CULLET AND CULLET WATER HANDLING SYSTEM

A glassware manufacturing system, waste handling system, and method are disclosed. The glassware manufacturing system, in accordance with one aspect of the disclosure, comprises an architectural installation having a forming floor and no basement beneath the forming floor; a glassware forming machine carried on the forming floor; a molten glass feeder configured to provide molten glass to the glassware forming machine; and a glassware manufacturing waste handling system including a sump pit in the forming floor, and a waste liquid trench substantially surrounding the glassware forming machine and flowing to the sump pit. Also, a cullet material handler and/or a molten waste glass sluice may be configured to receive molten glass and unused molten glass streams from the molten glass feeder and hot glassware rejects from the glassware forming machine.

TECHNICAL FIELD

This patent application discloses systems and methods for glassware manufacturing and, more particularly, a system for handling glassware manufacturing waste.

BACKGROUND

Glass container manufacturing processes can include using a glassware forming machine to shape and form glass containers from molten glass. During the forming process, a stream of the molten glass can be separated into a glass gob, formed into a parison, and shaped into a container. Additionally, the glass gobs, parisons, containers, or pieces thereof may be rejected due to various reasons. These rejected materials, along with streams of molten waste glass, are known as internal cullet and can be recycled to a glass melter to produce molten glass.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure embodies a number of aspects that can be implemented separately from or in combination with each other.

A glassware manufacturing system, in accordance with one aspect of the disclosure, comprises an architectural installation having a forming floor and no basement beneath the forming floor; a glassware forming machine carried on the forming floor; a molten glass feeder configured to provide molten glass to the glassware forming machine; and a glassware manufacturing waste handling system, including: a sump pit in the forming floor; a waste liquid trench substantially surrounding the glassware forming machine and flowing to the sump pit; and at least one of a cullet material handler or a molten waste glass sluice, configured to receive molten glass from the molten glass feeder and hot glassware rejects from the glassware forming machine. In some instances, the glassware manufacturing system may include an enclosure over the cullet trench, steam removal ductwork, an annealing lehr, a cold cullet return conveyor, a reject conveyor, a cullet crusher, a molten glass chute, and/or an operator pitch chute.

A glassware manufacturing waste handling system, in accordance with one aspect of the disclosure, comprises a sump pit in a forming floor of an architectural installation, where the architectural installation has no basement beneath the forming floor; a waste liquid trench substantially surrounding a glassware forming machine carried on the forming floor, the waste liquid trench flowing to the sump pit; and at least one of a cullet material handler or a molten waste glass sluice, configured to receive molten glass from a molten glass feeder and hot glassware rejects from the glassware forming machine.

A method for handling glassware manufacturing waste, in accordance with one aspect of the disclosure, comprises providing process water to a glassware forming machine carried by a forming floor, where the process water drains from the glassware forming machine to the forming floor; collecting the process water from the forming floor using a waste liquid trench and a sump pit formed in the forming floor; collecting cullet from the glassware forming machine using at least one of a cullet material handler or a molten waste glass sluice disposed adjacent to the glassware forming machine; and recycling the process water from the sump pit to the glassware forming machine. In some implementations, the method may include treating the process water from the sump pit.

A molten waste glass handling sluice, in accordance with another aspect of the disclosure, extends along a longitudinal axis, and includes a base; a platform carried above the base and including an upper wall having a plurality of apertures to deliver fluid from a location below the upper wall to a location above the upper wall; side walls extending in a direction upwardly away from the upper wall; an upstream inlet to receive hot molten glass; and a downstream outlet to transmit cooled glass.

A method of handling waste molten glass, in accordance with a further aspect of the disclosure, comprises receiving waste molten glass on a cushion of gas on a platform, and conveying the waste molten glass in a downstream direction on the cushion of gas on the platform. This method also may include vibrating the platform to assist with conveying the waste molten glass in the downstream direction, adjusting one or more characteristics of the vibrating to affect a flow of the waste molten glass along the platform, and/or adjusting one or more characteristics of the gas to affect a flow of the waste molten glass along the platform.

DETAILED DESCRIPTION

In accordance with at least one aspect of the disclosure, a glassware manufacturing system contains and recycles process water within the system, limits internal cutlet handling to a forming floor, and minimizes the volume and improves the quality of process water, thereby reducing environmental disposal costs and improving safety in a glassware forming area. External cullet arises from post-consumer recycling of glass products. Internal cullet arises from waste glass in a glass factory, including waste gobs or charges of molten glass from a gob or charge feeder spout, or streams of molten glass from a glass melter, a finer, a forehearth, or the gob or charge feeder spout, or hot glassware rejects, or cold glassware rejects.

