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The Carbon Trust - Cullet Energy Study

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200
150
100
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270

290

310

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The Carbon Trust - Cullet Energy Study

5
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y = 0.5417x + 124.57

Base Data

R2 = 0.683

Fuel input (MWh/day)

260
240
220
200
180
160
140
140

160

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200

220

240

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The Carbon Trust - Cullet Energy Study

Option 1

Calculated Fuel Input

y = 0.5417x + 124.57
R2 = 0.7958

Fuel input (MWh/day)

260
240
220
200
180
160
140
140

160

180

200

220

240

Furnace Load (tonne/day)

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Minimum Fuel Input

y = 0.5529x + 120.19
R2 = 0.7714

Fuel input (MWh/day)

260
240
220
200
180
160
140
140

160

180

200

220

240

Furnace Load (tonne/day)

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Input Data
Item
Furnace Load
Electric Boost
Nominal Cullet
Sand moisture
Cullet moisture
Age

Value
300
0
50
6
5
36

Units
tpd
MWh
%
%
%
months

Calculated Data
Item
Glass
Boosted glass
Glass
Virgin Glass produced
Cullet used

tpd
tpd

237
132
98

MWh
MWh
MWh

Moisture

Sand
Cullet

2.1
5.9

MWh
MWh

MWh

"6
;
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+

Total

Units

Holding Heat
Batch Glass
Cullet Glass

Value
0
153
148

Energy

Age

1)

& 3

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9!7
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Item
Fossil Energy Input - daily input
Specific Energy consumption (SEC)

Value
485
1.62

Units
MWh
MWH/t

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The Carbon Trust - Cullet Energy Study

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Furnace Load vs Model Predicted SEC

SEC (MWh/t)

1.8

30% Cullet

50% Cullet

1.7
1.6
1.5

70% Cullet

1.4
240

260

280

300

320

340

Furnace load (tonnes/day)

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Appendix 1

Instruction Sheet

page 1

Cullet Furnace Energy Model

This spreadsheet programme is designed to predict furnace enegy consumption based on historical data
The programme allows changes the operator to invesigate the infulence on furnace energy consumption of the following variables:
Furnace load
Cullet level
Sand moisture
Cullet moisture
Furnace age

Instructions
1

Use the "Input Sheet" to enter daily values of >>>

Furnace
Load
(tpd)

Cullet

Gas

Boost

(%)

(MWh)

(MWh)

Use the "Input Sheet" to ammend (if required) default values of sand moisture, cullet moisture, furnace ageing factor and furnace age

The programme will automatically calculate the relationships between furnace energy and the various parameters

Input the furnace conditions for which en energy prediction is required

The Carbon Trust - Cullet Energy Study

Appendix 1

Data Input Sheet

Page 2

Insert daily furnace data below

Data below is automatically calculated from the input data

The following data will be used as default but may be overwriten

Sand moisture
Cullet Moisture
Furnace aging factor
Furnace age

4
1
2
24

%
%
% deterioration per year

months

Cullet

Gas

Boost

(%)

(MWh)

(MWh)

Average

304

24

479

1
2
3
4
5
6
7
8
9
10
11
12
13
14

279.6
300.3
300.3
300.3
310.5
310.5
310.5
298.5
310.4
310.3
299
297.7
297.7
297.7

40
40
40
40
40
40
40
40
40
40
40
40
40
40

434.5
465.9
455.3
470.4
479.0
474.0
472.6
459.7
460.8
450.2
430.1
438.3
439.1
451.0

0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0

0.867
0.0756
0.4813

0.665
0.0823
14.6047

237
22.90
#N/A

0.90556

0.1588

2) age factor

Input default
values - can be
varied
Furnace
Load
(tpd)

1) furnace holding heat and cullet constants

Programme
calculates:- Holding
Heat, Batch and
Cullet constants

Programme
calculates age
factor

Input data:Load, Cullet, Fossil

Fuel and Boost

-0.234

Load
Cullet
Virgin
(less boost)(less boost)(less boost)
(tpd)
(tpd)
(tpd)
0.686
304
72
232
1
2
3
4
5
6
7
8
9
10
11
12
13
14

280
300
300
300
311
311
311
299
310
310
299
298
298
298

112
120
120
120
124
124
124
119
124
124
120
119
119
119

168
180
180
180
186
186
186
179
186
186
179
179
179
179

)$

"

The Carbon Trust - Cullet Energy Study

Appendix 1

Data Input Sheet

Page 3a

Cullet Furnace Energy Model

Methodolgy
Tabel 1

Calculated data from historical records

Regression Analysis
Item
Holding Heat
Batch Constant
Cullet Constant

Table 2

Units
MWh
MWh/tonne
MWh/tonne

Default values (can be overwritten)

Base Data
Item
Sand moisture
Cullet moisture
Age
Age Factor
Cullet base
Table 3

Value
237
0.867
0.665

Value
4
1
24
4
45

Units
%
%
months
% hh/year
%

Value
300
0
50
6
5
36

Units
tpd
MWh
%
%
%
months

Input data to obtain predicted fuel consumption

Input Data
Item
Furnace Load
Electric Boost
Nominal Cullet
Sand moisture
Cullet moisture
Age

)+

"

The Carbon Trust - Cullet Energy Study

Appendix 1
Table 4

Data Input Sheet

Calculation Routine

Calculated Data
Item
Glass
Boosted glass
Glass
Virgin Glass produced
Cullet used

Value
0
153
148

Units
tpd
tpd

Energy

Holding Heat
Batch Glass
Cullet Glass

237
132
98

MWh
MWh
MWh

Moisture

Sand
Cullet

2.1
5.9

MWh
MWh

MWh

Value
485
1.617

Units
MWh
MWH/t

Age

Table 5

Page 3b

Predicted Energy and SEC values

Total

Item
Fossil Energy Input - daily input
Specific Energy consumption (SEC)

"