ELECTRIC MELTING AND THE VALUE OF MODELLING › ... › 2017 › 08 ›...

ELECTRIC MELTING AND THE ELECTRIC MELTING AND THE ELECTRIC MELTING AND THE ELECTRIC MELTING AND THE VALUE OF MODELLINGVALUE OF MODELLINGVALUE OF MODELLINGVALUE OF MODELLING

STUART STUART STUART STUART HAKES FSGT, HAKES FSGT, HAKES FSGT, HAKES FSGT,

CEO F.I.C. (UK) LIMITED. CEO F.I.C. (UK) LIMITED. CEO F.I.C. (UK) LIMITED. CEO F.I.C. (UK) LIMITED.

14TH INTERNATIONAL SEMINAR ON FURNACE DESIGN

VELKÉ KARLOVICE, 21ST- 22ND JUNE 2017

ELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLING

WHY DISCUSS ELECTRIC MELTING?

21/6/17 2


WHY DISCUSS ELECTRIC MELTING?

BECAUSE WE HAVE TO!!

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ELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGWHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!WHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!WHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!WHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!

EU 2030 EU 2030 EU 2030 EU 2030 –––– 40% 40% 40% 40% REDUCTION REDUCTION REDUCTION REDUCTION cfcfcfcf1990 1990 1990 1990

Most of G7+1 group of nations Most of G7+1 group of nations Most of G7+1 group of nations Most of G7+1 group of nations agreeagreeagreeagree 21/6/17 4

ELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGWHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!WHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!WHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!WHY DISCUSS ELECTRIC MELTING? BECAUSE WE HAVE TO!!

EU 2050 EU 2050 EU 2050 EU 2050 –––– 80% 80% 80% 80% REDUCTION REDUCTION REDUCTION REDUCTION cfcfcfcf1990 1990 1990 1990

Most of G7+1 group of nations Most of G7+1 group of nations Most of G7+1 group of nations Most of G7+1 group of nations agreeagreeagreeagree

British Glass RoadmapBritish Glass RoadmapBritish Glass RoadmapBritish Glass Roadmap21/6/17 5


ARE ELECTRIC FURNACES SUITABLE FOR MAINSTREAM

USE?

21/6/17 6


ARE ELECTRIC FURNACES SUITABLE FOR MAINSTREAM USE?

BECAUSE THEY ARE

• EXPENSIVE• HAVE SHORT LIFE• LACK FLEXIBILITY

21/6/17 7


EXPENSIVE ??

CAPITAL COST IS LOW but operating cost can be high due to electricity pricing, BUT this is changing!

THERMAL EFFICIENCY is considerably better. DOUBLE

SHORT LIFE – NOT NECESSARILY, could be an advantage

FLEXIBILITY – FAKE NEWS!!21/6/17 8


CURRENT STATE OF THE ART

ENERGY EFFICIENCY COMPARISONS

21/6/17 9

Electric

21/6/17 10

15

20

25

30

35

40

45

50

55

30

40

50

60

70

80

90

10 50 90 130 170 250

Fuel

Fuel

Fuel

Fuel

-- --Fi

red F

urn

ace

Ener

gy

Effi

cien

cy

Fire

d F

urn

ace

Ener

gy

Effi

cien

cy

Fire

d F

urn

ace

Ener

gy

Effi

cien

cy

Fire

d F

urn

ace

Ener

gy

Effi

cien

cy

%% %%

Elec

tric

Furn

ace

Ener

gy

Effi

cien

cy %

Elec

tric

Furn

ace

Ener

gy

Effi

cien

cy %

Elec

tric

Furn

ace

Ener

gy

Effi

cien

cy %

Elec

tric

Furn

ace

Ener

gy

Effi

cien

cy %

Pull Tonnes/Day

Furnace Size and Energy Efficiency

Electric

Fuel-Fired

21/6/17 11


WHERE ARE WE NOW? SIZES

SMALL 1 to 30 tpd

MEDIUM 30 to 100 tpd

LARGE 100 to 250 tpd

21/6/17 12

TYPES OF ALLTYPES OF ALLTYPES OF ALLTYPES OF ALL----ELECTRIC ELECTRIC ELECTRIC ELECTRIC FURNACESFURNACESFURNACESFURNACES

COLD TOP, HOT TOP, SEMICOLD TOP, HOT TOP, SEMICOLD TOP, HOT TOP, SEMICOLD TOP, HOT TOP, SEMI----HOT TOPHOT TOPHOT TOPHOT TOP

