Michael Greenman Executive Director Efficient Enterprises: Powering American Industry Industry Examples Cannon House Offic...
Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges f...
Traditional Furnace <ul><li>“ Siemens” Furnace – “Float Glass” </li></ul>
Submerged Combustion Melter 1- Batch charger;  2- Refractory lining;  3- Water cooled panels; 4- Melting zone;  5- Exhaust...
Submerged Combustion Melter <ul><ul><li>Primary Features </li></ul></ul><ul><ul><ul><li>Metal Box – Watercooled Walls </li...
Indiana Melting and Manufacturing, LaPorte, IN
SCM Partners <ul><li>Corning </li></ul><ul><li>Owens Corning </li></ul><ul><li>PPG </li></ul><ul><li>Johns Manville </li><...
Cross-Cutting Applications <ul><li>Steel Industry – Electric Arc Furnace Dust </li></ul><ul><li>Aluminum – Spent Aluminum ...
Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul>
Laser Contouring of Basic Oxygen Furnace – Fast Measurement of the Converter for Process Control
Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul>
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 <ul><ul><li>93 E-SMARRT Industry Cost Share Partners </li></ul></ul><ul><ul><ul><li>Most...
Melting Efficiency Improvement Projects <ul><li>Results:  </li></ul><ul><ul><li>Trials for new “sandwich” ladle lining res...
Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges f...
Strength of Glass <ul><li>Condition of Glass lb/Square Inch </li></ul><ul><li>Surfaces ground and sandblasted < 4,000 </li...
Possible New Markets for Ultra-Strong Glass <ul><li>Ultra-Thin film Solar Cells </li></ul><ul><li>Energy Storage </li></ul...
Ultra-Strong Glass
Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges f...
Waste Heat Recovery <ul><li>Largest “low hanging fruit” </li></ul><ul><ul><li>Pre-Heat raw materials (batch/cullet) </li><...
Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges f...
<ul><li>www.gmic.org </li></ul><ul><li>+1-614-818-9423 </li></ul>
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Efficient Enterprises: Powering American Industry - Industry Examples , Michael Greenman, Glass Manufacturing Industry Council

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Nov 17, 2009: Alliance to Save Energy Congressional briefing, "Heavy Industries: Advancing American Manufacturing," - A discussion by industry experts centering on the current and future prospects for energy efficiency in their four respective industries. All agreed on the great potential for energy efficiency projects but acknowledged the formidable barriers that inhibit investment.

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Efficient Enterprises: Powering American Industry - Industry Examples , Michael Greenman, Glass Manufacturing Industry Council

