73rd Conference on Glass Problems

Presents an indispensable resource to the glass manufacturing industry The 73rd Conference on Glass Problems was organized by the Kazuo Inamori School of Engineering, Alfred University, Alfred, New York, and The Glass Manufacturing Industry Council, Westerville, Ohio. Since 1934, the annual Conference on Glass Problems has addressed the challenges facing the glass industry with innovative solutions that have led to new and enhanced glass products and processes. Each year, the proceedings from this conference, which has become the largest industrial glass meeting in the United States, have been published for the benefit of glass, ceramics, and materials scientists and engineers around the world. This volume features the state-of-the-science collection of papers presented at the 73rd Conference on Glass Problems. During the conference, leading international scientists and engineers met for two days to discuss the latest innovations and solutions for glass manufacturing. Moreover, they forecasted and explored future directions of the glass industry. The proceedings are grouped into five sections: Glass Melting Melting, Raw Materials, Batch Reactions, and Recycling Coatings and Strengthening Refractories Process Control and Modeling The 73rd Conference on Glass Problems is essential reading for all who need to stay abreast of the latest research in the glass manufacturing field. Readers will find valuable information that enables the glass industry to continue to innovate with new and improved glass products and processes to meet the needs of both industrial and general consumers.

Foreword ix Preface xi Acknowledgments xiii Glass Melting Energy Recovery from Waste Heat in the Glass Industry and Thermochemical Recuperator 3 Hans van Limpt and Tuud Beerkens Development of DFC (Direct Fusion Combustion) using Oxy–Fuel Burner 17 Takayuki Fujimoto Finding Optimal Glass Compositions 27 Oleg A. Prokharenko and Sergei O. Prokhorenko Melting Raw Materials, Batch Reactions, and Recycling Advanced Melting Technologies with Submerged Combustion  45 I.L. Pioro, L.S. Pioro, D. Rue, and M. Khinkis The Influence of Borate Raw Material Choice on the Glass Manufacturing Process 67 Andrew Zamurs, David Lever, Simon Cook, and Suresh Donthu Electrical Heating Systems for Melting Tanks, Forehearths, and Feeders 75 Werner Bock, Gunther Bock, and David Boothe A Furnace Combustion System Conversion by Flammatec during Operation at Libbey, Inc.–How Flame Geometry Improvement and Excess Air Control Contributes to Fuel Savings 91 Dan Cetnar, Petr Vojtech, and H.P.H. Muljsenberg Coatings and Strengthening Color Control of Glass and Multilayer Coatings on Glass 105 David Haskins, Paul A. Medwick, and Mehran Arbab Hard Glass – Thermal Strengthening of Container Glass 119 Steven Brown Effects of Glass Coatings on the Glass Tempering Process 131 Clarles Cocagne The Usable Glass Strength Coalition Initiative to Provide Funding for Fundamental Research in Glass Stregth 141 Robert Weisenburger Lipetz Refractories Performance of Fusion–Cast and Bonded Refractories in Glass Melting Furnaces 161 Amul Gupta, Kevin Selkregg, Matthew Wheeler, and Goetz Heilemann Energy Savings and Furnace Design 177 Matthias Lindig–Nikolaus New Tin Oxide Electrodes for Glass Melting 183 Julien Fourcade and Olivier Citti Structural Health Monitoring of Furnace Walls 201 Eric K. Walton, Yakup Bayram, Alexander C. Ruege, Jonathan Young, Robert Burkholder, Gokhan Mumcu, Elmer Sperry, Dan Cetnar, and Thomas Dankert New CIP SEFPRO Refractory Solution to Extend Soda Lime Glass Furnace Life 207 C. Linnot, M. Gaubil, T. Consales, O. Citti, T. Champion, and J. Poiret Process Control and Modeling Non–Isothermal Pendant Drops of Molten Glass: Part 1 211 Byron L. Bemis ICG TC21 Modeling of Glass Melting Processes–How Reliable and Validated Simulation Tools can Help to Improve Glass Melting Efficiency and Productivity 227 H.P.H Muijsenberg Proper Modeling of Radiative Heat Transfer in Clear Glass Melts 249 A.M. Lankhorst, L. Thielen, P.J.P.M Simons, and A.F.J.A. Habraken Novel Method for Stress Inspection of Tempered or Thermally Strengthen Glass 259 Sarath Tennakoon Author Index 267

S. K. SUNDARAM, PhD, is an Inamori Professor of Materials Science and Engineering at Alfred University. Before joining Alfred University, Dr. Sundaram was a chief materials scientist at the Pacific Northwest National Laboratory (PNNL). He joined the PNNL in 1994 as a post-doctoral fellow and became a senior research scientist in 1996. He was then promoted to chief materials scientist in January 2002. Dr. Sundaram is internationally recognized for interdisciplinary research. He has made over 100 technical presentations, edited/contributed to twelve books, published over eighty peer-reviewed publications and technical reports, mentored/supported over forty-five students, and organized/co-organized several national and international symposia on advanced topics in materials science. He is also a co-inventor in three issued patents and two provisional patent applications.