3. World Glass
4000 years history
• Sars-Poteries, France: 200 glass factories
20th Century. Today a few hot shops and a
Glass Museum
• Barcelona, Spain: 0 Hotshops, Centre del
Vidre closed down furnace, 4 production
hotshops left in the country
• Paris, France: 24 hotshops in 2004
dramatically dropped to 2 current artist
hotshops in the city.
• Murano, Venice: Glass factories closing due
to high operations costs and Chinese
competition
5. modern challenges
• Waterford crystal-- 750 tons glass/year closed after 226 years-
reopened as a tourist destination
• Stuben closed after 109 years production
• Glass community: individual shops closing due to hardships
• Blenko Glass, Caramea, and many others closing to high overhead
costs
Time for new opportunities? New inventions?
7. Calculate your
efficiency….
Cam Ocagi: Istanbul Saves 45%
of fuel usage and cost due to
good equipment, new habits,
closing new furnace doors!
Furnaces with Recuperators and
Variable Speed Blowers, and
GOOD Insulation =
11. ReCycle: Kauai Recycling for the Arts, Tulane Univ,
Maho Bay Resort, The Crucible Green VI Tortola
QuickTime™ and a
TIFF (Uncompressed) decompressor
are needed to see this picture.
12. Landfill Arts Centers
Energy Xchange- North Carolina
OVCE -Kentucky
Jackson County Green Energy Park
- North Carolina
Colma Landfill Project- California
16. • New Equipment
• 1000lb Furnace
• recuperator system
• nozzle mix burner that
introduces air in stages
to reduce NOx
emissions
• Ceramic Burner Block
takes hig temp pre-
heated air
• 500,000 btu/hr burner=
50% reduction gas
• Charge 150lbs in 1.5 hr
17. BioGlassTM OBJECTIVE:
The research and development of eco-efficient studio glassmaking techniques
• World
Overview
• Efficient
Studio
Practices
• Community
Resource
Sharing
• Recuperation
and Re-Use
• Alternative
Fuel
Sources:
elec/vo/(?
• Keeping
track of
innovative
and green
glassmaking
studios
18.
19. Kitengela Glass- Kenya Africa
GreenVI Tortola British Virgin Islands
Canberra Glassworks, Australia
Oaxaca, Mexico
20. 4000 years….
• What is the future of Studio Glass?
1350 BC
200 AD
1920 AD
2011 AD
21. • getting involved is your opportunity
to make a difference for the
glassmaking community?
Glass Art Society
www.glassart.org
www.bioglass.org
info@bioglass.org
facebook: BioGlass: Eco Efficient Glass Making
22. Energy Savings = Money Savings
• Community Shops
• Recuperation
• Electrical- Solar offset?
• Wood-fired
• Recycled Glass
• Methane Landfill
• Bio-digesters
• Thermal Cascade/ Use
• BioDiesel- alt fuels
28. Previous Glass Furnace
1000 pound capacity
Traditional tiled liner
1.5 MBTU/Hr Thermjet burner
Rebuild interval 2 ••• to 3 years
New Glass Furnace
WET DOG RDT1000
1000 pound capacity
Round monolithic liner
Highly Insulated
750 KBTU/Hr Thermjet burner
Recuperated preheat of combustion
air
Onboard variable speed blower for
combustion air
Estimated rebuild interval 6 to 8
years
GRANT $ Money and Applications for Change
Furnace Gas Usage Comparisons Traditional 1000# Tank Wet Dog RDT1000
Therms/Hour @ Idle 1.29 .84
Therms/Hour @ Charge 3.3 2.11
Total Annual Therms 14818 9581
Utility Cost Comparisons
Traditional 1000# Tank & glory hole combustion
Feb 2008-Jan 2009
12 month averaged cost/month $5,045
Total Annual Cost: $60,540
-----------------------------------------------------------------------
Wet Dog RDT1000 and upgraded glory hole combustion
Feb 2012 – Jan 2013
12 month averaged cost/month $3,374
Total Annual Cost: $40,493
Project Costs and Funding
Furnace installations costs $56,026
Glory hole change over costs $6,872
PSE Custom Grant $39,218
4Culture Support $20,000
Used Equipment Sales $3,000
Net installation costs $680
example: Pratt Fine Arts Center
35. Green Initiatives @IGNITE STUDIOS
Ignite is committed to improving our
environmental
foot print. Our facility won the AIA
Sustainable
Design award in 2013. !
We will continue to become more “green”
but in the
meantime, we have invested in: !
740 lb round day-tank with recuperator
2 x 80 lb crucible furnace with recuperator
Programmable VSDs for our main exhaust
fans
Rotary screw air compressor with a VSD !
We have switched our batch to cullet,
reducing
charging times and temperatures needed to
create
beautiful glass art.
