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Nippon Gases Confidential

Joint Meeting of DGG – USTV13 – 15. May 2019 Nürnberg (Germany)

Operation data from OPTIMELT™ Heat Recovery Systemon a Tableware Glass Furnace

at Libbey Leerdam

de Diego J.****; van Valburg M.*; Schuurmans F.*; Sperry E. **, Vetter J.***

* Libbey Royal Leerdam** Libbey Inc.

*** Nippon Gases Germany**** Nippon Gases Euro-holding

LIFE15 CCM/NL/000121 - LIFE OPTIMELT


Change the world with us

2Outline

- OPTIMELT Technology. Short explanation

- OPTIMELT Project at Libbey Leerdam. Furnace Discussion

- Project Introduction

- Project description

- OPTIMELT Project at Libbey Leerdam. Furnace Data

- Preliminary Results

- OPTIMELT Project at Libbey Leerdam. Furnace Experience




3OPTIMELT™ Technology I- High efficiency non-catalytic reforming process

- Reforming of natural gas in regenerators recovers twice as much heat from the flue gas of oxy-fuel furnaces as just preheating oxygen/fuel

- Regenerative system takes advantage of high operations temperatures

- Recycled flue gas contains CO2 and H2O needed for endothermic CH4 reforming

- Hot syngas is burned with oxygen in the furnace2CH4 + H2O +CO2 3CO + 5H2

CH4 + H2O CO + 3H2 2060 kcal/Nm3 CH4 + CO2 2CO + 2H2 2630 kcal/Nm3

Oxy-fuel Glass Furnace

Flue Gas Recycle (~20%)

FLUE GASCO2+2H2O

O2

REGENERATORS

NG (CH4)

Hot Syngas~1250°C ~2300°F

Flue gas~1500°C~2700°F

1

2




4OPTIMELT™ Technology II

Injection of Natural Gas into Flue Gas Recirculation

Preheating of Mixture

Endothermic Reaction to Syngas (CO and H2)

Hot Syngas to Furnace




5OPTIMELT™ Technology III

HeatingRegenerator

ReformingRegenerator

Combustion of Syngas with Oxygen jets




6

OPTIMELT Project at Libbey LeerdamFurnace Discussion




7OPTIMELT Project at Libbey Leerdam - Libbey’s Goals

- Best-in-class furnace technology to reduce energy consumption and lower emissions

- Support of Libbey’s sustainability strategy and alignment with European carbon reduction roadmap

- Positioning Leerdam location for the sustainable production of premium tableware products

- Changes at Libbey Leerdam plant- From recuperative to oxy-fuel combustion

- OPTIMELT technology as highest potential in energy saving compared to other existing waste heat recovery options


1 x OPTIMELT System2 x Recuperative Furnaces


Change the world with usLIFE OPTIMELT Project Timeline - Oxy-fuel furnace in operation since May 2017- OPTIMELT continuous operation January 2018- Frequent project updates at http://www.lifeoptimelt.com

FirstSyngas

Today projectstatus


8



9OPTIMELT Project - System Description I

- Side-fired oxy-fuel furnace with two end-port TCR- Cycle time typically 20 min. Possible 30 min.- Oxy-fuel system always on stand-by

TCR SkidOxy-fuel

Skid

Regen Left

Natural Gas

Oxy-Fuel Flue Gas

Oxy-FuelOPTIMELT

RFG Skid

RFG ~20%

Safety Skid

Regen Right

Oxygen




10OPTIMELT Project - System Description II


Oxy-Fuel Port Neck

Downcomer for Flue Gas

OPTIMELT Port Necks

Right/Left Regenerator

OPTIMELT Flue Gas Skid

3 OPTIFIRE JL Oxy-fuel Burners


Change the world with usOPTIMELT Project - System Description III

Oxy-fuel flames nearly invisible at IR camera image

Oxy-fuel Burners Oxy-fuel BurnersOPTIMELT Ports

High luminosity flame / More effective heat transferFoam disappears under OPTIMELT flame


Oxy-Fuel Mode Flames OPTIMELT Syngas Flame

11



12OPTIMELT Project – Final Installation




13

OPTIMELT Project at Libbey LeerdamFurnace Data




Best-in-class furnace. Reduce Energy & emissions

60 65 70 75 80 85 90 954

4.5

5

5.5

6

6.5

Fue

l Co

nsu

mp

tion

[GJ/

ton

]

Pull [tpd]

OxyOPTIMELTEstimatedToday

Overall Fuel Consumption with Pull


Cross-firedEnd-portOxy-fuel

OPTIMELT™



15Key Parameters Affecting Fuel Savings

- Basic input parameters- Fuel & Oxygen quality variation and flow measurement

- Charge rate and quality variation

- Batch composition and moisture

- Cullet ratio and moisture

- Operating parameters and condition - Throat temperature (linked to Furnace temperature)

- Flame profile (Oxy-fuel firing profile or OPTIMELT flame shape)

- Excess O2

- Ambient temperature

- Cycle time affects oxy-fuel firing

- Furnace pressure affects air infiltration




16Normalization Parameters

- Throat Temperature- Fuel consumption in the distributor depends on throat temperature, the same throat temperature should be used for

comparison

- If different throat temperatures are used, then fuel consumption in distributor should be included for comparison

- Batch/Cullet Moisture- Batch & Cullet moisture could be influenced by weather. Is controlled?. Which % to be used?

