LBNL-57335-Revision

ERNEST ORLANDO LAWRENCE

BERKELEY NATIONAL LABORATORY

Energy Efficiency Improvement

® Guide for Energy Environmental Energy Technologies Division and Cost Saving Opportunities for the Glass Industry An ENERGY STAR and Plant Managers Ernst Worrell, Christina Galitsky, Eric Masanet, and Wina Graus Sponsored by the U.S. Environmental Protection Agency March 2008

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This document was prepared as an account of work sponsored by the United States

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not necessarily state or reflect those of the United States Government or any agency

thereof, or The Regents of the University of California.

Ernest Orlando Lawrence Berkeley National Laboratory is an equal opportunity

employer.

LBNL-57335-Revision

Energy Efficiency Improvement and Cost Saving Opportunities for the

Glass Industry

An ENERGY STAR® Guide for Energy and Plant Managers

Ernst Worrell, Christina Galitsky, Eric Masanet, and Wina Graus

Energy Analysis Department

Environmental Energy Technologies Division

Ernest Orlando Lawrence Berkeley National Laboratory

University of California

Berkeley, CA 94720

March 2008

This work was funded by U.S. Environmental Protection Agency’s Climate Protection Partnerships Division as part of ENERGY STAR. ENERGY STAR is a government-backed program that helps businesses protect the environment through superior energy efficiency. The work was supported by the U.S. Environmental Protection Agency through the U.S. Department of Energy Contract No. DE-AC02-05CH11231.

Energy Efficiency Improvement and Cost Saving Opportunities

for the Glass Industry

An ENERGY STAR Guide for Energy and Plant Managers

Ernst Worrell, Christina Galitsky, Eric Masanet, and Wina Graus

Energy Analysis Department

Environmental Energy Technologies Division

Ernest Orlando Lawrence Berkeley National Laboratory

March 2008

ABSTRACT

The U.S. glass industry is comprised of four primary industry segments—flat glass, container glass, specialty glass, and fiberglass—which together consume $1.6 billion in energy annually. On average, energy costs in the U.S. glass industry account for around 14% of total glass production costs. Energy efficiency improvement is an important way to reduce these costs and to increase predictable earnings, especially in times of high energy price volatility. There is a variety of opportunities available at individual plants in the U.S. glass industry to reduce energy consumption in a cost-effective manner. This Energy Guide discusses energy efficiency practices and energy-efficient technologies that can be implemented at the component, process, system, and organizational levels. A discussion of the trends, structure, and energy consumption characteristics of the U.S. glass industry is provided along with a description of the major process steps in glass manufacturing. Expected savings in energy and energy-related costs are given for many energy efficiency measures, based on case study data from real-world applications in glass production facilities and related industries worldwide. Typical measure payback periods and references to further information in the technical literature are also provided, when available. The information in this Energy Guide is intended to help energy and plant managers in the U.S. glass industry reduce energy consumption in a cost-effective manner while maintaining the quality of products manufactured. Further research on the economics of the measures—as well on as their applicability to different production practices—is needed to assess potential implementation of selected technologies at individual plants.

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Table of Contents

1. Introduction.....................................................................................................................1

2. The U.S. Glass Industry..................................................................................................3

3. Process Description.........................................................................................................8

4. Energy Use in Glass Making........................................................................................14

5. Energy Efficiency Improvement Opportunities............................................................23

5.1 Energy Management Systems and Programs.........................................................26

5.2 Compressed Air.....................................................................................................29

5.3 Motors....................................................................................................................37

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