Size the virgin raw-material batch (sand, soda ash, limestone…) for a target glass weight, with cullet (recycled glass) substitution plus estimates of batch-oxide composition and the CO₂ released from the carbonates.
OpenSize the melting area from daily pull and specific melting rate, check the forehearth pull against furnace capacity, and verify the glass residence time for a quality melt.
OpenSplits total cost into fixed and variable, gives the cost per tonne and the break-even tonnage.
OpenCompare melting specific energy (GJ/t glass) against best-available-technology and industry bands, then quantify the energy, CO₂ and cost you save by closing the gap.
OpenBalance the firing + electric-boost heat input against the theoretical melt heat, flue/shell/other losses and the unaccounted closure, and read the effective melt efficiency.
OpenEnter pull and input energy for each furnace to rank them by specific melting energy (GJ/t) against industry benchmark bands, with annual energy and fuel-cost totals.
OpenEstimate the heat recoverable from the stack at a realistic exchanger efficiency, and value the avoided fuel, CO₂ and cost over a year.
OpenCompare how to monetize recoverable stack heat — combustion-air preheat, a waste-heat boiler, ORC power or batch preheat — ranked by payback and discounted NPV.
OpenChain the levels in one loop — melting-theory floor → current heat balance → benchmark target → flue-recovery supplement → staged reconstruction → economics — and iterate year by year until the specific energy converges on the target.
OpenCompute the induced-draft (negative-pressure) fan energy for the exhaust, then split the plant's gas and electric between the melting furnace and each forehearth zone, with per-zone economics and conditioning specific energy.
OpenCompare supplying a fixed heat-in-melt duty by natural-gas firing versus submerged electrode boosting: input energy, annual cost, CO₂ and the breakeven electricity price.
OpenSeveral furnaces draw exhaust through one common flue stack under a single suction. Each induced-draft fan delivers its own flow against that head, so this apportions the shared draft energy, cost and CO₂ to each furnace.
OpenRecover heat from the flue or stack, raise steam and turn it into electricity: model gross and net output, annual revenue, displaced grid CO₂ and simple payback.
OpenPick the benchmark level you want to reach; this breaks the required cut down per heat-balance loss item, respecting each lever's realistically cuttable floor, and shows what good practice alone can close versus what needs recovery capital.
OpenAfter good practice has cut every loss lever to its realistic floor, any remaining gap must be closed with capital. This page plans that capital: flue-gas waste-heat recovery first (primary), then electric boosting tops up the rest, reporting capex, annual saving, payback per lever, total investment and the final achievable input.
OpenCompares the residence time the glass needs in the annealing (critical) and fast-cooling zones to what the lehr physically provides from belt speed, and reports whether cooling is over-fast with an over-rate index.
OpenSize the cullet mass available from your pack, apply the melt-energy credit of using cullet vs virgin batch, and value material plus energy cost savings.
OpenSizes the heat a shaft regenerator recovers by preheating combustion air with flue gas: preheat effectiveness, heat recovered per hour, annual energy, avoided fuel and simple payback.
OpenChecks the glass flow through the melting throat: required flow velocity from pull and density, versus a design maximum, giving utilization, capacity and bottleneck status.
OpenFull-electric versus gas melting: inputs, daily and annual cost, CO₂, the breakeven electricity price and the payback when the electric route wins.
OpenCO₂ = combustion (natural gas + grid electricity) plus process carbonate CO₂ scaled by cullet content. Reports per-day, per-year and per-tonne-of-glass footprint.
OpenPlans hot repairs over a furnace campaign: scheduled jobs, cumulative and annual hot-repair cost, and the cost spread per tonne of glass produced over the campaign.
OpenBuilds a cold-repair budget by zone: each furnace zone carries a replacement cost and expected life; the annualized cost = Σ cost/life, a weighted composite life, and the cost per tonne of glass.
OpenStokes rise of a refining bubble through the glass depth compares rise time with residence to estimate defoaming and prices the clarifier dose.
OpenPlans the cost of switching glass color or product: transition glass, lost production margin and scrap, and the production hours needed to recover the changeover cost.
OpenRaising the oxidant O₂ from air toward oxy-fuel removes inert nitrogen, saving fuel and cutting NOx.
OpenInfers excess air from flue O₂ and shows the stack loss you can save by tuning to a lower target O₂.
OpenCompares natural stack draft with the target crown pressure and estimates the heat lost through door gaps.
OpenConverts each fuel's price and LHV into cost per GJ, applies a utilization efficiency, and ranks by annual cost and CO₂.
OpenSlices total fuel and electricity across plant stages, with cost and CO₂ per slice and totals.
OpenBalances annual ordering cost against holding cost for one raw material: EOQ = √(2DS/H).
OpenSplits total cost into fixed and variable, gives the cost per tonne and the break-even tonnage.
OpenShows NPV and simple payback as the annual saving moves ±20% around the base case.
OpenCombines capex, discounted running cost, scheduled repairs (after start-up) and end-of-life net across a horizon.
OpenSpreads all annual cost lines (production, annealing, packing, quality, overhead) over tonnes and bottles.
OpenScores unmelted-specks, bubble, stone and cord levels against their acceptable targets into one 0-100 index, grades the melt and flags the largest driver.
OpenStokes rise of a refining bubble through the glass depth compares rise time with residence to estimate defoaming and prices the clarifier dose.
OpenFeO% and a redox index from the total iron and the reduced fraction; a reducing melt affects colour, refining and fining-foaming.
OpenFuel swap of natural gas for green H₂ by equal delivered heat: mass of H₂, the cost swing, CO₂ saved and payback.
OpenFull-electric versus gas melting: inputs, daily and annual cost, CO₂, the breakeven electricity price and the payback when the electric route wins.
OpenPick the regenerator reversal interval that balances switch fuel-loss against checker recovery.
OpenRelate the pull to the melter footprint and the batch→melt→refine temperature profile.
Open