7 nihon yamamura - control system for batch pile · 2017-09-19 · 4/9/2017 1 “evaluation of...

4/9/2017

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“Evaluation of Control System for Batch Pile

Inside Furnace with Catch Image Camera”

2012/9/26AFGM in VietnamNihon Yamamura GlassMichihiro Andoh

*Batch pile: Glass material before melting2012/9/26 AFGM in Vietnam

Content

* Introduction of Nihon Yamamura Glass

1. Course of Development2. Outline of Glass Furnace3. Outline of the Equipment4. Performance of the Equipment5. Conclusion

2012/9/26 AFGM in Vietnam

Founded as Yamamura Glass Works (1914)

1955 Incorporated as Yamamura Glass1960 Machine Department (now Engineering Co.) established1961 Tokyo Plant completed and production starts1972 Recycling business started1980 Harima Plant completed and production starts1989 Merger with Hiroshima Glass Kogyo Co. Ltd (now Osaka

Plant)1991 San Miguel Yamamura Asia Corporation established1998 Merger with Nihon Glass Co. Ltd. (now Saitama Plant)

to form Nihon Yamamura Glass

2014 Centennial Anniversary !

History of Glass Bottle CompanyHistory of Glass Bottle Company


Yamamura Warehouse Co.,Ltd.

Yamamura Glass WorksCo.,Ltd.

Yamamura Kosan Co.,Ltd.

New GlassResearch Center

PlasticsPlasticsCompanyCompany

EngineeringEngineeringCompanyCompany

New GlassNew GlassCompanyCompany

Glass BottleGlass BottleCompanyCompany

Overseas PartnersJoint Venture Companies

Seisho Co.,Ltd.

Glass Studio Yamamura Co.,Ltd.

Nissho Seiki Co.,Ltd.Nissho Keisha Inc.

Yamamura Photonics Co.,Ltd.


Business ActivitiesBusiness Activities

MTC: Automatic Mould Temperature Control

Decorated Bottles

Manufacture and sales of glass bottles and related glass equipments

Ultra-lightweight bottles

Unique bottle designs

Decorated Bottles

GMW: Gob Measurement and

Weight Control


Production PlantsProduction Plants

Production Plants

Harima Plant Osaka Plant

Saitama Plant

Tokyo Plant

KansaiHead Office

All Plants are:Certified ISO 9001 in 1998Certified ISO 14001 in 2000

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NYG Glass Bottles: Overseas Partner & Affiliate

Kumbi Corporation(South Korea)

SMYHG (Vietnam)

SMCSMYPC, SMYPIL (Packaging)SMYFMC (Glass Molds)SMYAC (Glass) (Philippines)

Yamamura International (Shanghai) Co., Ltd.

(Sales Company/China)

Mulia Glass (Indonesia)

Affiliate, JV, Technology Assistance,

YOS (Sales Company/Thailand)Osotspa Co., Ltd. (Thailand)Siam Glass (Thailand)


1. Course of Development

INTRODUCTION

� Stability is a very important factor for furnace operation.

� Operator adjusts some parameters tosuppress various agitation in the process.

� I developed a new batch pile control system, that will automate the system that relies on the operator’s experience.


1. Course of developmentPurpose・Improvement of glass quality

to prevent the batch pile from going to the throat side, to reduce occurrence of seed.

・Improvement of energy efficiencyto improve heat transfer rate to batch pile for better energy efficiency.


1. Course of Development2009 Apr Start of development

Jul Planning of specs2010 Mar First trial at Harima#3F

Application of patentSep Start of operation

2010 Dec Identify of quality improvement2010 Sep Reduce of operation temperature2012 Jan Identify of reduce temperature


2. Outline of Glass Furnace

蓄熱室

ポート

スロート

大迫

チェッカーフォアハース

作業室

バッチ投入口

溶解室

Glass melting furnace

WE

Throat

Forehearth

MECrown

DH

Port

Checker Regenerator

TV Camera

*ref: PSR catalogue2012/9/26 AFGM in Vietnam


WE

Throat

Forehearth

ME

Crown

Dog House

Port

Checker

Regenerator

TV Camera TV Camera

Glass Melting Furnace

*ref: PSR catalogue

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Furnace firing of right and left-side with a uniform amount of time

Left firing Right firing



The raw materials that are charged in a melting furnace, and move slowly in a certain direction depending on the charging system are called “Batch pile”. During furnace reversal



Bad condition Good condition

Batch are split into small piles and are distributed over the DH side.


