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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
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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
O
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
9
MWh
9
0
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%
Units
Holding Heat
Batch Glass
Cullet Glass
%
*
Value
0
153
148
Energy
Age
%
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Item
Fossil Energy Input - daily input
Specific Energy consumption (SEC)
0
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1.62
Units
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SEC (MWh/t)
1.8
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50% Cullet
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1.6
1.5
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300
320
340
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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)
2
Use the "Input Sheet" to ammend (if required) default values of sand moisture, cullet moisture, furnace ageing factor and furnace age
3
The programme will automatically calculate the relationships between furnace energy and the various parameters
4
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
0
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
9
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)
!
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