GEOMETRYGEOMETRYGEOMETRYGEOMETRY

SQUARESQUARESQUARESQUARE

RECTANGULARRECTANGULARRECTANGULARRECTANGULAR

HEXAGONALHEXAGONALHEXAGONALHEXAGONAL

DUODECAGONALDUODECAGONALDUODECAGONALDUODECAGONAL

ROUNDROUNDROUNDROUND

SHELFSHELFSHELFSHELF

TRANSFORMERSTRANSFORMERSTRANSFORMERSTRANSFORMERS

THREE THREE THREE THREE PHASE PHASE PHASE PHASE

DELTA:-OPEN/CLOSED/PARTIAL

STAR

TWO PHASETWO PHASETWO PHASETWO PHASE

SCOTT SQUARES (BALANCED)

SINGLE PHASESINGLE PHASESINGLE PHASESINGLE PHASE

ELECTRODE ELECTRODE ELECTRODE ELECTRODE POSITIONSPOSITIONSPOSITIONSPOSITIONS

TOP TOP TOP TOP ELECTRODESELECTRODESELECTRODESELECTRODES

SIDEWALL ELECTRODESSIDEWALL ELECTRODESSIDEWALL ELECTRODESSIDEWALL ELECTRODES

SHELF ELECTRODESSHELF ELECTRODESSHELF ELECTRODESSHELF ELECTRODES

BOTTOM ELECTRODESBOTTOM ELECTRODESBOTTOM ELECTRODESBOTTOM ELECTRODES

PLATE ELECTRODESPLATE ELECTRODESPLATE ELECTRODESPLATE ELECTRODES

21/6/17 13


OPTIONS: 1) TYPES

SQUARE

RECTANGULAR

HEXAGONAL & VARIANTS

SHELF

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SQUARE FURNACESQUARE FURNACESQUARE FURNACESQUARE FURNACE

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RECTANGULAR FURNACERECTANGULAR FURNACERECTANGULAR FURNACERECTANGULAR FURNACE

21/6/17 16

21/6/17 17

21/6/17 18

21/6/17 19


OPTIONS: 2) ELECTRODE PLACEMENTTOP

SIDE

BOTTOM

COMBINATION

PLATES

21/6/17 20

21/6/17 21

21/6/17 22

21/6/17 23

21/6/17 24

ELECTRIC FURNACES AND ELECTRIC FURNACES AND ELECTRIC FURNACES AND ELECTRIC FURNACES AND MODELLINGMODELLINGMODELLINGMODELLINGWHAT IS THE FUTURE?WHAT IS THE FUTURE?WHAT IS THE FUTURE?WHAT IS THE FUTURE?

SO WHAT DO WE DO AND WHERE DO WE GO

WHAT ARE OUR OPTIONS?

21/6/17 25

WHAT WHAT WHAT WHAT ARE OUR OPTIONS?ARE OUR OPTIONS?ARE OUR OPTIONS?ARE OUR OPTIONS?

STEP CHANGE REQUIREDSTEP CHANGE REQUIREDSTEP CHANGE REQUIREDSTEP CHANGE REQUIRED

U.S.AU.S.AU.S.AU.S.A ---- G.M.I.CG.M.I.CG.M.I.CG.M.I.C NEXTGENNEXTGENNEXTGENNEXTGEN MELTER PROJECTMELTER PROJECTMELTER PROJECTMELTER PROJECT

SUBMERGED BURNERS ?SUBMERGED BURNERS ?SUBMERGED BURNERS ?SUBMERGED BURNERS ?

INFLIGHT PLASMA FURNACESINFLIGHT PLASMA FURNACESINFLIGHT PLASMA FURNACESINFLIGHT PLASMA FURNACES

WE HAVE TO CONSIDER THE ENVIRONMENT! CO2 NOX WE HAVE TO CONSIDER THE ENVIRONMENT! CO2 NOX WE HAVE TO CONSIDER THE ENVIRONMENT! CO2 NOX WE HAVE TO CONSIDER THE ENVIRONMENT! CO2 NOX SOXSOXSOXSOX

FOSSIL FUEL LONG TERM AVAILABILITYFOSSIL FUEL LONG TERM AVAILABILITYFOSSIL FUEL LONG TERM AVAILABILITYFOSSIL FUEL LONG TERM AVAILABILITY

