2014 v.1 greenforumgas-1


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2014 v.1 greenforumgas-1

  1. 1. GAS 2014 Chicago GREEN GLASS FORUM Roundtable Discussion for Energy Efficient Glass Studios
  2. 2. chiuso-closedafter 550 years of operation
  3. 3. World Glass 4000 years history • Sars-Poteries, France: 200 glass factories 20th Century. Today a few hot shops and a Glass Museum • Barcelona, Spain: 0 Hotshops, Centre del Vidre closed down furnace, 4 production hotshops left in the country • Paris, France: 24 hotshops in 2004 dramatically dropped to 2 current artist hotshops in the city. • Murano, Venice: Glass factories closing due to high operations costs and Chinese competition
  4. 4. fuel source? trees..coal..oil..natural gas.....
  5. 5. modern challenges • Waterford crystal-- 750 tons glass/year closed after 226 years- reopened as a tourist destination • Stuben closed after 109 years production • Glass community: individual shops closing due to hardships • Blenko Glass, Caramea, and many others closing to high overhead costs Time for new opportunities? New inventions?
  6. 6. CORRELL: fuel calculator
  7. 7. Calculate your efficiency…. Cam Ocagi: Istanbul Saves 45% of fuel usage and cost due to good equipment, new habits, closing new furnace doors! Furnaces with Recuperators and Variable Speed Blowers, and GOOD Insulation =
  8. 8. Communit yCommunity Studios = Energy efficient! SHARE • Fuel bills & utilities • Building Materials • Resources • Shop Duties • Expensive tools • Shipping raw material • Assistants • Improves the neighborhood
  9. 9. Recuperation : Re-Use • Recuperation saves 20-60 % of fuel usage • Less carbon footprint • Saves money
  10. 10. Valkema Elec Furnace ELECTRIC SOLUTIONS Wet Dog 135# furnace Solar Array @ The Crucible, Oakland, CA
  11. 11. ReCycle: Kauai Recycling for the Arts, Tulane Univ, Maho Bay Resort, The Crucible Green VI Tortola QuickTime™ and a TIFF (Uncompressed) decompressor are needed to see this picture.
  12. 12. Landfill Arts Centers Energy Xchange- North Carolina OVCE -Kentucky Jackson County Green Energy Park - North Carolina Colma Landfill Project- California
  13. 13. Alternative Fuel Sources landfill methane, algae, vegetable oil, solar off-set
  14. 14. • Moooo x 2400! METHANE DIGESTERS
  15. 15. HYDRO POWER Simon Pearce- Ottauquechee River Waterfall, VT
  16. 16. • New Equipment • 1000lb Furnace • recuperator system • nozzle mix burner that introduces air in stages to reduce NOx emissions • Ceramic Burner Block takes hig temp pre- heated air • 500,000 btu/hr burner= 50% reduction gas • Charge 150lbs in 1.5 hr
  17. 17. BioGlassTM OBJECTIVE: The research and development of eco-efficient studio glassmaking techniques • World Overview • Efficient Studio Practices • Community Resource Sharing • Recuperation and Re-Use • Alternative Fuel Sources: elec/vo/(? • Keeping track of innovative and green glassmaking studios
  18. 18. Kitengela Glass- Kenya Africa GreenVI Tortola British Virgin Islands Canberra Glassworks, Australia Oaxaca, Mexico
  19. 19. 4000 years…. • What is the future of Studio Glass? 1350 BC 200 AD 1920 AD 2011 AD
  20. 20. • getting involved is your opportunity to make a difference for the glassmaking community? Glass Art Society www.glassart.org www.bioglass.org info@bioglass.org facebook: BioGlass: Eco Efficient Glass Making
  21. 21. Energy Savings = Money Savings • Community Shops • Recuperation • Electrical- Solar offset? • Wood-fired • Recycled Glass • Methane Landfill • Bio-digesters • Thermal Cascade/ Use • BioDiesel- alt fuels
  22. 22. Pittsburgh Glass Center
  23. 23. Pittsburgh Glass Center
  24. 24. Community Glass Studios / Partnerships/ Sharing Pratt Fine Arts Center- Seattle
  25. 25. Previous Glass Furnace 1000 pound capacity Traditional tiled liner 1.5 MBTU/Hr Thermjet burner Rebuild interval 2 ••• to 3 years New Glass Furnace WET DOG RDT1000 1000 pound capacity Round monolithic liner Highly Insulated 750 KBTU/Hr Thermjet burner Recuperated preheat of combustion air Onboard variable speed blower for combustion air Estimated rebuild interval 6 to 8 years GRANT $ Money and Applications for Change Furnace Gas Usage Comparisons Traditional 1000# Tank Wet Dog RDT1000 Therms/Hour @ Idle 1.29 .84 Therms/Hour @ Charge 3.3 2.11 Total Annual Therms 14818 9581 Utility Cost Comparisons Traditional 1000# Tank & glory hole combustion Feb 2008-Jan 2009 12 month averaged cost/month $5,045 Total Annual Cost: $60,540 ----------------------------------------------------------------------- Wet Dog RDT1000 and upgraded glory hole combustion Feb 2012 – Jan 2013 12 month averaged cost/month $3,374 Total Annual Cost: $40,493 Project Costs and Funding Furnace installations costs $56,026 Glory hole change over costs $6,872 PSE Custom Grant $39,218 4Culture Support $20,000 Used Equipment Sales $3,000 Net installation costs $680 example: Pratt Fine Arts Center
  26. 26. jam factory- australia urban glass- brooklyn, ny public glass- san francisco starworks, north carolina
  27. 27. Recuperation Techniques
  28. 28. Text CORRELL recuperated furnace
  29. 29. Percent fuel saved is calculated as follows:Example: At 2300F exhaust temperature with 10% excess air at 60 ͦF, available heat is 34%. When air is
  30. 30. Recuperation SidexSide Test
  31. 31. Green Initiatives @IGNITE STUDIOS Ignite is committed to improving our environmental foot print. Our facility won the AIA Sustainable Design award in 2013. ! We will continue to become more “green” but in the meantime, we have invested in: ! 740 lb round day-tank with recuperator 2 x 80 lb crucible furnace with recuperator Programmable VSDs for our main exhaust fans Rotary screw air compressor with a VSD ! We have switched our batch to cullet, reducing charging times and temperatures needed to create beautiful glass art. LEED CERTIFIED BUILDING
  32. 32. Learning from History Applying new energy efficient technology
  33. 33. XAQUICHE work station 3 GH, pipe warmer, pick up oven, recuperation and multi fuel capability; propane, methane, hydrogen and veggie oil. Rated at 250,000 btu XAQUICHE The other is our typical two door melting furnace. We work from the furnace, there is an optional cap for the glory hole entrance for when we are in other types of production. It is rated at 400,000 btu multi fuel; propane, methane, hydrogen and or veggie oil AND recuperation which feeds the burner, annealing ovens, oil preheat and water heater.
