This volume is part of theCeramic Engineering and Science Proceeding (CESP) series. This series contains a collection of papers dealing with issues in both traditional ceramics (i.e., glass, whitewares, refractories, and porcelain enamel) and advanced ceramics. Topics covered in the area of advanced ceramic include bioceramics, nanomaterials, composites, solid oxide fuel cells, mechanical properties and structural design, advanced ceramic coatings, ceramic armor, porous ceramics, and more.

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.

Foreword ix

Preface xi

Acknowledgments xiii

OPERATIONS

Glass Plant AuditsThree Case Studies in Glass Production 3

Problems and Their Solutions
J. M. Uhlik

Furnace Design and Operation for the Long Term 19
D. Boothe

CONTROLS

Energy Reduction with Model Based Predictive Control 33
M. Powys and D. Armagost, M. P. H. Muijsenberg, R. Bodi, J. Muller, J. David, and G. Neff

Smart Manufacturing for Continuous, High-Technology 45

Glass Production
D. Kuhn and J. Ahrens

Optimal Control Strategy for Predictive Compensation of Gas 55

Quality Fluctuations in Glass Melting Furnances
P. Hemmann

ENERGY

New Furnace Design Solution Breaks the 3 Gigajoules per Ton 67

Benchmark Limit
M. Lindig-Nikolaus

Ox-Fuel Tableware Furnace with Novel Oxygen- and Natural 73

Gas Preheating System
T. Görüney, Ne et Arzan, Süleyman Koç, O. Öztürk and H. ahin, H. Kim and T. Kang, Y. Joumani, X. Paubel, and L. Jarry

Advanced Heat Recovery for Ox-Fuel Fired Glass Furnaces with 83

Plus Technology
S. Laux, U. Iyoha, R. Bell, J. Pedel, A. Francis, K.T. Wu, and H. Kobayashi

Improving Energy Efficiency of Glass Furnances 93
M. van Kersbergen, and S. Lessmann

Optimization of Combustion Settings: An Energy Efficient Approach to the Reduction of Emissions by Glass Melting Furnaces 103
S. Tiozzo, W. Battaglia, R. DallIgna, and A. Migatta

MELTING

Impact of Redox in Industrial Glass Melting and Importance of 115

Redox Control
M. Hubert, A. J. Faber, H. Sesigur, F. Akmaz, S-R. Kahl, E. Alejandro, and T. Maehara

MODELING AND FORMING

Fluid Dynamics Analysis Leading to Innovative Glass 131

Homogenization Device Arctwister
A. Fuchs

Non-Isothermal Glass Moulding of Complex LED Optics 141
H. Kreilkamp, A. T. Vu, O. Dambon, and ND F. Klocke

REFRACTORIES

Tin Bath Block Evolution and Development: A Case of Toil, 153

Endeavour and Fears
Christopher J. Windle

New Oxy-Combustion Crown Efficient Flue Gas 167

Heat Recovery
W. Kuhn and A. Reynolds

Extending the Life of Fused Cast Ceramics 171
R. McGrath and J. Crowe

Enhanced Radar Control for High Performance Bottom Paving 179
J-G. Vuillermet, M. Gaubil, I. Cabodi, and O. Bories

High Performance Superstructure Concept for Container Glass 187

Furnaces
B. C. Snow and T. Close

Enhanced Hydrated LimeA Simple Solution for Acid Gas 201
Compliance
G. Hunt and M. Sewell