LEED CERTIFIED BUILDING
37. XAQUICHE
work station 3 GH, pipe warmer, pick
up oven, recuperation and multi fuel
capability; propane, methane,
hydrogen and veggie oil. Rated at
250,000 btu XAQUICHE
The other is our
typical two door
melting furnace. We
work from the
furnace, there is an
optional cap for the
glory hole entrance
for when we are in
other types of
production. It is
rated at 400,000 btu
multi fuel; propane,
methane, hydrogen
and or veggie oil
AND recuperation
which feeds the
burner, annealing
ovens, oil preheat
and water heater.
41. Durk Valkema
Durk Valkema comes from a well-known family of glass artists in
the Netherlands. He attended the Gerrit Rietveld Academie in
Amsterdam and worked with Stanislav Libenskỳ at the Academy of
Applied Arts in Prague.
Through his broad technical and practical knowledge, in
combination with aesthetic insight, Valkema acts as a sounding
board in the development of competitive and technically innovative
design for both art glass and product design. He specializes in
designing and building cost-effective, fuel-efficient furnaces,
annealing kilns, and related equipment.
Corning Fellow
47. This is a simple finned tube heat exchanger over a 12” glory hole
with doors closed during the entire test period. Below are
calculations describing heat reclaimed in the water pumped through
the heat exchanger. With another row of finned tube above the
existing one, even greater reclamation is possible.
40 gal water x 8.34 lbs/gal=333.6 lbs water.
First hour 70F to 120F=50F rise as gh went from room temp to
operating temp=16,680 Btu/hr=4,887W reclaimed with 92W pump.
Second hour 120F to 150F=30F rise as gh began to stabilize in
temp=10,008 Btu/hr=2,932W
Third hour 150F to 180F=30F rise as gh began to stabilize in
temp=10,008 Btu/hr=2,932W
Pressure relief valve opened.
Put in financial terms, the reclamation of this heat when used in
place of electric heat:
Note: this is based on electrical unit cost of $0.12 kWh. Savings will
vary with electrical cost.
4,887W reclaimed per hour for one hour=4.887kWh x
$0.12/kWh=$0.586/hr
Cost of running water pump=.092 kWh x $1.12=$0.011/hr.
Net gain at $0.12/kWh=$0.586/hr (reclaimed) minus $0.011/hr
(expended by pump) =$0.575/hr.
For eight hours a day over a glory hole, that’s $4.60/day x 24 days a
month=$110.40/mo. (assuming heat is pulled back out of water for
space heating, etc.)
Innovation -- New Technology/ Applications
48. These are images of our automated flue damper
system. It works by measuring the pressure inside
the flue and then opening or closing proportionally to
maintain a stable pressure in the furnace. When the
furnace goes to high fire, the pressure inside the
furnace rises and the damper opens. When it goes
to low fire, the pressure drops and the damper
closes. Anywhere between low and high fire will
cause the damper to be somewhere between open
and closed.
This system can reduce fuel consumption by about
5% compared to not using one. Maintaining positive
pressure in the furnace also helps prevent cold air
infiltration through the door and can help with other
issues such as emissions and glass quality as well.
49. Pilchuck Glass
School:
digital data
collecting /
recuperators
Pilchuck’s initial steps towards this goal begin with the plan for
redesign of efficient furnaces, glory holes and annealers for the
blowing studios. Over the past year PGS has installed “sage” flow
meters and data capture system (Hobo-USB data logging) on their 2
furnaces and glory holes to study and analyze gas usage and
energy costs. This information is being used to support future
decisions to rebuild and redesign the casting shop and hotshop to
meet programmatic needs.
52. MARY WHITE:
RECYCLED GLASS EDUCATION
teaching "re use" practice:
a forum for discussion on
sustainable practice,
environmental activism
glass chemistry and engineering
61. CONNECT.....
Julie Conway info@bioglass.org
BIOGLASS.ORG
Chris Clarke
PITTSBURGH GLASS CENTER www.pittsburghglasscenter.com
please let us know what you are doing for eco-efficient glass studio practice
JCGEP.ORG
ENERGYXCHANGE.ORG
PITTSBURGHGLASSCENTER.ORG
PRATT.ORG
PILCHUCK.COM
GREENVI.ORG
XAQUICHE.COM
SPIRALARTS.COM
SIMONPEARCE.COM
VALKEMA.COM
CORRELLGLASSSTUDIO.COM
KITENGELA GLASS KENYA
KETTLERIVERARTS.ORG
BIGISLANDGLASS.COM
THE CRUCIBLE.ORG
URBANGLASS.ORG
WETDOGGLASS.COM
STARWORKSNC.ORG
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BioGlass: Eco Efficient Glass Making