21/6/17 26


STATUS QUO STATUS QUO STATUS QUO STATUS QUO • CONTINUE TO FINE TUNE EXISTING METHODOLOGYCONTINUE TO FINE TUNE EXISTING METHODOLOGYCONTINUE TO FINE TUNE EXISTING METHODOLOGYCONTINUE TO FINE TUNE EXISTING METHODOLOGY

• TAKE A CAUTIOUS STEPWISE APPROACHTAKE A CAUTIOUS STEPWISE APPROACHTAKE A CAUTIOUS STEPWISE APPROACHTAKE A CAUTIOUS STEPWISE APPROACH

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ELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGELECTRIC FURNACES AND MODELLINGWHAT IS THE FUTURE?WHAT IS THE FUTURE?WHAT IS THE FUTURE?WHAT IS THE FUTURE?

STATUS QUO • THE INDUSTRY IS NOTORIOUSLY CONSERVATIVE

• SOME OF YOUR COMPETITORS ARE THINKING RADICALLY

• THEY ARE SEEKING STEP CHANGES

• WE NEED TO WAKE UP BEFORE ITS TOO LATE!

21/6/17 28


MAINTAIN STATUS QUO MAINTAIN STATUS QUO MAINTAIN STATUS QUO MAINTAIN STATUS QUO

AND GET LEFT BEHIND?? AND GET LEFT BEHIND?? AND GET LEFT BEHIND?? AND GET LEFT BEHIND??

!!!!!!!!21/6/17 29


WHAT ARE OUR WHAT ARE OUR WHAT ARE OUR WHAT ARE OUR OPTIONS?OPTIONS?OPTIONS?OPTIONS?

21/6/17 30


WE NEED A SAFE WE NEED A SAFE WE NEED A SAFE WE NEED A SAFE STEP CHANGESTEP CHANGESTEP CHANGESTEP CHANGE

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O.O.B.T.O.O.B.T.O.O.B.T.O.O.B.T.

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O.O.B.T. = OUT OF THE BOX THINKING • WE NEED TO RE-EXAMINE OLD WAYS WITH NEW

TECHNOLOGY

• WE NEED TO THINK CREATIVELY – START FROM SCRATCH

• WE NEED A STEP CHANGE (A PARADIGM SHIFT)

21/6/17 33


HOW?HOW?HOW?HOW?

21/6/17 34

ELECTRIC FURNACES ELECTRIC FURNACES ELECTRIC FURNACES ELECTRIC FURNACES AND AND AND AND MODELLINGMODELLINGMODELLINGMODELLINGDREAMING OF MODELLING AND MODELLING DREAMING OF MODELLING AND MODELLING DREAMING OF MODELLING AND MODELLING DREAMING OF MODELLING AND MODELLING

DREAMSDREAMSDREAMSDREAMS

HOW?HOW?HOW?HOW?

MODELLING OF MODELLING OF MODELLING OF MODELLING OF

COURSECOURSECOURSECOURSE21/6/17 35

DREAMING OF MODELLING AND MODELLING DREAMING OF MODELLING AND MODELLING DREAMING OF MODELLING AND MODELLING DREAMING OF MODELLING AND MODELLING DREAMSDREAMSDREAMSDREAMS

MODELLING FROM SCRATCH IS NOT MODELLING FROM SCRATCH IS NOT MODELLING FROM SCRATCH IS NOT MODELLING FROM SCRATCH IS NOT

THE WAY FORWARDTHE WAY FORWARDTHE WAY FORWARDTHE WAY FORWARD

BECAUSEBECAUSEBECAUSEBECAUSE WE NEEDWE NEEDWE NEEDWE NEED TO BUILD FROM TO BUILD FROM TO BUILD FROM TO BUILD FROM

AN RELIABLE BASE CASEAN RELIABLE BASE CASEAN RELIABLE BASE CASEAN RELIABLE BASE CASE

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GLASS SERVICE/ FICGLASS SERVICE/ FICGLASS SERVICE/ FICGLASS SERVICE/ FIC

