Art Appreciation ART T113
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Date Created: 09/12/15
ENERGY SAVINGS Are view of some 0 tions Cullebuvalwe mpulbylhelulluwmg uvgamzalmnswilh pvesenlaliun byAE in and Thevmal Tianslev Cum A HAMON Ron D Argent FSGT Argent Enterprises Inc 163 Graysvme Pa 15337 e 0163 Tel 724 7499 e 5800 Fax 724 e499 7 5715 email aemcame1 net Wm Larry D Maddox LDM Glass Consulting 23 Lake Drive Parkersburgh WV 26104 Tel 304 r 428 r 5007 Fax 304 r 428 r 5007 aMail l u mepemnk m Ter Thermal Transfer Corporation d on of HAMON 50 North Linden Street Duquesne PA 15110 U s A Tel 412 46074004 WWW hamon ethermalti ansfer Com Pvesenlalmn m The Society for Glass Science and Practices 36 quot A nnual Hand Glass Symposium May 4th to May 6 quot 2005 Wilson Lodge Oglebay Park Wheeling West Virginia USA A at Energy Savings A review of some options for presentation at the 36th Annual Hand Glass Symposium aka The Society for Glass Science and Practices Prior to being asked to make this presentation I had hoped to have an opportunity to reflect upon the rst 36 years of the USA Hand Glass Symposium as I did for the first 25 years which was in1994 that is before I faded away being human some of my reflection is based upon my personnel involvement but I will try to minimize that well here it is What does that have to do with Energy Savingsquot you may ask well the answer lies in the records ofthe Symposium starting with the first which took place on September 23 25 of 1970 Mr Joseph Saliga who was associated with the Hope Natural Gas Company was extremely active in the USA Hand made glass industry and upon his retirement he was kind enough to present to me his copies of the symposium records from 1970 to 1976 PROCEEDINGS 0 THE FIRST ANNI L GLASS SYMPOSIUM The first annual Glass Symposium recorded proceedings gllwa Aw mummm mu Immmm ixlmm Reference text associated with the Society for Glass Science and Practices published papers from 1970 to 1991 inclusive plus 10 additional relevant Hand made Glass study reports held in Argent s private library I made my first presentation appearance at the SGSP in 1977 together with Mr Malcolm Reynolds I had attended the meeting 2 years prior to 77 and l have attended all of the meetings since that time and l have retained copies of the published papers when ever they were available in 1977 Malcolm and l were with the company K T G Glassworks Technology Inc which is now part of TECO the subject of our presentation was Electric energy in the glass industry Concerns about pollution in lead glass melting and the increased competition from Europe led Lenox Crystal to accept electric melting it was interesting that the total energy used by Lenox to produce one ton of lead crystal glass was reduced by about 75 there was no direct comparisons made as the driving force for change was quality and pollution not energy From 1977 onwards I became more involved with the SGSP It was in1984 that Michael Grealey again with K T G presented a paper the subject was recuperator safety the paper was presented by Mike but was prepared by Ken Hrycik and Argent It is interesting that again the subject was not directed towards energy but safety of energy related equipment Now referring to those records let us reflect on the past energy related papers starting in 1970but first note that the symposiums from 1970 to 1980 were entitled not as the Society of Glass and Science Practices but as Annual symposium on the reduction of cost in the hand operated glass plants If that is not linked to energy I do not know what is m The very first paper by R W Marshall in his first paragraph states The fuel crisis in our country is really serious and all of us will be affected by drastic fuel shortages and price increases in the next few years The second paper by H D Bud Fresch outlines the energy savings obtained by the correct use of burners he sites an example of the first flat flame burner being installed in Kopp Glass on a 15 ton borosilicate day tank where melting times were reduced from 36 hours to 15 hours and energy reductions were in the order of 19 MCF 43 to 24 Frank Linforth of the Sismey amp Linforth Company presents a very comprehensive paper relating to the state of the art in Europe and in his summary he states that among the improvements made during the past 10 years that is from 1960 to1970 The installation of recuperators are made in order to reduce energy costs Some of you may be aware of the 2005 current hot topic of submerged combustion it is interesting to note that in the 1970 past papers a presentation was made on that very subject M Joseph Saliga states that very little will be reported upon relating to reduction of fuel but there is a continuation of the burner subject that was presented in 1970The importance of maintaining a correct stoichiometric ratio of 10 CFH of air to 1 CFH of gas is explained 1972 A good year for the subject of energy Thomas P Jarvis of Thermatics lnc writes about recirculation of hot air in lehrs which is common practice today in many glass factories or is it John McElwain has a paper The current energy crisis His last paragraph begins There are a few people more each day