Conventional glassware forming systems often combine manual or semi-automatic methods for handling glass cullet (e.g., steel hoppers, drag chains into bunkers, fork trucks, and the like) in a basement under glassware forming machines. The forming systems can include a system that allows process water and/or other material to gravity flow through collection pans, pipes, and chutes onto the basement floor and into an API oil-water separator pit. Oils and grease can be skimmed from the collected process water, and the remaining process water can be recycled back into the system. As part of this process, some process water may escape the basement with the cullet and has the potential to be comingled with storm or other water. This requires collection and conveyance of the escaped water back to the basement, where increased water volumes, due to comingling with storm water, can upset the system water balance and result in excess water that must be hauled off for environmental disposal at extra expense.

Consequently, the present disclosure is directed to a glassware manufacturing system, and a glassware manufacturing waste handling system that includes an automated and closed cullet and cullet water handling system. By using the systems and methods disclosed herein, the glassware manufacturing system can be contained within a production building without a basement. Additionally, the cullet, process, and/or shear water can be collected and recycled within the system to minimize cost from environmental disposal, and cullet handling can be limited to the forming floor.

Referring generally toFIGS. 1 through 3, a glassware manufacturing system10and glassware manufacturing waste handling system12are shown in accordance with an illustrative embodiment of the present disclosure. The glassware manufacturing system10can comprise an architectural installation14, a glassware forming machine16carried on a forming floor18of the installation14, a glass furnace forehearth20, and a glassware manufacturing waste handling system12. Although not shown, the system10also may include a submerged combustion melting (SCM) furnace or “melter” and a molten glass finer between the melter and the forehearth20.

Additionally, the architectural installation14can include a concrete foundation establishing the forming floor18. The architectural installation14may also include a factory building (not shown) on the foundation including walls, a roof, and/or an upper level or raised platform above the forming floor18. The architectural installation14can be configured to support and shelter a compact, single-level glassware manufacturing system10. For example, the architectural installation14can be configured to carry glassware forming equipment.

In the embodiment shown inFIGS. 1 and 2, the architectural installation14has no basement beneath the forming floor18as utilized in conventional systems. In conventional glassware forming systems, a basement is required because traditional cullet chutes use large amounts of high pressure water to keep the steel chutes cool and maintain the flow of rejected or streaming glass into a basement, where the water and cullet are collected. Generally, the level of the water and cullet collecting equipment has been at least one full level below a forming machine. However, utilizing a basement may be less efficient compared to implementing the glassware manufacturing system10disclosed herein because using the glassware manufacturing system10can reduce the amount of capital investment needed, allow for reductions in process equipment labor requirements, and increase up-time across the glassware forming process. As used herein, the term “basement” includes the lowest habitable level of the glass factory below a forming floor of the factory and can include a first level or a below grade or below ground level portion that may require excavation of earthen material. In contrast, according to the present disclosure, no basement is required, such that the architectural installation14includes a concrete slab with earthen material directly underneath the slab, wherein the slab establishes the forming floor18.

In some embodiments, and with reference toFIG. 2, the forming floor18can be sloped to direct process water and/or other liquids on the forming floor18away from process equipment. In the context of this disclosure, process water may include shear spray water, cooling water, cullet water, quench water, and the like. For example, the forming floor18can be sloped away from a glassware forming machine16to a waste liquid trench22. The forming floor18can be sloped or crowned such that liquid efficiently flows but does not create a safety hazard within the glassware manufacturing system10. It is contemplated that the forming floor18may be sloped or crowned just enough to facilitate runoff of liquids, like water, lubricants, or the like.

With continued reference toFIG. 2, the glassware manufacturing system10can include the glassware forming machine16carried on the forming floor18. The glassware forming machine16can include a machine that holds and moves molten glass, often in the form of a glass gob, and shapes the molten glass to form glassware (e.g., containers). In one example, the glassware forming machine16may include an individual section (IS) machine comprising a bank of identical sections, each of which contains a complete set of equipment to form a glass container. The sections may be in a row and may be fed molten glass from a forehearth and moving chutes. The glassware forming machine16can be completely housed by the architectural installation14. It will be appreciated that other types of forming machines may be used in the glassware manufacturing system10.

The glassware manufacturing system10can include a glass furnace forehearth20having a molten glass feeder24configured to provide molten glass26to the glassware forming machine16. The glass furnace forehearth20can be located downstream of a melting furnace (not shown) and may be part of a hot-end subsystem. The glass furnace forehearth20can receive molten glass from the furnace and cool the molten glass to a uniform temperature and viscosity suitable for downstream forming operations.

