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38 views2 pages

Naces

Ca

Uploaded by

Pawan Chavan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Mathematical Formulation and Derivation of Fuel

Consumption in Glass Melting Furnaces


Gabriele Zucchetta

August 20, 2020

1 Introduction
To calculate the fuel consumption of a furnace, the following simple formula can be employed:
C = (1 + i · n) · [C0 + Cm T · (1 − α · c)]

where:

C = Total consumption of the furnace;


i = aging index (typically set at 1.25% per year);
n = unitary aging time (in years);
T = Throughput;
C0 = Base consumption of the furnace at zero throughput (representing losses);
Cm = Consumption for melting a unit of glass (e.g., per ton);
c = Fraction of cullet relative to total throughput (ranging between 0 and 1);
α = Energy savings achieved by using cullet relative to the mix (commonly assumed to be 0.4).

This formula is applicable specically to furnaces that utilize fossil fuel (no electric boosting) .
This simplication is adopted to facilitate analysis of the simplest scenario.
From a conceptual standpoint, the equation indicates that the furnace's consumption comprises
the sum of the energy necessary to compensate for losses and the energy required to melt a unit of
glass, multiplied by the number of glass units produced. The energy saved by using cullet is then
subtracted from this total. Additionally, it is important to account for an increase in consumption
attributable to the aging of the furnace.
The purpose of this equation is to facilitate comparisons between actual and projected consump-
tions based on the parameters C0 and Cm , which are determined during the furnace's design phase.

2 Analytical development of model


Let us derive this equation to enhance our understanding. We commence with the premise that the
total consumption of a furnace comprises the consumption to maintain operational warmth plus the
consumption for producing glass from the mix (CM ) and from cullet (CR ):
C = C0 + CM + CR

We can substitute CM and CR with their respective consumptions per unit multiplied by the units
of material melted, specically Cm and Cr :
C = C0 + Cm Tm + Cr Tr

Here, Tm represents the amount of glass produced with the mix, equivalent to the mix quantity
accounting for its ring loss, while Tr denotes the glass produced with cullet, which practically does
not incur ring loss.

1
The equation thus derived, however, does not yet adopt a form that is most conducive to our
analysis. By recognizing that Tm + Tr = T (the total glass output equals the throughput), we nd
that Tm = T − Tr . Substituting this relationship into the previous equation yields:
C = C0 + Cm (T − Tr ) + Cr Tr

Continuing with simplications:


C = C0 + Cm T − Cm Tr + Cr Tr
 
Cm − Cr Tr
C = C0 + Cm T · 1 − ·
Cm T
This equation formally equates to the initial consumption formula, provided c = Tr
T and α = Cm .
Cm −Cr

Substituting these values, we obtain:


C = C0 + Cm · T · (1 − α · c)

This expression represents the initial formula where n = 0, meaning the furnace is new.
With data on C , Tm , and Tr , which respectively represent consumption, the quantity of glass
produced with mix, and the quantity produced with cullet, a two-variable linear regression can be
performed to determine C0 , Cm , and Cr . A robust dataset, ideally encompassing several dozen
observations, is necessary to produce a reliable regression, ensuring sucient variability among the
data points.

3 Conclusions
This document elaborates on the mathematical derivation of a formula to calculate furnace consump-
tion based on throughput and the proportion of cullet in the mix.
The parameters C0 and Cm are essential design metrics for the furnace, calculated by the designer
using suitable methods.
Discrepancies between actual and projected consumptions should be rigorously investigated to
ascertain their causes, thereby addressing operational issues or enhancing future furnace designs.

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