rising in our midst who are facing up to the problem and seeking a path which will lead us in years to come to a workable energy policy Mr J A Al Johnson of NuTech lnc writes about the Optimization of fuel in the Hand Plant Industry in 1973 he uses 80 cents per MCF for gas and he goes on to say The next step to consider is some type of fuel conservation You have heard about recuperators First paper Energy Management then an additional paper relating to Performance of recuperation by Larry Barrickman of Viking Glass with his gas at 70 cents per MCF he had 4000 plus MCF savings per year on a small day tank and at that time the pay back on the recuperator was 15 years The last paper by John P Gallagher outlines the benefits of ceramic recuperation and sows the seed for more thought The Carborundum Company Mr John Bevilacqua presents a paper relating to Creating Fuel Savings by applied insulation in Lehrs and Melter s Floyd R Showalter from The Fenton Art Glass Company gave a perfect paper on the benefits of automatic furnace pressure control and he provides some factual results where on a small day tank 2400 plus MCF can be saved per year using furnace pressure control at that time he was using 100 per MCF of gas which resulted in a 15 year pay back Mr Allen S Powell of the Consolidated Natural Gas Services Co Inc tells us that Oxygen is a way to reduce fuel consumption this is the first reference that we see in the symposium records about oxygen we will refer to this again later but it is interesting to note that the glass industry as a whole did not act upon this technology aggressively for another 8 to 10 years There is also a good paper in this1976 record by General Electric Mr Robert L Weise reports on a recuperator installation that was made in the 1970 s he states that 1400000 was saved in 1971 and 1972 but that with 1976 gas prices they would save 3000000 I wonder what the savings would be to day M Well we finally got to the first year that I made a presentation at the Symposium Lenox Crystal was the only hand made glass manufacturer in the USA that adopted the all electric furnace technology that we were promoting even though we could show a massive 75 savings in energy Princess House also used electric melting for lead glass however that was for automatic machine made products only and that factory closed after a short period of operation due mainly to European competition1977 was the first time that the Symposium organization changes were announced and appropriate recognition was given to Mr Joseph V Saliga as being the individual that carried almost the entire burden of the organization for the first 7 years Mr Domhnall O Broin as current Chairman suggested that his opening remarks should have been Welcome to this Dying Industry Domhnall talked about the gas prices quadrupling since 1970 and he talked about furnaces that were burning twice as much fuel as is necessary resulting in 200000 250000 being wasted per year on small continuous furnaces To the best of my knowledge all of the companies that used such furnaces have either stopped the manufacturing of glass or they have shut down the gas hogs Domhnall went on to explain what was going on in Europe with many factories closing because of energy costs and a lack of capital investment in energy saving devices The first paper this year was given by Floyd R Showalter of the Fenton Art Glass Company it was such a good paper it related to energy savings and what Fenton was doing about it I understood most of it at the end of the presentation I asked Floyd to sign the paper I think it was the first and may be the last time that any person asked a presenter to sign the presentation at these meetings Well l was younger then Automatic furnace temperature and pressure control combined with recuperator installations were the major topics of the paper Floyd R Showalter Signed paper CJ Kitt Sismey made an excellent presentation relating to furnace designs and the relationship of design amp function V s energy Please note the slide he presented This part of the slide is unrelated to the paper it is from Orrefors Crystal SNeden The Glass Blower Part of Argents glass collection 135mm R 739 3 H E ma W McF u 57 Highest possible energy use is single pot furnaces and day tanks The only reason to show this slide is to remind the hand made glass manufacturer that the type and size of furnaces that are currently in use here remain the highest energy consumers out of all of the furnaces that are used in glass manufacturing Dale Chihuly also made a presentation this year I am sorry to say I do not recall this but having seen Dale sign one of his off hand sketches recently which went from 500 value without signature to 500000 value just because he signed it may be I should have had Dale sign his presentation instead of Floyd m This years the papers included several energy related papers Mike Sturm Louie Glass replaced old furnaces with a modern recuperative unit claiming 45 energy savings Tim Brannon Harvey Industries Inc talked about fuel reductions technologies that were applied to a week tank Tim shows actual savings of 29 in fuel Floyd R Showalter gave another good presentation regarding