2. Outline of Glass Furnace Seed count is important index regarding glass

quality.①Na2CO3（Soda ash）→Na2O＋CO2②CaCO3（Lime stone）→CaO＋CO2When batch piles get closer to the throat, amount of seed increases.

DH FH

TH


2. Outline of Glass FurnaceOscillating type batch charger (OBC)

Oscillating？Move to right and left side like a

pendulumPictures source: http://www.zippe.de/batch-chargers-for-glass-melting-furnaces.html


2. Outline of Glass Furnace Movement of batch charger

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2. Outline of Glass Furnace The setting condition of batch charger

Vibrating feeder

Charging direction2012/9/26 AFGM in Vietnam

2.Outline of Glass Furnace Adjustment of Batch charger

Adjustment of batch pile by adjusting the stop timer.

Leveler

Output% of charger

Factor of R&L

Good condition with a few batch piles in front of throat

DH

TH


2. Outline of Glass Furnace Disturbance for

batch pile

Differential of pull

Adhesion of batch

Load of batch

Moisture, Cullet%

Even if the output% is the same, the actual input volume changes.


3.Outline of the equipmentSystem flow

TV cameraPower supply Monitor

PC for furnace control

Input parameter

ＰＣ for Catching Image

Distributer

Exis

ting

equi

pmen

t

Signal of reversing→←Signal for batch charger

New equipment


3. Outline of the equipment

Three functions of this equipment① Adjust the batch piles at R&L

sides② Adjust the batch piles at DH&TH

sides③ Alarm when batch piles at

the TH side increase2012/9/26 AFGM in Vietnam

3. Outline of the equipment Capture of image

After reversing signal, capture of image to PC

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3. Outline of the equipment Make an image, a 2 level image in black & white

Black area are judged to be the batch pile


3. Outline of the equipment①Adjust batch piles at the R&L sides

Adjust the output% of A&B batch charger so that batch piles at A&B become same.

A B


3.Outline of this equipment②Adjust batch piles at DH&TH sides

Adjust the A1 timer when the area of A1 vary from the set point

A1


3.Outline of this equipment③Alarm when batch piles at the TH side increase

Alarm when batch piles increase in area C

C


1

3

2

For single DH

The control to the DH & TH direction is effective

3.Outline of this equipment


3.Outline of this equipmentFor screw charger

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正常異常

Increase output%

For screw charger

Bad conditionGood condition

3.Outline of this equipment


4.Performance of this equipmentSchedule of test run

In 201109/01〜09/14 Grasp of bench mark09/27〜10/05 Adjust of R&L11/02〜11/15 Adjust of DH&TH11/16〜11/22 Stop of operation to