  1. 1. Michael Greenman Executive Director Efficient Enterprises: Powering American Industry Industry Examples Cannon House Office Building November 17, 2009
  2. 2. Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges for the future </li></ul>
  3. 3. Traditional Furnace <ul><li>“ Siemens” Furnace – “Float Glass” </li></ul>
  4. 4. 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)
  5. 5. Submerged Combustion Melter <ul><ul><li>Primary Features </li></ul></ul><ul><ul><ul><li>Metal Box – Watercooled Walls </li></ul></ul></ul><ul><ul><ul><li>Oxy-Fuel Burners </li></ul></ul></ul><ul><ul><ul><ul><li>Low Capital Cost </li></ul></ul></ul></ul><ul><ul><ul><ul><li>(-60%) </li></ul></ul></ul></ul><ul><ul><ul><li>Low Footprint </li></ul></ul></ul><ul><ul><ul><ul><li>(6-8 X Pull Rate for equivalent area) </li></ul></ul></ul></ul><ul><ul><ul><li>High Efficiency, Low Emissions </li></ul></ul></ul><ul><ul><ul><ul><li>(20% more efficient) </li></ul></ul></ul></ul><ul><ul><ul><ul><li>High Flexibility </li></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>4 hours hot to cold or cold to hot </li></ul></ul></ul></ul></ul><ul><ul><ul><li>New products, markets, business models </li></ul></ul></ul><ul><ul><ul><ul><li>IMM – first commercial Application </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Water Glass </li></ul></ul></ul></ul>
  6. 6. Indiana Melting and Manufacturing, LaPorte, IN
  7. 7. SCM Partners <ul><li>Corning </li></ul><ul><li>Owens Corning </li></ul><ul><li>PPG </li></ul><ul><li>Johns Manville </li></ul><ul><li>Schott </li></ul><ul><li>Gas Technology Institute (GTI) </li></ul><ul><li>GMIC </li></ul><ul><li>DOE, NYSERDA, GRI funding </li></ul>
  8. 8. Cross-Cutting Applications <ul><li>Steel Industry – Electric Arc Furnace Dust </li></ul><ul><li>Aluminum – Spent Aluminum Potliner </li></ul><ul><li>Forest Products – Black Liquor Gasification </li></ul><ul><li>Cement – Blended and Specialty Cements </li></ul><ul><li>Chemicals – Sodium Silicate </li></ul><ul><li>Waste Vitrification – Portable – Move to location </li></ul><ul><li>Mineral Wool – Original Application </li></ul><ul><li>Nuclear Waste Stabilization – Increase Cost-Effectiveness </li></ul>
  9. 9. Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul>
  10. 10. Laser Contouring of Basic Oxygen Furnace – Fast Measurement of the Converter for Process Control
  11. 11. Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul>
  12. 12. Energy-Saving Melting and Revert Reduction Technology (E-SMARRT)
  13. 13. Energy -SMARRT R&D Project Team Thirteen foremost metalcasting R&D organizations CANMET Oak Ridge National Lab
  14. 14. Energy-SMARRT Industrial Partners <ul><ul><li>93 E-SMARRT Industry Cost Share Partners </li></ul></ul><ul><ul><ul><li>Most are early adopters </li></ul></ul></ul><ul><ul><li>Cost share through October 2009: $10,642,487 (125% of government provided funds) </li></ul></ul>
  15. 15. Melting Efficiency Improvement Projects <ul><li>Results: </li></ul><ul><ul><li>Trials for new “sandwich” ladle lining resulted in energy consumption reduction by 30-60% </li></ul></ul><ul><ul><li>The addition of chemical energy through use of a supersonic oxyfuel system resulted in a decrease of 20 kwh/ton </li></ul></ul><ul><ul><li>Benchmarking the efficiency of holding furnaces for aluminum die casting operations and disseminating results through industry workshops </li></ul></ul>Develop new melting technologies and processes to improve energy efficiency of melting processes in foundry operations
  16. 16. Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges for the Future </li></ul><ul><ul><li>Glass - Strength </li></ul></ul>
  17. 17. Strength of Glass <ul><li>Condition of Glass lb/Square Inch </li></ul><ul><li>Surfaces ground and sandblasted < 4,000 </li></ul><ul><li>Pressed Articles 3,000 – 8,000 </li></ul><ul><li>Blown Ware: </li></ul><ul><ul><li>Hot Iron Molds 4,000 – 9,000 </li></ul></ul><ul><ul><li>Paste Molds 5,000 – 1,500 10,000 </li></ul></ul><ul><ul><li>Inner Surfaces 15,000 – 40,000 </li></ul></ul><ul><li>Drawn tubing or rod 6,000 – 15,000 </li></ul><ul><li>Window Glass 8,000 – 20,000 </li></ul><ul><ul><li>LCD (0.65 mm) ~45,000 </li></ul></ul><ul><li>Annealed fibers </li></ul><ul><ul><li>Annealed 10,000 – 40,000 </li></ul></ul><ul><li>Freshly drawn 30,000 – 400,000 </li></ul><ul><li>Gorilla Glass (Samsung – Mobile Phone) 100,000-200,000 </li></ul><ul><li>Telecommunications Fiber >100,000 </li></ul>
  18. 18. Possible New Markets for Ultra-Strong Glass <ul><li>Ultra-Thin film Solar Cells </li></ul><ul><li>Energy Storage </li></ul><ul><li>Glass Balloon Satellites </li></ul><ul><li>Structural Supports </li></ul>
  19. 19. Ultra-Strong Glass
  20. 20. Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges for the Future </li></ul><ul><ul><li>Glass – Strength </li></ul></ul><ul><ul><li>All Energy Intensive Industries: </li></ul></ul><ul><ul><ul><li>Waste Heat Recovery </li></ul></ul></ul>
  21. 21. Waste Heat Recovery <ul><li>Largest “low hanging fruit” </li></ul><ul><ul><li>Pre-Heat raw materials (batch/cullet) </li></ul></ul><ul><ul><li>Steam for facility use </li></ul></ul><ul><ul><li>Distributed Generation </li></ul></ul><ul><ul><li>“ Glass Plant (or other) as Power Plant” </li></ul></ul>
  22. 22. Examples from Industry <ul><li>Glass </li></ul><ul><li>Steel </li></ul><ul><li>Metalcasting </li></ul><ul><li>Challenges for the Future </li></ul><ul><ul><li>Glass – Strength </li></ul></ul><ul><ul><li>All Energy Intensive Industry: </li></ul></ul><ul><ul><ul><li>Waste Heat Recovery </li></ul></ul></ul><ul><ul><li>Commercial Implementation </li></ul></ul><ul><ul><ul><li>“ Everyone wants to be first to be second ” </li></ul></ul></ul>
  23. 23. <ul><li>www.gmic.org </li></ul><ul><li>+1-614-818-9423 </li></ul>

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