the 12 pot pot furnace that Fenton Art Glass had installed Floyd said that the new ceramic recuperative furnace was using about 92 MCF of gas per day by comparison to the old Fenton non recuperative pot furnace of 198 MCF of gas per day Jim Ulmer Bowman Lehrs talked about fuel savings on remodeled Lehrs with 30 to 35 savings potential available This all sounded like a good opportunity to me so I moved to the USA with great expectations in May of 1978 1979 This was the first time that the Annual Symposium was held at the Wilson Lodge Oglebay Park the registration fee was 7000 for early registration and 7500 for late There were 55 Companies represented 33 Glass Manufacturers and 22 Suppliers 86 registered attendees 61 from the glass manufacturing side and 25 from the supplier s side There was no energy saving related papers this year E It is hard to imagine that it was just 25 years ago Joseph Doble from Holcroft presented a paper concerned with adding a recuperator to a Davis Lynch Glass fluoride opal day tank We shall refer to this again later in the year of 2005 Gordon Hanson and Tim Ottie from the Thermal Transfer Corp describe how to avoid problems with recuperators During these past 10 years recuperation has been an important topic and we feel it is one that should be considered again or reconsidered for the future therefore now would be a good time to turn the presentation over to our co presenter Mr Terry King of the Thermal Transfer Corp After Terry has explained the advantages of using recuperation and some of the technical aspects associated with it we intend to outline some new methods or applications to use recuperation in the glass industry Phil Ross Improving efficiency by furnace design and operating practices Anselm Brach Electric boosting and our good old friend Floyd Showalter with a case study of fuel savings at Fenton Art Glass on a small recuperative continuous furnace m Tom Bobbitt Fenton Art Glass talks about oxygen use to reduce noise on glory holes but he also states that there is energy savings Lee Williams Swindell Dressler Outlines how to save fuel by as much as 50 this is by using the correct control systems and refractory structures 1983 Tim Ottie Thermal Transfer presents a foundation paper concerning energy saving by the use of recuperation now we have just received from Terry an update on Tim s paper There is also a second paper on recuperation by Phillip Van Huffel Industrial Co Energy Systems This was the first year that I became a member of the S for GSP committee The SGSP was now 15 years young and Domhnall O Broin was asked to review its history this is indeed worth reading as it explains much about the fun and some of the goings on well I guess that s for you to look into Oakland Bailey Mason Glassware tells of 42 energy saving by the addition of a recuperator on the melter plus an additional 27 form a recuperator on the refiner Regenerators are typically more thermally efficient than metallic recuperative furnaces this is mainly due to the fact that they provide a higher air pre heat for combustion so you can imagine the surprise when Jim Kroner Kopp Glass gave a presentation on the conversion of his regenerative multi pot furnace resulting in a 40 energy saving this was one of my early contracts with Kopp Mike Grealey KTG presented a paper that Ken Hrycik and I wrote on recuperator safety which we referred to at the beginning of the presentation Harry Fontana L E Smith gave a paper on oxygen enrichment with recuperators this paper has been used over and over again to explain the energy savings that can be obtained with just a small amount of oxygen being added to the combustion air supply Anselm Brach Consultant was back this time to talk about the potential use of coal in the glass industry I am not sure about John Browns presentation of to day but from the title it appears to be on the same subject I am not aware of any hand made glass producer here in the USA that has seriously considered coal amp From the records we see that my tenure as a committee member was extended to 1988 This year energy recuperation and such subjects were not on the program but Anselm Brach Consultant came back again with his coal burning glass furnace reporting a success in Luenen Location unknown this was a continuous automatic production furnace 1986 John West Control Techtronics reports on a day tank control system installed at Fenton Art Glass that resulted in fuel savings of 12 1987 Oxygen enrichment is re visited by Bud Fresch American Combustion Inc and the Lehr subject is also revisited by Jim Ulmer Bowman From a new energy saving point of view this year saw for the first time a presentation on Regenerative Burner Technology by Geoff Turton KTG he reports on an installation in England where energy was reduced from 155 mcf per day down to 125 mcf this saving may not appear to be that significant but the furnace prior to being fitted with the regenerative burners had a recuperative system installed E North American Presenter unknown outlined their Twin bed regenerative system this was some what similar to the paper given the previous year by KTG Geoff Turton but North American stated that there