Glass manufacturing
According to an aspect of the disclosure, a glass manufacturing system includes a hot-end subsystem, including: a submerged combustion melter that melts feedstock to produce molten glass; a stiller that receives the molten glass from the submerged combustion melter and that includes a stilling tank to still the molten glass and that is configured to control outflow of the stilled molten glass to effectively decouple viscosity of the molten glass from the flow rate of the molten glass and thereby control finer molten glass levels; and a finer that is mechanically decoupled from the stiller, and that receives and fines the stilled molten glass to produce fined molten glass. Many other aspects of the system are also disclosed and claimed.
1. A glass manufacturing system, comprising:
a hot-end subsystem, including:
a submerged combustion melting furnace that melts feedstock to produce molten glass;
a finer that receives and refines the molten glass from the submerged combustion melting furnace to produce fined molten glass;
a forehearth that conditions the fined molten glass to a uniform temperature and viscosity for downstream forming operations;
a glass feeder that receives the conditioned molten glass from the forehearth and produces a molten charge therefrom;
a forming machine including a forming mold that receives the molten charge and forms glass product from the molten charge; and
an annealing lehr that receives and anneals the glass product; and
a cold-end subsystem, including:
an inspection station downstream of the annealing lehr; and
a packaging station downstream of the inspection station
wherein the hot-end subsystem and the cold-end subsystem produce between 95 and 126 tons of glass per day, and are encompassed by an installation having a capacity-adjusted size of less than 440 cubic meters per each ton of glass produced per day.
2. The glass manufacturing system set forth in claim 1 , further comprising:
a feedstock subsystem, including:
a batch material storage sub-system;
a batch material transfer sub-system; and
a batch material transmission sub-system to transmit batch material from the feedstock subsystem to the hot-end subsystem,
wherein the capacity-adjusted size is less than 200 cubic meters per each ton of glass produced per day.
3. The glass manufacturing system set forth in claim 1 , wherein the glass feeder is not a gob feeder and does not produce a freefalling gob.
4. The glass manufacturing system set forth in claim 1 , wherein the glass feeder feeds the molten glass directly into the forming mold.
5. The glass manufacturing system set forth in claim 4 , wherein the glass feeder cuts the molten glass upstream of the forming mold to establish the molten charge in the forming mold.
6. The glass manufacturing system set forth in claim 1 , wherein a vertical height differential between an outlet of the glass feeder and an open end of the forming mold is less than three meters.
7. The glass manufacturing system set forth in claim 1 , wherein the installation has a maximum length less than about 70 meters, a maximum width less than about 20 meters, and a maximum height less than about 15 meters.
8. A glass factory comprising:
the glass manufacturing system set forth in claim 1 ; and
an architectural installation including:
a forming floor carrying the forming machine,
walls,
a roof, and
excluding a basement.
9. The glass factory set forth in claim 8 , wherein the architectural installation includes a light industrial building.
10. The glass manufacturing system set forth in claim 1 , wherein the hot-end subsystem and the cold-end subsystem produce between 100 and 120 tons of glass per day, and wherein the capacity-adjusted size is less than 300 cubic meters per each ton of glass produced per day.
11. The glass manufacturing system set forth in claim 1 , further comprising a feedstock subsystem.
12. A glass factory comprising:
the glass manufacturing system set forth in claim 11 ; and
an installation including
a feedstock building that includes a foundation, walls, and a roof, wherein the height of the feedstock building is less than seventeen meters tall.
13. The glass factory of claim 12 , wherein the installation also includes a factory building that includes a forming floor carrying the forming machine, walls, and a roof, wherein the height of the factory building is less than thirteen meters tall.
14. The glass factory of claim 13 , wherein the forming floor includes a four to six inch thick slab and one or more isolation slabs less than four feet thick.
15. A glass factory comprising:
the glass manufacturing system set forth in claim 1 ; and
an installation including a factory building that includes a forming floor carrying the forming machine, walls, and a roof, wherein the height of the factory building is less than thirteen meters tall.
16. The glass factory of claim 15 , wherein the forming floor includes a four to six inch thick slab and one or more isolation slabs less than four feet thick.