Forehearths Process Control - Advanced Adaptive Process Control

The fact that physical properties of the glass as a function of temperature makes forehearth control difficult. Forehearth control is particularly important in the container glass industry where control of not only the temperature but also constant gob weight is critical. Proper control reduces the number of rejects, which in turn increases productivity and saves energy. 

BrainWave is an advanced adaptive process controller (APC) for forehearts. According to its developers, the system reduces the time required for typical control systems to settle the glass temperature by 50%, with increases in production ranging from 3.75 to 20% (for common containers) to 40% (for specialty containers). This cuts down the amount of scrapped glass and thereby reduces specific energy consumption. Maintenance requirements are also reduced. Unlike proportional, integral, derivative (PID) controls, re- tuning is not necessary for the APC system (Worrell et al., 2008. p.70).

Development Status Products
Commercial

Forehearths Process Control - Advanced Adaptive Process ControlCosts & Benefits

Parent Process: Conditioning and Forming
Energy Savings Potential

Specific energy savings are enabled due to production increases of 3.75 to 20% for common containers  and up to 40% for speciality containers (Worrell et al., 2008. p.70). 

CO2 Emission Reduction Potential
Costs

Paybacks for the advanced process controller system are estimated to be 2 to 9 months (Worrell et al., 2008. p.70).

Forehearths Process Control - Advanced Adaptive Process Control Publications

Page Number: 

70