was an amazing 58 fuel savings with their system they were reporting on a container glass manufacturers installation at Arkansas Glass Argent gave a paper this year on a new technology quotColor Cell for hand glass applications which was an expansion upon the technology developed for and operated by St George Crystal the hand glass application concept required some trials at St George these trials involved Marble King Roger Howdyshell and Youghiogheny Opalescent Glass John Triggs amp Argent KTG made a presentation on a Twin Pot Pot Furnace with Regenerative Waste Heat Recovery it was reported as being potentially the most efficient method of melting glass in closed pots The following slide shows the KTG design Note St Louis Glass France and the Stein Hurty installation H39 m39 m arm may Am nc39cnv mm suu mm mu cuman Pasta 9 cwsusum uuwaw mm mm WM 7 mausmN VASSABE Ranmmn a mm smaiimbna 27 mm wag N am HGURE m The industry in general in Europe and here in the USA was looking for new ideas in 1989 we heard about some this year 1990 Ron Moore Henry F Teichmann presents a new furnace The Flex Melter that is new to the USA energy consumption figures presented have been verified by several installations already in Europe but to the best of my knowledge there are no Flex Melter s in the USA hand made glass industry but there is no doubt that it is an extremely efficient way to melt glass Argent KTG presents a new furnace A non continuous all electric furnace for hand gathering The efficiency of the furnace and its general operation is that of a continuous furnace but it has the unprecedented flexibility to be able to work one two or three shifts in the gathering positions It works as a continuous day tank that is to say there is a variable glass level in the gathering position Refer to Simon Pearce Glass as being the original customer who now has multiple units The following slide is shown to out line the principals t m srcmll kg The cross section indicates the furnace or melter In this example it has tin oxide electrodes for use with lead glass There is a submerged entry into the gathering chamber the actual level in the furnace and the gathering bay goes down when the system is being worked The plan view indicates one of the possible gathering configurations it is shown only to enable the cross section to be understood Q7953 irmu r4 7 a Argent remains on the SGSP committee despite leaving KTG and Joining Frazier Simplex This year marks the last year that copies of the SGSP proceedings were distributed to participants according to my records There were no specific energy related papers presented this year 1992 Titles from VWU past proceedings records No apparent specific energy related papers Titles from VWU past proceedings records Argent Frazier Simplex presents a paper specifically about batch amp cullet preparation for the hand made glass industry No apparent specific energy related papers 1994 Titles from VWU past proceedings records Argent presents a paper The first 25 years of the SGSP Oxygen firing by Subhash S Kithany SK Group Inc paper not in the proceedings New installation at L E Smith H Fontana paper not in the proceedings Combi Melt a new glass melting system based upon the regenerative pot furnace concept shown earlier by Argent KTG This Combi Melt paper was prepared jointly by Christopher J Hoyle and Argent Frazier Simplex The paper outlines the use of a cassette regenerative system used in conjunction with 3 1 ton Closed Pots and 2 5 ton Day Tanks The projected net result is a staggering 70 energy savings by comparison to the existing individual recuperative conventional pot furnaces and recuperative day tank The following slide is used to demonstrate the concept Plan view of a Combi Melt with 3 Closed pots and 2 Day Tanks the clay tanks are filled from the rear of the furnace and the clay tanks have gathering boots to avoid combustion sting out going towards the gatherer MJTuffey and CJSismey Sismey and Linforth present a foundation paper entitled Pot Furnaces for the nineteen nineties this paper contains a great deal of information about energy use on single pot furnaces as they were used in Europe at that time but what we want to draw your attention to is the 2 sketches that demonstrate pre 1980 design principals with those of the current practice current being as it was in 1994 There are examples of these furnaces in operation in the USA to day Til Fm l Tmm lvPDT FIRNAEE FEE man Note the burner position above the pot relative to the exhaust exit position below the pot within the furnace Note the burner position relative to the pot the exhaust position not shown is the same as place as the older design shown previously This small design change has enabled many glass manufacturers to melt every day in pots where as previously it was every other day This has resulted in enormous energy savings Modern pot furnaces are based upon similar principals as those shown here 1995 Titles from VWU past proceedings records No apparent specific energy related papers 1996 Titles from VWU past proceedings records No apparent specific energy related papers 1997 Titles from VWU past proceedings records Insulating refractories Fred