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Abstract: This paper describes the application of a model reduction technique based on
proper orthogonal decomposition for the modelling of the dynamics of an industrial glass
feeder. A technique of missing point estimation is proposed to enhance the computational
speed. For a rather complex change of operating conditions, it is shown that the method
infers low complexity models of high accuracy. Copyright 2005 IFAC
Keywords: Model reduction, proper orthogonal decomposition, industrial applications,
glass.
1. INTRODUCTION
Among many glass products, the quality and specifications of container glass mainly depends on the
operating conditions of glass melts in industrial glass
furnaces. A schematic figure of a glass furnace is given
in Figure 1. A typical furnace consists of a melting
tank, a working end and a feeder section. The feeder is
located between the refiner, where bubbles in molten
glass are released and the spout or the glass outlet point,
which consists of a dosing mechanism. In the glass melt
feeder, the temperature of the glass melt is controlled
before the glass exits at the spout where a uniform temperature distribution is desired for the forming process
of the glass products. Industrial glass melt feeders are
designed to produce glass of different colors, different
weights and different viscosity. Among many physical
variables, especially the temperature in the melt need
to be controlled very tightly both in time as well as in
each position of the feeder.
A most critical change of operating conditions of
industrial glass feeders involves a color change in
the glass melt. Indeed, such a change effects density,
viscosity, redox values, conductivity and absorption
coefficients, to mention only a few physical parameters.
TT
pO
TT
pCO
hotsp
TT
bur
refi
feed
LT
PT
pO
com
TT
TT
TT
TT
thr
TT
glass
TT
where is the density, which is temperature dependent for glass, c p is the heat-capacity, is the heat
conductivity which is also temperature dependent for
glass, and q is the external energy sources applied to
the feeder. A complete dynamical model of the feeder
is based on Navier Stokes equations for incompressible
and laminar flows (Versteeg and Malalasekera, 1995)
and includes energy conservation equations, momentum equations, and mass balance equations.
TT
g
2. THE MODEL
A schematic view of a glass melt feeder is given in
Figure 2. The spatial configuration of the feeder is
captured in a subset X of a three dimensional coordinate
system. Here, we consider an industrial feeder for
which X = [0, 8.5] [0, 0.55] [0, 2] (in meters).
Parameters
Density (kg/m3 )
Viscosity (Ns/m2 )
Specific heat c p (J/kg.K)
Heat conductivity (W/mK)
Absorption coefficient
Surface emissivity
Green container
2540 0.14T
4242.904
102.592 + T 541.8413
1222 + 0.0957T
0.527 + 0.001T + 1.8 109 T 3
367.859
0.89
Flint container
2536 0.14T
4094.950
102.490 + T 553.2733
1220 + 0.0957T
0.527 + 0.001T + 2.54 108 T 3
26.029
0.89
iI
where ai (t) := hi , T (, t)i are the (Fourier) coefficients or the modal coefficients of the expansion (2).
The existence and uniqueness of expansions (2) is
therefore the consequence of the assumption that the
snapshots belong to a space equipped with the mathematical structure of an inner product. A time averaging
operator is a linear function av : RT R with the
property that mintT f (t) av( f ) maxtT f (t).
For discrete time sets T of finite cardinality L one may
define, for instance,
1X
av( f ) =
f (t).
(3)
L
tT
n
X
(5)
i T
t i
i = 1, . . . , n.
(6)
* n
+
X
L(ai ) = R
a j (t) j (x) , i (x)
j=1
ai (t)i (x)
(4)
i=1
n
X
a i (t)i (x),
x X0
(7)
i=1
(8)
(9)
x X.
n
X
r =1
(10)
Then, for k = 1, . . . , K , define ek by setting:
ek :=k E(xk ) k
(11)
a i (t)i (x),
i=1
Zone 2(K)
n
X
Zone 3(K)
Tn (x, t) =
Zone 4(K)
10
0
10
0
5
20
40
60
80
100
120
20
40
60
80
100
120
20
40
60
80
100
120
20
40
60
time (minutes)
80
100
120
0
5
0
10
0
10
0
10
0
10
0
L X
L
X
E i2j .
i=1 j=1
4. RESULTS
4.1 Collection of data
The color change will significantly change the physical
properties of the glass melt. If green container glass
melt is replaced by flint (transparent) container glass
melt, the heat conductivity will change by a factor
8. The reduced order model will need to take these
significant changes into account. If the reduced order
model is derived from simulation data where the color
change from green to flint is not simulated, then the
7
6
T (K)
5
4
3
original
reduced
2
1
0
0
20
40
60
80
time (minutes)
100
4.242
Ordered ex
4.244
120
4.24
4.238
less relevant
ex
T (K)
4.234
4.23
original
reduced
4.228
4.226
0
0
20
40
60
80
100
120
4.224
0
time (minutes)
0.08
0.07
glass
wall
0.06
0.05
0.04
0.03
0.02
0.01
500
1000
1500
2000
2500
3000
3500
500
1000
nth point
1500
2000
relevant
4.232
4
3
0
0
4.236
4000
6
5
T(K)
4
3
original
POD
MPE665
MPE465
2
1
0
0
20
40
60
80
100
120
100
120
time (minutes)
Temperature T at the surface
2
9
8
7
T (K)
5
4
original
POD
MPE665
MPE465
Despite the reduction of complexity, the reduced order model turns out to be about 2.3 times faster in
calculation time than the original model. To construct
a faster reduced order model, the method of missing
point estimation (MPE) as described in section 3.2 is
applied.
The selected points X0 of the spatial grid consists
of the union of two sets. The first being all points
adjacent to the points in which on which the crown
temperature, inlet temperature and pull rate are defined
(the excitation points in the feeder, 265 in total).
2
1
0
0
20
40
60
80
time (minutes)
Model
Type
POD
MPE-665
MPE-465
Maximum average
Absolute error
0.081 C
0.082 C
0.13 C
Computational
gain
226%
527%
754%
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
0
10
20
30
40
50
60
time (minutes)
5. CONCLUSIONS
This paper discusses the reduced order modelling of
a glass melt feeder for estimations of the temperature
distribution in the glass melt and in the refractory walls.
The method of proper orthogonal decomposition is
applied to the original feeder model and the results
show excellent performance of a reduced order model
consisting of only 18 modes.
Temperature (K)
1472
1470
Sensor position 1
1468
1466
1464
0
10
20
30
40
50
60
time (minutes)
1474
Temperature (K)
original
MPE
1472
Sensor position 2
1470
1468
1466
1464
0
10
20
30
time (minutes)
40
50
60
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of Technology. Department of Electrical Engineering.
Astrid, P., S. Weiland, K.E. Willcox and A.C.P.M.
Backx (2004). Missing point estimation in models
described by proper orthogonal decomposition.
In: Proceedings of the 43rd IEEE Conference on
Decision and Control. Bahamas.
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Glass Technology. Eindhoven.
Bird, B.B., W.E. Stewart and E.N. Lightfoot (1960).
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York.
Gnther, R. and J. Currie (1980). Glass-melting tank
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technology.
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Cambridge.
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Manual, version 2.2. TNO Institute of Applied
Physics. Delft.
Stanek, J. (1977). Electric Melting of Glass. Elsevier.
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