confirm of performance11/23〜11/30 Final confirmation


下流側のバッチ山の占有率

0

5

1 0

1 5

2 0

2 5

3 0

3 5

4 0

9/1

9/3

9/6

9/9

9/11

9/14

9/17

9/19

9/22

9/25

9/27

9/30

10/3

10/5

バッチ山増加

制御前調整中制御中

バッチ山安定

％

4.Performance of this equipment①Adjust of R&L Decrease of batch piles

front of THBatch piles% front of TH

Before operation Adjusting Operation

Increase of batch pile

Good condition


4.Performance of this equipment②Adjust of DH&TH

下流側のバッチ山の占有率

0

5

1 0

1 5

2 0

9/27

9/29

10/2

10/5

10/7

10/10

10/13

10/15

10/18

10/21

10/23

10/26

10/29

10/31

11/3

11/6

11/8

11/11

11/14

調整中制御中制御前％ Batch piles% front of TH

Before operation Adjusting Operation

No decrease of batch piles at the front of TH


Oscillate timer to throat side

0

40

80

120

160

200

11/3

11/4

11/5

11/7

11/8

11/9

11/11

11/12

11/13

A1タイマー A2タイマー A3タイマー（秒）

Before 10 sec

After 40 sec

4.Performance of this equipment


引上ｖｓシードC

0 .0 0

0 .0 5

0 .1 0

0 .1 5

0 .2 0

1 2 0 1 4 5 1 7 0 1 9 5 2 2 0

t/d

n /g 1 1 /1 6 -制御無し

1 1 /2 -制御

1 1 /2 3 -制御

4.Performance of this equipmentSeed count Decrease of seed count

Pull vs Seed count Operate

Operate

Stop

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引上ｖｓガス使用量

1 8 ,0 0 0

1 9 ,0 0 0

2 0 ,0 0 0

2 1 ,0 0 0

2 2 ,0 0 0

2 3 ,0 0 0

1 2 0 1 4 5 1 7 0 1 9 5 2 2 0

t/d

m 3 /d

1 1 /1 6 -制御無し

1 1 /2 -制御

1 1 /2 3 -制御

4.Performance of this equipmentEnergy efficiency

Not change of efficiency

Pull vs Gas Volume

OperateOperate

Stop


引上ｖｓ大迫＃１

1450

1470

1490

1510

1530

1550

120 145 170 195 220

t/d

℃ 11/16-制御無し

11/2-制御

11/23-制御

Almost same

4.Performance of this equipmentCrown Temp.

Pull vs Crown Temp.(DH) OperateOperate

Stop


4.Performance of this equipmentDrop BTM Temp by better seed2011/Sep.〜Dec.

炉底貫通温度vsシードC

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

1280 1290 1300 1310 1320℃

n/g

温度低い方がシードC悪化する率が高く見える

2008/9/15-2010/9/14 at Cullet45-55％

Target Temp of bottom-in glass ⊿10℃

BTM Temp vs Seed


4.Performance of this equipmentTarget Temp of bottom-in glass 1295→1285℃

引上ｖｓガス原単位

y = -0.1547x + 145.88

y = -0.2012x + 155.07

113

115

117

119

121

123

125

127

150 170 190 210t/d

ｍ3ｓ/ｔ

1295℃

1285℃

炉底温度：1295℃　2012/1/13-1/23（19,20除く）炉底温度：1285℃　2012/1/28-2/09カレット55%補正

Efficiency⊿１％ →⊿61,000 $/y

Pull vs Energy efficiency

BTMBTMCullet 55% Pull 171.7t/d Gas price 0.8$/m3


5.Conclusion

・Better batch pile distribution・Better glass quality (seed)・Better energy efficiency

(Lower temp. operation)


IssueMaintenance of TV Camera

① Adhesion of dust on top of lens② Spot on lens due to drain from cooling air③ Reset of camera after cleaning

A value of batch pile change

5.Conclusion

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5. ConclusionFor side port furnace

There are 2 TV cameras at the right & left of the back wall. The brightness & luminosity of two images are necessary.


5.ConclusionInstallation for customer

The improvement of this part is necessary

TV cameraPower supply

Monitor

PC for furnace

control

Input parameter

ＰＣ of Catch Image

Distributer

Signal of reversing→

←Signal for batch charger


5. ConclusionFuture directionality

１．I want to digitize the burner flame and plan the stability of the furnace operation by this catch image system.２．I want to accumulate data and do the self-adjustment of the parameter.


Thank you for your attention

2012/9/26AFGM in VietnamNihon Yamamura GlassMichihiro Andoh

7 nihon yamamura - control system for batch pile · 2017-09-19 · 4/9/2017 1 “evaluation of...

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