With continued reference toFIG. 2, the molten glass feeder24can be located at a downstream end of the glass furnace forehearth20and is configured to produce molten glass portions. In the illustrated embodiment, the molten glass feeder24can receive the molten glass from the glass furnace forehearth20, produce a continuous stream of molten glass, and separate the stream into discrete glass gobs that freefall into gob handling equipment (not shown), which may include a series of distributors, scoops, chutes, deflectors, and funnels. The gob handling equipment may also include ancillary lubrication equipment to apply lubricants to the gob handling equipment and liquid separators to separate or otherwise process the lubricants. The molten glass feeder24and gob handling equipment can be configured to provide glass gobs to the glassware forming machine16.

In another embodiment, not presently illustrated, the molten glass feeder24can receive the molten glass from the glass furnace forehearth20, produce a continuous stream of molten glass that that is fed downwardly into a molten glass transport cup and thereafter severed to produce a discrete portion of molten glass carried in the cup and separated from the molten glass stream. In this embodiment, the glass-filled cup is thereafter moved to the glassware forming machine16, over a mold, and either inverted to dump the glass in the mold, split open to dump the glass in the mold, or opened at an openable bottom end to dump the glass in the mold.

In a further embodiment, not presently illustrated, the molten glass feeder24can receive the molten glass from the glass furnace forehearth20, produce a continuous stream of molten glass that is directly injected into an inverted mold, and then severed to produce a discrete portion of molten glass carried in the cup and separated from the molten glass stream. In this embodiment, no gob handling equipment and no molten glass cup are used; instead, the molten glass is delivered directly into the mold.

Accordingly, the terminology “molten glass portion” includes a molten glass gob, gather, stream, chunk, charge, mold charge, and the like. In one example, a molten glass portion may include a molten glass gob cut from a stream of molten glass produced by a gob feeder and then dropped into gob handling equipment, a transport cup, or a mold. In other examples, a molten glass portion may include a stream of molten glass delivered from an upstream continuous supply of molten glass, and thereafter separated from the upstream continuous supply of molten glass in any suitable manner.

Additionally, and with reference toFIGS. 1 and 2, the glassware manufacturing system10can include the glassware manufacturing waste handling system12, which can further include a shear spray collection system13(FIG. 1), a sump pit28(FIG. 2), the waste liquid trench22, and a cullet material handler30. The glassware manufacturing waste handling system12can be used to remove, handle, and/or recycle process liquid, for example, water, oil, and other materials, used during forming processes, and for removing cullet and glassware rejects.

As illustrated inFIG. 1, the glassware manufacturing waste handling system12can include the sump pit28in the forming floor18. The sump pit28can include a pit or lowest-most volume in the forming floor18for collecting the process water and other liquid resulting from the forming process. When the forming floor18is sloped or crowned, the sump pit28can be located at a low portion of the forming floor18so that the liquid can generally flow from the glassware forming machine16and equipment to the sump pit28. The sump pit28may include means, for example a pump (not shown), for further transferring the liquid for treatment and/or other handling. For example, the liquid waste in the sump pit28can be transferred for treatment, for example, using a pump, and then can be recycled. In some instances, the sump pit28may include an oil-water separator (e.g., an API oil-water separator) and/or other treatment means. In this way, the glassware manufacturing system10can include a closed or open recirculating loop for treating and/or recycling the process water and other liquid, which can contribute to reducing human intervention in the forming process and potential negative environmental impact while improving safety and process stability.

The glassware manufacturing waste handling system12can include a waste liquid trench22substantially surrounding the glassware forming machine16and flowing to the sump pit28. As used herein, the phrase “substantially surround” means extending between 240 and 360 angular degrees around including all ranges, sub-ranges, and values including endpoints of that range. The waste liquid trench22can be carried by and integrally formed in the forming floor18. When the forming floor18is sloped, the liquid can fall onto the forming floor18from the glassware forming machine16, flow down the sloped forming floor18to the waste liquid trench22, and flow through the waste liquid trench22to the sump pit28. InFIG. 1, the waste liquid trench22forms a rectangle and completely surrounds the glassware forming machine16. It will be appreciated that the waste liquid trench22may include other configurations and may include more than one trench that flows to the sump pit28. For example, the waste liquid trench22may also substantially surround and/or be located adjacent to other equipment within the glassware manufacturing system10, for example steam removal ductwork32.