Fidler Thermal Ceramics paper not in the proceedings Cassette Regeneration on a pot furnace Gordon Dickinson Engineered Combustion Systems paper not in the proceedings Oxy Fuel Firing in a day tank Dave Grega Spectrum Glass paper not in the proceedings Titles from VWU past proceedings records Combustion Systems Don Showman SEETEC lnc Refer VWU for proceedings Furnace lnsulation for the glass industry Crystal Morcom RR Home Inc Refer VWU for proceedings 1999 Titles from VWU past proceedings records Refractories Larry Stover Minteq Refer VWU for proceedings 2000 Titles from VWU past proceedings records Commercial use of Synsil Larry Stover Minteq Refer VWU for proceedings 2001 Titles from VWU past proceedings records Thermal Transfer Heat recovery Terry King Thermal Transfer Refer VWU for proceedings Maintaining Furnace Efficiency with a Gas Analysis Don Coe AGA Gas Inc Refer VWU for proceedings 2002 Titles from VWU past proceedings records No apparent specific energy related papers 2003 Titles from VWU past proceedings records Energy Planner Doug Hunt Allegheny Process Systems paper not in the proceedings 2004 Titles from VWU past proceedings records Argent Argent Enterprises Inc New Practical Applications for Glass Melting to Increase Flexibility and Reduce Operating Costs this paper describes a whole new range and type of furnace which is available to the USA at the time of presentation there was about 15 such furnaces in the USA to day there are more than 30 refer to the following slide Refer VWU for proceedings Note the recuperator and its associated by pass ue or exhaust which is used durin the associated attack on the recuperator may happen 2004 cont d Don Coe Linde Gas Inc presented a paper on Oxygen Applications in the Hand Glass Industry Refer VWU for proceedings Sam Perry Amerada Hess Corp the presentation was Energy Crisis Fact or Fiction Refer VWU for proceedings Do you recall in the first year we recorded that in m The very first paper by R W Marshall in his first paragraph states The fuel crisis in our county is really serious and all of us will be affected by drastic fuel shortages and price increases in the next few years 36 years of Energy Saving papers and presentations we need to summarize and move on however it is important to recall these past presentations if for no other reason by now most of the ideas have been tried and some did work Refer to summary slide All of these designs work but now is the time to accept reality what the industry needs to do is not necessarily what the industry is prepared to do or what the industry can afford to do It is easy to say that the industry MUST change they MUST accept that investment is essential but perhaps we can make some small steps at a reasonable cost Having said all of the aforementioned and taking into account the real world e see opportunities for the American hand made Glass Industry and looking into our Crystal ball This is a piece of Argents Glass collection it weighs about 20 pounds and it resides in Argents current office Lead Glass globe held in a full sized hand Made by Cristalux in Mexico in an all electric furnace supplied by KTG Glass works Tech Inc We see improvements in the areas of recuperation and the use of oxygen both of these technologies are well proven and as you now know wel recorded What are we doing well let us show you some ofthese small steps just those involving recuperation A number of glass makers say we have tried recuperators and they failedquot but with to days gas cost it is time to re visit this subject and for those who have been putting it off may be this approach will appeal The following drawings were prepared for Argent Enterprises Inc by our Industry partner L D Maddox Consultants to the glass industry By Pass reouperator attached to a small conventional clay tank of about 1500 lbs Pass reouperator installation with conventional exhaust stack By g gt39 lllllllll o 39 nunquot I A V llllllllll mm W 2 39l I r AAquot 5 r liari m In Ff 4 aim 4 W I mum in lt i as n3 mwuw a nibmu Ham 5 in vgiwt LLAALLM Pass reouperator installation with un conventional exhaust stack By iiiiiiiiii 39a39 39gl v v iiiiiiii W I39Illlllgg39g39 39g quot E J J J vAi gu By Pass recuperative conventional day tank This paper has only just begun 39ust 39oking but to do this most important subjectjustice we need a lot more time to expand upon a number of the subjects reported on but I fear that l have used the time allocated Think of it my first meeting was 1975 that s 30 years ago I participated on the SGSP committee for 10 years as secretary treasurer program chairman for 5 years and as chairman my first participation was 1977 I hope this was not the last Gaffer 2003 Bronze casting Sports The Daily ME Athenaeum J p 1 a mu wadmacmmyhshdwnivut mummy mm m ml mammde yuhllzn f pm 5 wmwm Unws y mnmmmm al ll sBrlel mm mm m use s nytdien emy gwmmxm mda ehsdm wbxmm mkm mm am be we u m 5 mm wk 2 W m M m MMmm uw hmzmmhn eh m 35V mg m cm aim mmads m m medaim amms mpe mammmmmme amidehepamsAdemduy mm mm amalgamme m inalwebsnscysdmnd mmnmnnsbrsndans in mith am mg mg me my m uniEly D Plus 55 quotmi ivw s s ind m ms 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