Michael Greenman Executive Director Efficient Enterprises: Powering American Industry Industry Examples Cannon House Office Building November 17, 2009

Examples from Industry Glass Steel Metalcasting Challenges for the future

Glass

Steel

Metalcasting

Challenges for the future

Traditional Furnace “ Siemens” Furnace – “Float Glass”

“ Siemens” Furnace – “Float Glass”

Submerged Combustion Melter 1- Batch charger; 2- Refractory lining; 3- Water cooled panels; 4- Melting zone; 5- Exhaust; 6- Melt outlet; 7- Submerged oxygas burners; 8- Batch material (sloped pocket of batch)

Submerged Combustion Melter Primary Features Metal Box – Watercooled Walls Oxy-Fuel Burners Low Capital Cost (-60%) Low Footprint (6-8 X Pull Rate for equivalent area) High Efficiency, Low Emissions (20% more efficient) High Flexibility 4 hours hot to cold or cold to hot New products, markets, business models IMM – first commercial Application Water Glass

Primary Features

Metal Box – Watercooled Walls

Oxy-Fuel Burners

Low Capital Cost

(-60%)

Low Footprint

(6-8 X Pull Rate for equivalent area)

High Efficiency, Low Emissions

(20% more efficient)

High Flexibility

4 hours hot to cold or cold to hot

New products, markets, business models

IMM – first commercial Application

Water Glass

Indiana Melting and Manufacturing, LaPorte, IN

SCM Partners Corning Owens Corning PPG Johns Manville Schott Gas Technology Institute (GTI) GMIC DOE, NYSERDA, GRI funding

Corning

Owens Corning

PPG

Johns Manville

Schott

Gas Technology Institute (GTI)

GMIC

DOE, NYSERDA, GRI funding

Cross-Cutting Applications Steel Industry – Electric Arc Furnace Dust Aluminum – Spent Aluminum Potliner Forest Products – Black Liquor Gasification Cement – Blended and Specialty Cements Chemicals – Sodium Silicate Waste Vitrification – Portable – Move to location Mineral Wool – Original Application Nuclear Waste Stabilization – Increase Cost-Effectiveness

Steel Industry – Electric Arc Furnace Dust

Aluminum – Spent Aluminum Potliner

Forest Products – Black Liquor Gasification

Cement – Blended and Specialty Cements

Chemicals – Sodium Silicate

Waste Vitrification – Portable – Move to location

Mineral Wool – Original Application

Nuclear Waste Stabilization – Increase Cost-Effectiveness

Examples from Industry Glass Steel

Glass

Steel

Laser Contouring of Basic Oxygen Furnace – Fast Measurement of the Converter for Process Control

Examples from Industry Glass Steel Metalcasting

Glass

Steel

Metalcasting

Energy-Saving Melting and Revert Reduction Technology (E-SMARRT)

Energy -SMARRT R&D Project Team Thirteen foremost metalcasting R&D organizations CANMET Oak Ridge National Lab

Energy-SMARRT Industrial Partners 93 E-SMARRT Industry Cost Share Partners Most are early adopters Cost share through October 2009: $10,642,487 (125% of government provided funds)

93 E-SMARRT Industry Cost Share Partners

Most are early adopters

Cost share through October 2009: $10,642,487 (125% of government provided funds)

Melting Efficiency Improvement Projects Results: Trials for new “sandwich” ladle lining resulted in energy consumption reduction by 30-60% The addition of chemical energy through use of a supersonic oxyfuel system resulted in a decrease of 20 kwh/ton Benchmarking the efficiency of holding furnaces for aluminum die casting operations and disseminating results through industry workshops Develop new melting technologies and processes to improve energy efficiency of melting processes in foundry operations

Results:

Trials for new “sandwich” ladle lining resulted in energy consumption reduction by 30-60%

The addition of chemical energy through use of a supersonic oxyfuel system resulted in a decrease of 20 kwh/ton

Benchmarking the efficiency of holding furnaces for aluminum die casting operations and disseminating results through industry workshops

Examples from Industry Glass Steel Metalcasting Challenges for the Future Glass - Strength

Glass

Steel

Metalcasting

Challenges for the Future

Glass - Strength

Strength of Glass Condition of Glass lb/Square Inch Surfaces ground and sandblasted < 4,000 Pressed Articles 3,000 – 8,000 Blown Ware: Hot Iron Molds 4,000 – 9,000 Paste Molds 5,000 – 1,500 10,000 Inner Surfaces 15,000 – 40,000 Drawn tubing or rod 6,000 – 15,000 Window Glass 8,000 – 20,000 LCD (0.65 mm) ~45,000 Annealed fibers Annealed 10,000 – 40,000 Freshly drawn 30,000 – 400,000 Gorilla Glass (Samsung – Mobile Phone) 100,000-200,000 Telecommunications Fiber >100,000

Condition of Glass lb/Square Inch

Surfaces ground and sandblasted < 4,000

Pressed Articles 3,000 – 8,000

Blown Ware:

Hot Iron Molds 4,000 – 9,000

Paste Molds 5,000 – 1,500 10,000

Inner Surfaces 15,000 – 40,000

Drawn tubing or rod 6,000 – 15,000

Window Glass 8,000 – 20,000

LCD (0.65 mm) ~45,000

Annealed fibers

Annealed 10,000 – 40,000

Freshly drawn 30,000 – 400,000

Gorilla Glass (Samsung – Mobile Phone) 100,000-200,000

Telecommunications Fiber >100,000

Possible New Markets for Ultra-Strong Glass Ultra-Thin film Solar Cells Energy Storage Glass Balloon Satellites Structural Supports

Ultra-Thin film Solar Cells

Energy Storage

Glass Balloon Satellites

Structural Supports

Ultra-Strong Glass

Examples from Industry Glass Steel Metalcasting Challenges for the Future Glass – Strength All Energy Intensive Industries: Waste Heat Recovery

Glass

Steel

Metalcasting

Challenges for the Future

Glass – Strength

All Energy Intensive Industries:

Waste Heat Recovery

Waste Heat Recovery Largest “low hanging fruit” Pre-Heat raw materials (batch/cullet) Steam for facility use Distributed Generation “ Glass Plant (or other) as Power Plant”

Largest “low hanging fruit”

Pre-Heat raw materials (batch/cullet)

Steam for facility use

Distributed Generation

“ Glass Plant (or other) as Power Plant”

Examples from Industry Glass Steel Metalcasting Challenges for the Future Glass – Strength All Energy Intensive Industry: Waste Heat Recovery Commercial Implementation “ Everyone wants to be first to be second ”

Glass

Steel

Metalcasting

Challenges for the Future

Glass – Strength

All Energy Intensive Industry:

Waste Heat Recovery

Commercial Implementation

“ Everyone wants to be first to be second ”

www.gmic.org +1-614-818-9423

www.gmic.org

+1-614-818-9423