Shown inFIG. 1, the glassware manufacturing waste handling system12can include the cullet material handler30configured to receive discrete molten glass portions and unused molten glass streams from the molten glass feeder24. Although not illustrated, the handler30also may be configured to receive molten glass streams from the SCM furnace and/or the finer when it is desired to drain or “dump” molten glass therefrom, for example, to accommodate a glass color changeover, equipment maintenance, equipment relocation, or the like. Any suitable conduit, sluice, or the like may be used to communicate drains, outlets, or the like of the SCM furnace and/or the finer to the handler30. The handler30is also configured to receive hot glassware rejects from the glassware forming machine16, cold glassware rejects from a cold cullet return conveyor48, and the like. The cullet material handler30may include a cullet drag chain, which may include a chain conveyor comprising a continuous chain arrangement with a series of single pendants, where the chain arrangement can be driven by a motor to convey the rejected molten glass portions, the unused molten glass streams, the cold glassware rejects, and/or the hot glassware rejects. In an example, the cullet drag chain can include a stainless steel hinged drag chain that is suitable for exposure to heat and a humid environment. It is contemplated that the cullet material handler30can include other types of conveyors configured to handle hot glass and glass cullet, for example a belt conveyor, a pneumatic conveyor, and/or any other type of material handler suitable for use in moving cullet.

In the illustrated example ofFIG. 2, as the molten glass feeder24distributes glass gobs to the glassware forming machine16, some of the glass gobs may be rejected due to commercial variations. At least some of the rejected glass gobs may be transferred from the molten glass feeder24and/or the glassware forming machine16to the cullet material handler30by way of a waste molten glass chute34. The waste molten glass chute34may include a chute or sloping channel or enclosure through which rejected mold charges can fall and be directed to the cullet material handler30. The waste molten glass chute34may include material suitable for handling high temperatures and/or corrosion. In some instances, the waste molten glass chute34may be enclosed and/or cooled.

Additionally, and with reference toFIG. 2, as the glassware forming machine16forms the glassware, some of the hot glassware may be rejected due to commercial variations. A reject conveyor36can be configured to transport hot glassware rejects from the glassware forming machine16and/or a glassware conveyor38to the cullet material handler30. The reject conveyor36can be located downstream from the glassware forming machine16and upstream from an annealing lehr40. The reject conveyor36may include a belt conveyor, a chain conveyor, and the like. In some instances, the reject conveyor36may be covered and/or enclosed for containing the cullet to the reject conveyor36. Additionally, the reject conveyor36may include an air assist plate and/or may include high temperature plating. When glassware from the glassware forming machine16is rejected, the rejected glassware can be blown from the glassware conveyor38and to the reject conveyor36upstream from the annealing lehr40.

A cullet trench42may be formed integrally and within the forming floor18and may be located proximate to the glassware forming machine16. As used herein, the term “proximate” means between two inches and twenty feet including all ranges, sub-ranges, endpoints, and values of that range. In specific examples, the cullet material handler30can be partially recessed in the cutlet trench42or can be fully recessed in the cullet trench42. Placing the cullet material handler30at least partially recessed in a cullet trench42can improve access and safety around the glassware forming machine16. In some instances, the cullet material handler30may be mounted to and disposed at or above a level of the forming floor18.

With reference toFIG. 3, the cullet material handler30can include an enclosure44over the cullet trench42to establish a cullet trench conduit46. The enclosure44can include a cover (e.g., stainless steel cover) that covers at least the top portion of the cullet material handler30and can be configured to contain glass cullet to the cullet material handler30and contain steam within the cullet trench conduit46. The steam may be produced from water-cooling jackets, evaporated process water, and from other forming processes.

With reference toFIGS. 1 and 2, steam removal ductwork32can be in fluid communication with the cullet trench conduit46to remove the steam from the cullet trench conduit46. The steam removal ductwork32can include ducting (e.g., stainless steel sheet metal and the like) and/or other conduit that couples to the enclosure44and/or steam removal fans (not shown) for moving the steam and/or other gases from the cullet trench conduit46to outside the glassware manufacturing system10. It will be appreciated that the steam removal ductwork32can include other materials that may be suitable for high-temperature and/or corrosive environments. Removing the steam can serve to improve system safety by improving visibility.

With reference toFIG. 2, the shear spray collection system13can include a shear spray collector15under the feeder24to collect shear spray water. In one embodiment, the shear spray collector15may include a funnel, tray, or pan that may be in fluid communication with the cullet trench, for example, via the mold charge chute. In another embodiment, the shear spray collection system13may be independent from the cullet quench water collection equipment such that shear spray water can be processed and recycled independently of the cullet quench water.

In some implementations, and with reference toFIG. 1, an annealing lehr40can be disposed downstream of the glassware forming machine16and can be configured for annealing glassware formed by the glassware forming machine16. The annealing lehr40can include a gas-fired oven where the glassware conveyor38transports glassware from the glassware forming machine16and extends longitudinally through the oven. Additionally, a pusher (not shown) can be configured to push long, transversely extending rows of glassware into the annealing lehr40.