  34. 34. Xaquiche Studios- Oaxaca, Mexico
  35. 35. Ed Van Dijk: wood fired furnace
  36. 36. Durk Valkema Durk Valkema comes from a well-known family of glass artists in the Netherlands. He attended the Gerrit Rietveld Academie in Amsterdam and worked with Stanislav Libenskỳ at the Academy of Applied Arts in Prague. Through his broad technical and practical knowledge, in combination with aesthetic insight, Valkema acts as a sounding board in the development of competitive and technically innovative design for both art glass and product design. He specializes in designing and building cost-effective, fuel-efficient furnaces, annealing kilns, and related equipment. Corning Fellow
  37. 37. Jackson County Green Energy Park Methane Landfill
  38. 38. Salem Community College Methane Gas Program
  39. 39. Alfred NY
  40. 40. This is a simple finned tube heat exchanger over a 12” glory hole with doors closed during the entire test period. Below are calculations describing heat reclaimed in the water pumped through the heat exchanger. With another row of finned tube above the existing one, even greater reclamation is possible. 40 gal water x 8.34 lbs/gal=333.6 lbs water. First hour 70F to 120F=50F rise as gh went from room temp to operating temp=16,680 Btu/hr=4,887W reclaimed with 92W pump. Second hour 120F to 150F=30F rise as gh began to stabilize in temp=10,008 Btu/hr=2,932W Third hour 150F to 180F=30F rise as gh began to stabilize in temp=10,008 Btu/hr=2,932W Pressure relief valve opened. Put in financial terms, the reclamation of this heat when used in place of electric heat: Note: this is based on electrical unit cost of $0.12 kWh. Savings will vary with electrical cost. 4,887W reclaimed per hour for one hour=4.887kWh x $0.12/kWh=$0.586/hr Cost of running water pump=.092 kWh x $1.12=$0.011/hr. Net gain at $0.12/kWh=$0.586/hr (reclaimed) minus $0.011/hr (expended by pump) =$0.575/hr. For eight hours a day over a glory hole, that’s $4.60/day x 24 days a month=$110.40/mo. (assuming heat is pulled back out of water for space heating, etc.) Innovation -- New Technology/ Applications
  41. 41. These are images of our automated flue damper system. It works by measuring the pressure inside the flue and then opening or closing proportionally to maintain a stable pressure in the furnace. When the furnace goes to high fire, the pressure inside the furnace rises and the damper opens. When it goes to low fire, the pressure drops and the damper closes. Anywhere between low and high fire will cause the damper to be somewhere between open and closed. This system can reduce fuel consumption by about 5% compared to not using one. Maintaining positive pressure in the furnace also helps prevent cold air infiltration through the door and can help with other issues such as emissions and glass quality as well.
  42. 42. Pilchuck Glass School: digital data collecting / recuperators Pilchuck’s initial steps towards this goal begin with the plan for redesign of efficient furnaces, glory holes and annealers for the blowing studios. Over the past year PGS has installed “sage” flow meters and data capture system (Hobo-USB data logging) on their 2 furnaces and glory holes to study and analyze gas usage and energy costs. This information is being used to support future decisions to rebuild and redesign the casting shop and hotshop to meet programmatic needs.
  43. 43. Green VI- Recycled Glass & Island Trash Program
  44. 44. Nanda Soderberg @ Pilchuck recycled glass class 2013
  45. 45. MARY WHITE: RECYCLED GLASS EDUCATION teaching "re use" practice: a forum for discussion on sustainable practice, environmental activism glass chemistry and engineering
  46. 46. recycled glass projects wayne harjula ruth allen studio manufact
  47. 47. Veg Oil use with Recuperation BIG ISLAND GLASS Solar Panels: Offset entire studio $60 - 9 months operation
  48. 48. Change the Game...
  50. 50. methane digester for pueblo cistern for waste water XAQUIXE
  51. 51. BIODEISEL new fuels Eddie Bernard: BioDiesel experiments at Star
  52. 52. multi-use equipment -- pipe warmer on GH
  53. 53. Flameworking: Glass making low costs and little carbon footprint
  55. 55. VOLUNTEERS needed : info@bioglass.org it’s not easy being green..... THANK YOU! GREEN FORUM @GAS CHICAGO 2014