GPC GMIC Presentation 10 26 05 FINAL

High Intensity Plasma Glass Melter: 

High Intensity Plasma Glass Melter Glass Problems Conf—GMIC Workshop Oct. 26, 2005 Ron Gonterman & Mike Weinstein

High Intensity Glass Plasma Melter—GO13093: 

High Intensity Glass Plasma Melter—GO13093 Goal: Develop a 500 lb/hr transferred-arc plasma melting process that can produce high quality glass suitable for processing into a commercial article. Challenge: Plasma melting of glass potentially provides high intensity, highly flexible, efficient glass melting but is hampered by short torch lives and unstable process operating conditions. Benefits: Ability to turn off production glass furnaces when business dictates; rapid startup / shutdown capabilities saves energy; skull melting eliminates refractories/minimizes heat losses; high temperature capabilities can be applied to new materials. Potential End-User Applications: Specialty glasses; Frit manufacturers; Fiberglass; Labware, Mineralwool, Specialty materials, Refractory melting, Minerals melting, etc. FY06 Activities: (With funding) Melt numerous glass and other materials compositions of broad interest to glass industry; Build and install first commercial pilot melter; Participants: Plasmelt Glass Tech AGY Johns Manville

Plasma Melter Operation-Boulder, CO: 

Plasma Melter Operation-Boulder, CO

AGENDA: 

AGENDA Glasses Melted Glass Quality Data Fiber Tensile Strength Fiberizing Performance Break Rates Fiber Quality Seed Levels / Oz Glass Chemistry Volatilization Redox Metal contamination levels – Copper & Moly Energy Efficiency Marketing Study Attributes of Plasmas / Best Fit Applications / New Concepts Plasmelt’s Path Forward & IMPLEMENTATION

GLASSES MELTED WITH PLASMAS: 

GLASSES MELTED WITH PLASMAS Glasses Already Melted E Glass S Glass Frit Glass Lighting Glass Scrap E-Glass Quartz Sand (SiO2) Calcium Silicate Glass Planned November, 2005 Trials E-glass with no boron/no fluorine AR-Glass C-Glass Calcium silicate glasses Specialty Electrical Glasses Scrap Glass – Higher Throughput Fine Fiber Diameter

GLASS QUALITY: 

GLASS QUALITY Fiberizing trials of fine filaments at AGY’s Huntingdon, PA facility Marble re-melt process Using plasma-produced glass “nuggets”

GLASS QUALITY: 

GLASS QUALITY Fiber Quality Conclusion: No statistically significant difference in the plasma-melted and standard glass. {60} {55} Overall Quality Metrics Glass Chemistry Seeds/stones/cords Contamination from spurious materials Volatilization REDOX Fiberization performance Fiber quality

GLASS QUALITY: 

GLASS QUALITY

GLASS QUALITY—AGY Fiberizing Trial Data: 

GLASS QUALITY— AGY Fiberizing Trial Data < Preliminary Conclusion > Zero breaks were demonstrated on fibers diameters of 7 to 13 µ. 85-90% of all commercial fiberglass is produced in diameters of 9 to 24 microns!

GLASS QUALITY—Seeds/Stones/Cord: 

GLASS QUALITY —Seeds/Stones/Cord Seed levels = 400 to 4000 ZERO STONES AND NEAR-ZERO CORDS WERE DEMONSTRATED.

Influence of Plasma Melting on Volatilization and REDOX of E-Glass: 

Influence of Plasma Melting on Volatilization and REDOX of E-Glass CONCLUSION: Volatilization is similar to “all-gas firing” but can be further optimized.

GLASS QUALITY: 

GLASS QUALITY Contamination by metals Copper oxide ~ 60 ppm Molybdenum oxide ~50 ppm High MoO3 E-Glass Normal E-Glass with MoO3 ~ 50 ppm

ENERGY EFFICIENCY—E-GLASS: 

ENERGY EFFICIENCY—E-GLASS For E-glass, we have already demonstrated 350 #/hr ~ 6MM BTU/Ton vs actual commercial furnaces using 4 to 12 MM BTU/Ton.

MARKETING STUDY: 

MARKETING STUDY Market Study Results Highest benefits of the Plasmelt Melter: Rapid changeover capability Low initial capital Low maintenance costs New Materials / New Products / New Lines

INDUSTRIAL APPLICATIONS: 

INDUSTRIAL APPLICATIONS Attributes of Plasma Melting: Flexible Ability to melt several different formulations per week Ability to melt on shifts / adjust for market demands Higher temperature capabilities than gas firing Uses electricity and can be dual fuel No / minimal refractories Low capital cost Rapid startup / shutdown Can be used for scrap glass melting Low cost melter bowl allows multiple bowls for multiple glass compositions

.BEST FIT INDUSTRIAL APPLICATONS: 

. BEST FIT INDUSTRIAL APPLICATONS Fiberglass (both continuous and insulation) Specialty glasses e.g. S-glass, frit glass, etc. New, test market products Low volume operations with multiple compositions Flexible production operational schedules High temperature glasses / materials Melter boost for commercial melters Scrap re-melt

Multi-glass Configuration : 

Multi-glass Configuration

Dual-Fuel Portable Plasma Melter: 

Dual-Fuel Portable Plasma Melter

PLASMELT’S PATH FORWARD: 

PLASMELT’S PATH FORWARD Parallel Activities: Build industrial pilot melter for AGY’s specific application (s) Seek out other glass company clients to continue to melt broad range of glass compositions and materials to broadly match US industry needs Seek partners to develop a Dual-Fuel Portable Plasma Melter for broad industry applications Seek partners to conduct refining work to lower the seed content

PLASMELT’S PATH FORWARD: 

PLASMELT’S PATH FORWARD Business Plans Seek Equity Partners Continue to support projects with our cost share partners— plasma melting and other ancillary developments Pursue already-identified business applications for plasma melting / identify new business opportunities Work with individual companies to find fastest means to get the technology implemented Seek marketing or end-user partners who can assist with commercial implementation

CONCLUSIONS: 

CONCLUSIONS Plasmelt has run a low-overhead, cost-efficient, rapid development cycle time program. We have demonstrated RESULTS from our efforts. We are now the leaders in plasma melting of glass. We have demonstrated 15 minute startups E glass of quality that can fiberize Flexible system that melts E glass, scrap, and others Capable of melting high temperature materials Dramatic torch life improvements Controlled process stability Plasmelt is now soliciting GMIC to help locate companies who can realize the benefits of plasma-melting technology.

IMPLEMENTATION OF PLASMA MELTING: 

IMPLEMENTATION OF PLASMA MELTING Estimated capital cost of melter ~ $500K Estimated time to commercialization: 12 months for glass applications 6 months for minerals/materials applications

Questions???: 

Questions???

RESULTS: Glass Quality—Chemistries : 

RESULTS: Glass Quality—Chemistries

RESULTS: Chemical Stability During 4-12-05 Trial: 

RESULTS: Chemical Stability During 4-12-05 Trial CONCLUSION: Overall chemistries were reasonably stable during this 6-hour “hands-off” production run.

Slide26: 

MILESTONES FROM ORIGINAL PLASMELT PROPOSAL

RESULTS: Plasma Melting: 

RESULTS: Plasma Melting Estimated operating costs (current)

Plasma Refiner Concept: 

Plasma Refiner Concept