The glassware manufacturing system10can include a cold cullet return conveyor48configured to receive cold glassware rejects and cullet from the glassware conveyor38and/or a lehr reject conveyor41at a location downstream from the annealing lehr40. The lehr reject conveyor41and/or the cold cullet return conveyor48may include a belt conveyor, a chain conveyor, and/or another type of conveyor suitable for conveying the cold glassware rejects and cullet to the cullet material handler30.

The glassware manufacturing system10may include a cullet crusher50on the forming floor18and disposed between the cullet material handler30and the cold cullet return conveyor48. The cullet crusher50can be configured to crush and further break rejected glassware and cullet received from the cold cullet return conveyor48and can direct the resulting cullet to the cullet material handler30. The cullet crusher50can include, for example, a high speed rotor with wear resistant tips and a crushing chamber, which the rejected glassware can be thrown against. It is contemplated that other types of cullet crushers may be used in the glassware manufacturing system10, for example, a cylinder/piston impact crusher, hammer mill, rotating breaker bars, rotating drum and breaker plate, or the like.

In some implementations, the glassware manufacturing system10may include an operator pitch chute52with bottle crushing equipment54configured to receive hot glassware rejects from the glassware forming machine16. The operator pitch chute52and/or the bottle crushing equipment54can be disposed adjacent, or proximate, to the glassware forming machine16. Glassware rejected by an operator can be placed into the operator pitch chute52and crushed by the bottle crushing equipment54. The bottle crushing equipment54may include a bottle or cullet crusher, and the resulting cullet can be recycled. Similar to the cullet crusher50, the bottle crushing equipment54may include a high speed rotor and a crushing chamber for crushing the rejected glassware to form glass cullet, and/or any other suitable crushers.

With reference toFIG. 4, a waste glass handling sluice56is provided to receive molten glass gobs and/or streams at an upstream location, and cool and convey such molten glass to a downstream location, for example, in solidified form. In one example, hot molten glass may be received at a temperature in the range of 1300 to 1100 degrees Celsius and may be conveyed at a temperature in the range of 1100 to 600 degrees Celsius, and may be discharged from the equipment at a temperature in the range of 600 to 450 degrees Celsius.

In the illustrated embodiment, the sluice56is configured to be carried on an upper surface of a forming floor or in a shallow trench in the upper surface of the forming floor. Therefore, the location of the sluice56represents a significant departure from conventional arrangements wherein waste molten glass is conveyed down through a forming floor and into a water tank in a basement beneath the forming floor. Nonetheless, in other embodiments, the sluice56could be located in the basement of a conventional glass factory architectural installation. In any case, the construction and arrangement of the sluice56represents a significant departure from conventional waste molten glass quenching tanks, as described below.

The sluice56extends along a longitudinal axis, and includes a base58configured to be carried on or by a forming floor of an architectural installation, and a table or platform60carried above the base and configured to convey waste glass from an upstream location to a downstream location. The sluice56also includes an upstream inlet62to receive hot molten glass, and a downstream outlet64to transmit cooled, preferably solidified, glass. The sluice56also may include vibrators66operatively coupled to the platform60to vibrate the platform60for assisting with moving waste glass in a downstream direction, and vibration isolators68operatively coupled between the base58and the platform60to reduce transmission of vibrations outside of the sluice56.

The base58may include a rectangular frame, as illustrated, and may be fastened or otherwise coupled directly to the forming floor. In other embodiments, the base58may include four or more pedestals; one at each corner of the sluice platform. In any embodiment, the base58may be adjustable to adjust an angle of declination of the platform60. For example, the base58may include adjustable legs59, which may include feet, rollers, wheels, or the like, between the forming floor on the one hand and corners of the frame or the pedestals on the other, to raise or lower one or more corners of the sluice platform60.

The platform60includes an upper wall70to support, distribute, and convey glass in a downstream direction, and side walls72extending in a direction upwardly away from the upper wall70to guide and retain glass along and on the upper wall70. The platform60also may include a cover73extending between the side walls72and spaced above the platform60, and also the steam removal ductwork and related equipment described above with respect toFIGS. 1 and 2. The upper wall70has a plurality of apertures74to allow fluid to flow therethrough from a location below the upper wall70to a location above the upper wall70. The apertures74may be straight cylindrical in shape, tapered with larger upper ends, chamfered at upper ends, or provided in any other suitable configuration.