- +1% moisture increase in cullet ==> increases fuel consumption by 0.8% for oxy-fuel and 0.6% for OPTIMELT

- VPSA O2 purity- Normalization at 91% O2 is recommended

- Ambient temperature effect: - NG & O2 temperature drops by 10 C (less heat available)- Batch/cullet temperature drops by 10C (more heat required)- Furnace wall cold face temperature drops by 10C (more heat loss)




17Key Parameters Affecting Fuel Savings I

21-12 09-02 31-03 20-05 09-07 28-08 17-10 06-12 25-01 16-03 05-050

1

2

3

4

5

6

7

8

9

10

O2 C

on

cen

tra

tion

(%

)

Date (dd-mm)

Averaged daily O2 Concentration at the fan inlet


Averaged daily Glass Bottom Temperature TDL0101R

Throat temperature is a result of the target glass quality = < 0,03 seeds/gr

21-12 09-02 31-03 20-05 09-07 28-08 17-10 06-12 25-01 16-03 05-051310

1320

1330

1340

1350

1360

1370

Tem

pera

ture

[o C]

Date (dd-mm)



18Key Parameters Affecting Fuel Savings II

Averaged daily gas inlet temperature of NG and O2

21-12 09-02 31-03 20-05 09-07 28-08 17-10 06-12 25-01 16-03 05-050

5

10

15

20

25

30

35

40

Date (dd-mm)

NG

Inle

t te

mp

era

ture

[o C

]

O2 NG

Averaged daily crown temperature profileLegend: blue=OPTIMELT:Feb-Apr, margenta=Oxy:Apr-Jun,red=OPTIMELT:Jun-Aug, black=Today

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 110001320

1340

1360

1380

1400

1420

1440

1460

1480

1500

1520

Tem

pera

ture

[o C]

Location [mm]




OPTIMELT – Positive Experience - Energy- Good energy results

- Goal, recuperative / OPTIMELT energy reduction of 54 %

- We are at 53% reduction on energy consumption

- Goal, Oxyfuel / OPTIMELT 15 % reduction (80 TPD production)

- We are at 13,5 % reduction on energy consumption. Can be reached by further tuning of the process

4517

4620

5314

9728

0 2000 4000 6000 8000 10000 12000

GOAL

OPTI

OXY

RECU

ENERGY L1 MJ/ton

~13,5%~ 53%

0,3

0,27

0,32

0,55

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

GOAL

OPTI

OXY

RECU

CO2 L1 kg/ton

~ 16%~ 51%


19



OPTIMELT – Positive Experience - Quality- Glass quality can be met

- Identified lowest possible furnace temperature for good quality

- Slight differences in operation to achieve glass quality with OPTIMELT

- No production losses during all project!

8

9

9

7

6 6,5 7 7,5 8 8,5 9 9,5 10

GOAL

OPTI

OXY

RECU

GLASS COLOR

0,03

0,02

0,01

0,035

0 0,01 0,02 0,03 0,04 0,05

GOAL

OPTI

OXY

RECU

GLASS QUALITY seeds/gram


20



OPTIMELT – Positive Experience - Emissions- Excellent emission results

- 50-90% reduction vs. L7/L9 achieved in all emissions

- OPTIMELT emissions lower than Oxy-fuel

0,9

0,38

0,4

1,6

0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8

GOAL

OPTI

OXY

RECU

NOx L1 kg/ton

0,5

0,19

0,23

0,94

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

GOAL

OPTI

OXY

RECU

SOx L1 kg/ton


21



22

OPTIMELT Project at Libbey LeerdamFurnace experience



Change the world with usL1 OPTIMELT – Lessons Learned- Condensation in cold parts of ducts

- Lower OPTIMELT exhaust temperature makes condensation more challenging –redesign of air dilution system

- Regenerator design/construction and seal at port neck

- Seal of regenerators against air inleakage at the bottom and syngas leak at the top not easy – solved with additional effort

- Energy recovery a little less than expected and requires further optimization

- Air inleakage must be minimized

- Heat loss in regenerators limits recoverable energy – add better insulation for skew lines and doors

- Traditional regenerator design not a good choice

- Difficult to seal

- High heat loss from supporting structure and skew lines

No fundamental issues encountered – system operates well


23

Integrated outside support & seal structure is better



24Inspection September 2018

- Port Necks, Regenerator and RFG Ducts inspected after 10 months- Very little deposits on walls and checkers- Checker passages completely free- Clean checkers suggest possible self-cleaning process?? Thermodynamic analysis with Celsian to confirm

Right Regenerator. Crown Right Regenerator. Checker TopRight Regenerator. Bottom


[email protected] CCM/NL/000121 - LIFE OPTIMELT

The support of this project by the European Union is gratefully acknowledged

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