350 150 128 Port neck
300 85
72
250
200 87 109
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Time (min) 97
100
100
Flue gas outlet temperature 103
135

112 99 108

3 April, 2006 Regenerator wall temperature 21

 Furnace Model Input
Parameters
Design parameter Operating parameters
Design capacity of
furnace
Melting area
Length to width ratio
Height of combustion
volume
Refractory and
insulation details
Furnace draw
Type of fuel
Batch to cullet ratio
Moisture in batch
Furnace pressure
Oxygen at furnace outlet
Atomization pressure
Reversal time
Flux line and burner tip
cooling air pressure

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 Output of Model
Output parameters
Glass outlet temperature
Flue gas outlet temperature
Flue gas outlet temperature regenerator
Super structure side wall temperature
Furnace bottom temperature

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 Energy Performance Model
(EPM)
Gap in flux line Gap near burner Fuel calorific
Fuel calculation value
Oxygen % (dry
Furnace operating pressure
basis v/v)
Cooling air pressure Furnace air leakage Air species
Number of burner calculations
Combustion
Air nozzle diameter Combustion zone Mass of
Fuel species stoichiometric flue gas
Fuel consumption Mass
stoichiometric Gas from calculation of air
calculation glass reaction
Fuel composition Heat loss from
flue gas
Glass composition Regenerator
Glass reaction Regenerator calculation Heat loss from
Moisture in batch efficiency
calculation regenerator wall Total
Batch / cullet Heat of reaction for heat
Raw Heat of glass
Furnace draw added
material reaction and Heat loss batch gas
Furnace design in
composition heat carried
characteristics Heat carried with furnace
by glass
Heat loss from glass
Furnace design capacity
Furnace refiner wall Heat loss from
Melting area
geometry batch moisture
Type of furnace Furnace
calculation
geometry
Color of glass Furnace Heat loss from
Furnace operating wall losses melting area wall
characteristics
3 April, 2006 24
 Sankey Diagram for Furnace
Batch gas
Heat lost Cold air losses
Heat carried in in moisture ingress Heat lost steel
glass superstructure
5.2
4.5 2.4 Heat of glass
1.6 reaction
25.9
Energy 7.2
introduced100 (5658) 175
in furnace
Heat loss from
3.3 furnace
opening

7.8
33.8
Heat recovery in Furnace wall
air heating losses

Heat loss Regenerator Wall

from flue Losses % (kJ/kg)
gas No to the scale
38.5 2.4 25
 Regenerator Model Parameters
Design parameters Operating parameters
Regenerator checkers
arrangement
Regenerator checkers
geometry
Checkers overall
dimensions
Outer wall refractory
details
3 April, 2006
Mass flow rate of flue gas
Mass flow rate of all the
species in flue gas
Inlet temperature of flue
gas to regenerator
Mass flow rate of
combustion air
Amount of water vapor
in air
Blockage percentage of
checkers
Oxygen measurement of
flue gas
26
 Regenerator Model Flow Diagram
Number of flue Oxygen % at regenerator
gas blockage outlet
Regenerator
efficiency
Type of regenerator Free passage Air leakage Air leakage in
packing area calculation flue gas
Regenerator in
geometry Heat Flue gas
Brick size regenerator Flue gas inlet Overall
calculation transfer area outlet
temperature heat
Regenerator balance temperature
Mean beam Air inlet
dimensions Radiative for Air outlet
length temperature
heat model temperature
coefficient
Hydraulic transfer
diameter calculations
Heat duty of
regenerator

Regenerator Velocity of Convective

Mass flow rate of flue gas operating flue gas heat transfer Radiative Overall heat
parameters Velocity of air coefficient heat transfer transfer
Mass flow rate of calculations calculation coefficient coefficient for
combustion air thermal
Properties of Convective storage of
Inlet flue gas temperature flue gas heat transfer bricks
Flue gas composition coefficient
Properties of
air

3 April, 2006 27
 Tutorial Sheet for Model
Operation
Synthetic furnace sample cases for 60, 100,
150 and 200 TPD furnace
Design and operating data input to model
Study effect of variation of following
parameters
Cullet percentage
Regenerator efficiency
Moisture percentage
Air leakage

3 April, 2006 28
 Energy Conservation
Opportunities (ECOs)
Cullet Preheating
Oxygen enrichment
Cogeneration
Regenerator and Recuperator
Oxygen trim for Excess Air Control
Optimum Regenerator Design
Batch Pelletising
3 April, 2006 29
 US Glass Industry Strategy for
Feature

Source: www.eere.energy.gov, GMIC report on road map for glass industry 2002 30
 Technology Challenges for
Energy Efficiency

Source: www.eere.energy.gov, GMIC report on road map for glass industry 2002 31
 Technology Challenges for
Energy Efficiency

Source: www.eere.energy.gov, GMIC report on road map for glass industry 2002 32
 Strategy
Competition and Collaboration
Country wide target energy reduction
-X million tonnes of fuel oil, N.Gas
Emissions Reduction- Carbon credits
Government support Funding of new
technologies
Consortium approach for R&D ensure
global competitiveness

3 April, 2006 33
 References
UNIDO report on Glass Industry, 1993
GMIC report on Road map for glass
industry, April 2002
www.oilnergy.com
TERI report on glass industry, 1999

Thank You
3 April, 2006 34