The platform60also includes one or more fluid ducts76a,b,cbeneath the upper wall70of the platform60to communicate fluid to the plurality of apertures74. In the illustrated embodiment, the fluid duct(s)76a,b,cmay be constituted by a space between the upper wall70, a lower wall78beneath the upper wall70, and side walls80and end walls81extending therebetween. In other embodiments, the fluid duct(s)76a,b,cmay be constituted from V-shaped lower trough connected to the upper wall, and/or any other configuration suitable for use with an apparatus that conveys molten glass. The plurality of fluid ducts76a,b,cbeneath the upper wall70of the platform60can communicate fluid to the plurality of apertures74according to a plurality of different parameter values. For example, an upstream fluid duct76amay be supplied with a fluid at a first pressure and flow rate, a downstream fluid duct76cmay be supplied with a fluid at a second pressure and flow rate, and soon. Likewise, in this regard, the apertures74corresponding to any given fluid duct of the plurality of fluid ducts may be different in quantity and/or size to convey fluid according to different parameter values. The fluid may be a gas or a liquid, for example, air or water, but can be any fluid suitable for use in cooling and/or conveying glass.

The upstream inlet62includes a deflector panel82having an upstream end82aand a downstream end82bat a lower elevation than the upstream end82asuch that the deflector panel82is declined at an oblique angle with respect to horizontal. The deflector panel82may be a fluid-cooled panel including a molten glass contact wall84to receive molten glass and convey the molten glass downwardly toward the upper wall70of the platform60. The deflector panel82also may include a plurality of other walls including side walls86and a lower wall88to define an internal fluid chamber between the walls, and a fluid inlet and a fluid outlet to receive cooled fluid into the fluid chamber and transmit warmed fluid out of the fluid chamber. The internal fluid chamber may include a serpentine fluid passage between the fluid inlet and the fluid outlet. The upstream inlet also may include a plurality of compressed air nozzles90directed toward the molten glass contact wall84of the deflector panel82to provide external cooling to the deflector panel82. The upstream inlet62also includes inlet side walls92on opposite sides of the deflector panel82and an inlet front wall94extending between the side walls92and spaced downstream of the downstream end of the deflector panel82.

The vibrators66may be mounted to a lower surface of the platform60, or to any other portions of the platform60suitable to impart vibrations to the platform60to facilitate conveyance of molten glass in a downstream direction along the sluice56. The vibrators66may include pneumatic vibrators, hydraulic vibrators, electric vibrators, and/or any other vibrator types suitable to facilitate conveyance of molten glass in a downstream direction along the sluice56.

The vibration isolators68may be coupled to a lower surface of the base58, or to any other portions of the base58suitable to promote confine the vibrations from the vibrators66to the platform60. The vibration isolators68may include coil springs, leaf springs, shock absorbers, hydraulic dampeners, viscoelastic components, and/or any other devices suitable to promote isolation of the vibrations from the vibrators66to the platform60.

With reference toFIGS. 1 and 2, and although not specifically illustrated inFIGS. 1 and 2, the sluice56ofFIG. 4may be positioned between the waste liquid trench22and the cullet trench42, alongside the cullet trench42. In another embodiment, the sluice56may be positioned alongside the cullet trench42on a side of the cullet trench42opposite that of the waste liquid trench22. In a further embodiment, the sluice56may be positioned above and parallel to the cullet trench42. In an additional embodiment, the sluice56may replace the cullet trench42. In any embodiment, the waste molten glass chute34is positioned such that its downstream outlet transmits molten glass to the upstream inlet62of the sluice56and, more particularly, to the deflector82of the sluice56.

FIGS. 5-14illustrate another illustrative embodiment of a waste glass handling sluice156. This embodiment is similar in many respects to the embodiment ofFIG. 4and like numerals between the embodiments generally designate like or corresponding elements throughout the several views of the drawing figures. Accordingly, the descriptions of the embodiments are hereby incorporated into one another, and description of subject matter common to the embodiments generally may not be repeated.

With reference toFIG. 5, the sluice156is elongate or oblong and extends along a longitudinal axis, and includes a base158configured to be carried on or by a forming floor of an architectural installation. The sluice156also includes a platform160carried above the base158and configured to convey waste glass from an upstream location to a downstream location, and also includes an upstream inlet162to receive hot molten glass, and a downstream outlet164to transmit cooled, preferably solidified, glass. As will be discussed in more detail below, the sluice156also may include one or more vibrators166(FIG. 11) operatively coupled to the platform160to vibrate the platform160for assisting with moving waste glass in a downstream direction, and vibration isolators168operatively coupled between the base158and the platform160to reduce transmission of vibrations outside of the sluice156.