HAVE THE KNOWLEDGE HAVE THE KNOWLEDGE HAVE THE KNOWLEDGE HAVE THE KNOWLEDGE

AND EXPERIENCEAND EXPERIENCEAND EXPERIENCEAND EXPERIENCE21/6/17 37


BUT WE NEED TO BE SMARTBUT WE NEED TO BE SMARTBUT WE NEED TO BE SMARTBUT WE NEED TO BE SMART

21/6/17 38


MODEL FOR LONGER FURNACE MODEL FOR LONGER FURNACE MODEL FOR LONGER FURNACE MODEL FOR LONGER FURNACE

LIFELIFELIFELIFE

DESIGN FOR LONGER FURNACE DESIGN FOR LONGER FURNACE DESIGN FOR LONGER FURNACE DESIGN FOR LONGER FURNACE

LIFELIFELIFELIFE

OPERATE FOR LONGER FURNACE OPERATE FOR LONGER FURNACE OPERATE FOR LONGER FURNACE OPERATE FOR LONGER FURNACE

LIFELIFELIFELIFE

21/6/17 39


MODEL FOR LONGER FURNACE MODEL FOR LONGER FURNACE MODEL FOR LONGER FURNACE MODEL FOR LONGER FURNACE

LIFELIFELIFELIFE

BORMIOLIBORMIOLIBORMIOLIBORMIOLI DID JUST DID JUST DID JUST DID JUST

THISTHISTHISTHIS 21/6/17 40

Observations• Irregular corrosion

• Energy transmission• Current density

• Irregular thermal distribution

B o rm io li L uig iS id e V ie w (X Z )

1125 1050

1 30 0

1 2 0 0

142

5

150 0

147 5 150

0

14

50

127

5

14

75

150

0

14

75

145

0 14

25

1 05 0

13

00

14

50

1 4 7 5 1 4 7 5

132

5

1 4 5 0

1 4 2 5 1 4 2 5

12

75

1 4 0 0

1400 1 10 01 05 0

1 37 5

1 25 0

1 05 0

10

75

1 0 5 0 1 0 5 0

T e m p e ra tu re [ °C ] 1 0 5 0 1 0 7 5 1 1 0 0 1 1 2 5 1 1 5 0 1 1 7 5 1 2 0 0 1 2 2 5 1 2 5 0 1 2 7 5 1 3 0 0 1 3 2 5 1 3 5 0 1 3 7 5 1 4 0 0 1 4 2 5 1 4 5 0 1 4 7 5 1 5 0 0 1 5 2 5 1 5 5 0

10050

15050

100

50

150

5050

Joulean heat [kW / m3] 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

www.gsl.cz

Strategic parameters• Energetic Efficency• Lifetime• Pull range and flexibility• Cullet recycling• Maximum pull

Aim of the study is to verify the impact of design and materials evolution in the last 30 years and 20 furnaces onthe strategic parameters of the furnace, by comparing at leastthree evolution steps, and understand if electrical melting is becoming more competitive in the hollow glass market.

www.gsl.cz

Palisades Lifetime

0

1

2

3

4

5

6

7

<2000 2000-2010 >2010

period

year

s

Palisades Lifetime (years)

Lifetime

• In the analyzed period it was obtained a good improvement in the heat extraction from joints (+ 13%)

• Lifetime for the palisades is increased by 85%.

• Some other elements are now more critical

• Introduce the concept of Minor Repair

Heat Extraction from Joints Area

0

1000

2000

3000

4000

5000

6000

7000

8000

no cooling homogeneous cooling(<2000-2010)

High velocity targeted cooling(>2010)

period

W/m

2

Thermal Flow (W/m2)

www.gsl.cz


DESIGN FOR LONGER FURNACE DESIGN FOR LONGER FURNACE DESIGN FOR LONGER FURNACE DESIGN FOR LONGER FURNACE

LIFELIFELIFELIFE

ELIMINATE THE ELIMINATE THE ELIMINATE THE ELIMINATE THE

THROATTHROATTHROATTHROAT21/6/17 44

21/6/17 45

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BUT I’M FORGETTINGBUT I’M FORGETTINGBUT I’M FORGETTINGBUT I’M FORGETTING

YOU’RE ALL RISK YOU’RE ALL RISK YOU’RE ALL RISK YOU’RE ALL RISK

ADVERSE!!ADVERSE!!ADVERSE!!ADVERSE!!21/6/17 47


SO A STRUCTURED, SAFE SO A STRUCTURED, SAFE SO A STRUCTURED, SAFE SO A STRUCTURED, SAFE

APPROACH IS REQUIREDAPPROACH IS REQUIREDAPPROACH IS REQUIREDAPPROACH IS REQUIRED

BY SOME OF YOUBY SOME OF YOUBY SOME OF YOUBY SOME OF YOU21/6/17 48


SUPERBOOSTINGSUPERBOOSTINGSUPERBOOSTINGSUPERBOOSTING

21/6/17 49

ELECTRIC MELTING AND THE VALUE OF MODELLING › ... › 2017 › 08 ›...

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