With continued reference toFIG. 5, the platform160includes an upper wall170to support, distribute, and convey glass in a downstream direction, and side walls172extending in a direction upwardly away from the upper wall170to guide and retain glass along and on the upper wall170. The platform160also may include a cover173extending between the side walls172and spaced above the platform160. The upper wall170has a plurality of apertures174to allow fluid to flow therethrough from a location below the upper wall170to a location above the upper wall170. The apertures174convey fluid so as to cool and levitate molten glass and prevent adhesion of the molten glass to the upper wall170of the platform160. The apertures174may facilitate provision of a cushion of gas on which the molten glass may be carried, and may include gas supplied on the platform at any pressure suitable to produce that cushion. It is also contemplated that gas pressure might not be applied and that the sluice156still may operate to one degree or another. Therefore, gas pressure may be applied through the apertures174, for example, from 0 to 4 PSI including all ranges, sub-ranges, values, and endpoints of that range. With reference now toFIG. 6, the platform160also includes one or more fluid ducts176a,b,ccoupled to a lower wall178of the platform160to communicate fluid to the plurality of apertures174.

In the illustrated embodiment, and with reference toFIGS. 9 and 10, the fluid duct(s)176a,b,ccommunicate with a space between the upper wall170, the lower wall178beneath the upper wall170, and side walls180and end walls181extending therebetween. The walls170,178,180,181may be welded together in an airtight manner. Preferably, the upper wall170is welded to the side walls180and then the lower wall178is welded to the side walls180. As also shown inFIG. 10, the fluid duct(s)176a,b,cmay be laterally offset from a longitudinally extending centerline of the sluice156to accommodate various structural elements of the vibratory equipment.

With reference toFIG. 9, the plurality of fluid ducts176a,b,cbeneath the upper wall170of the platform160can communicate fluid to the plurality of apertures174according to a plurality of different parameter values. For example, an upstream fluid duct176amay be supplied with a fluid at a first pressure and flow rate, a downstream fluid duct176cmay be supplied with a fluid at a second pressure and flow rate, and so on. Likewise, in this regard, the apertures174corresponding to any given fluid duct of the plurality of fluid ducts176a,b,cmay be different in quantity and/or size to convey fluid according to different parameter values. The apertures174may be 1 mm to 5 mm in diameter including all ranges, sub-ranges, values, and endpoints of that range. The apertures174may be arranged in a rectangular array, as illustrated, or in any other suitable arrangement, and may be spaced apart from one another in longitudinal and lateral directions by 25 mm to 75 mm including all ranges, sub-ranges, values, and endpoints of that range. From the present disclosure, those of ordinary skill in the art would recognize that size, quantity, spacing, and configuration, of the apertures174and air pressure through the apertures174may be adjusted merely to achieve a fundamental minimum air velocity to provide enough force to lift glass off the surface like an air hockey puck, and such parameters may be depend on a mode of operation (receiving and conveying streams of molten glass or individual gobs of molten glass), and estimated weight of the glass.

With reference toFIG. 5, the fluid supplied to the platform160of the sluice156may be a gas or a liquid, for example, air or water, but can be any fluid suitable for use in cooling and/or conveying glass. Preferably, however, no cooling liquid is used, such that neither the bottom wall198of the inlet162nor the rest of the lower wall178need be liquid-cooled. The platform160may be composed of AISI 1018, 1020, 1065, and/or any other suitable carbon steel, 304 stainless steel, Inconel 601, and/or any other suitable metal, and/or any other material suitable for use with molten glass. Likewise, although the sluice156may be configured to receive process water with the molten glass, preferably the sluice156operates on a waterless basis such that it does not receive process water with the molten glass and, instead, receives “dry” molten glass and conveys the dry molten glass downstream. Accordingly, the sluice156may be waterless in one or more respects. Although not separately illustrated, those of ordinary skill in the art would recognize that the sluice156may be supplied with fluid using conduit, connectors, fans, pumps, controllers, valves, power supplies, and/or any other equipment suitable for use in supplying fluid to the sluice156. Likewise, although not separately illustrated, those of ordinary skill in the art would recognize that the vibrators66may be supplied with electricity, or pneumatic or hydraulic fluid, via wiring, conduit, controllers, valves, and/or any other equipment suitable for use in supplying power and control to the vibrators66.

The upstream inlet162includes inlet side walls192on opposite lateral sides, an inlet front wall194extending between the side walls192at downstream ends of the side walls192, and an inlet rear wall196that may have an upper edge that is vertically recessed from corresponding upper edges of the side walls192and front wall194. The inlet rear wall196may be shorter than the side walls192, for example, to accommodate a molten glass chute (not shown) cooperating with the sluice156to deliver molten glass to the inlet162. The inlet162also includes a bottom wall198extending between the side walls192and supporting the platform160thereon, and a top wall200extending between the side walls192and forward from the front wall194. The top wall200has an aperture202that may be configured to be coupled to steam removal conduit and a corresponding pump, fan, and/or any other equipment (not shown) suitable to pull air and steam out of the sluice156.

The base158may include a rectangular frame that may include four or more legs or pedestals204at each corner of the base158, longitudinally extending side rails206extending between the pedestals204, and laterally extending end rails208extending between the pedestals204.

Finally, the sluice156may be equipped with one or more sensors209, for example, proximate the outlet164of the sluice156to sense presence of glass, temperature of the glass, and/or any other characteristics suitable for use as feedback in adjusting performance characteristics of the sluice156such as air flow, air pressure, vibration frequency, vibration intensity, and/or the like. For example, the sensor(s)209may include an IFM TW2000 infrared sensor to measure temperature of the glass as it exits the sluice156. Those of ordinary skill in the art would recognize that the sensor(s)209can be coupled to any suitable controllers, which, in turn, may be coupled to the vibrators, fans, pumps, power supplies, and/or any other equipment used to operate the sluice156and which may be coupled to and controlled by such controllers.

With reference toFIGS. 11-13, the cradle157is carried by the base158and, in turn, carries the sluice156. The cradle157includes a base wall210, rear flanges212extending laterally outwardly from the base wall210at a rear end of the cradle157, and front flanges214extending laterally outwardly from the base wall210at a front end of the cradle157. The flanges212,214may extend upwardly along the sidewalls172of the sluice156to laterally restrain the sluice156and may be welded, fastened, or otherwise coupled thereto. Also, the flanges212,214may be welded, fastened, or otherwise coupled onto the isolators168. The cradle157also includes one or more webs216(FIGS. 11 and 12) extending downwardly from and longitudinally along the base wall210and may be welded, fastened, or otherwise coupled thereto.

As best shown inFIG. 14, the cradle157further includes one or more cross-members217that extends laterally between the webs216and that may be welded, fastened, or otherwise coupled thereto. In the illustrated embodiment, there are three webs216; one centrally located and two on lateral outboard sides of the centrally located one. The cradle157further includes a vibrator mounting plate218that may be welded, fastened, or otherwise coupled to upstream ends of the webs216for mounting the vibrators166thereto, and a reinforcement strut220that may be welded, fastened, or otherwise coupled to the base wall210, and to the vibrator mounting plate218and extending upstream therefrom to a rear wall222, which may be welded, fastened, or otherwise coupled to and extending downwardly from the base wall210at the rear end of the cradle157. Of course, the vibrators166may be fastened, welded, or otherwise coupled to the mounting plate218in any suitable manner.

Although the illustrated embodiment shows the sluice156supported by the base158resting on a factory floor, in other embodiments, the sluice156may be suspended from overhead, for example, from girders, trusses, and/or any other suitable overhead structure of a building in which the sluice156is used. In such embodiments, suitable tie rods, cables, and/or the like, along with corresponding fasteners, brackets, and/or the like may be used to coupled the cradle157to such building overhead structure. Likewise, the vibration isolators168may be configured to be coupled between such overhead structure and the cradle157in any suitable manner

The sluice156and its ancillary equipment like the sensor(s)209, a fluid fan or pump to supply fluid through the apertures174, and the vibrators166may be instrumented and/or communicated with one or more controllers for closed loop control of rate of flow of molten glass through the sluice156. For instance, a temperature of the glass can be sensed or monitored by one or more of the sensors209, for example, at or proximate the end of the platform160as it exits the sluice156. In response to such glass temperature sensing, when the glass temperature is determined to be in excess of some temperature threshold, and in one example, the vibration energy can be decreased to slow the glass flow rate across or along the platform thereby allowing more time for the glass to cool down more, and/or, in another example, air pressure supplied through the apertures174can be increased to increase cooling of the glass.

FIG. 15illustrates an example of a method300for handling glassware manufacturing waste using the glassware manufacturing system10and glassware manufacturing waste handling system12described herein. For purposes of illustration and clarity, method300will be described in the context of the glassware manufacturing system10described above and generally illustrated inFIGS. 1 through 14. It will be appreciated, however, that the application of the present methodology is not meant to be limited solely to such an arrangement, but rather method300may find application with any number of arrangements (i.e., steps of method300may be performed by components of the glassware manufacturing system10other than those described below, or arrangements of the glassware manufacturing system10other than that described above).

Method300comprises a step310of providing process water to the glassware forming machine16carried by the forming floor18, where the process water drains from the glassware forming machine16to the forming floor18. In the context of this disclosure, providing process water may include providing plant water, cullet water, shear spray water, cooling water to the waste molten glass chute34, and/or any other liquid to the glassware forming machine16. In an example, process water can be provided to the glassware forming machine16by way of spray nozzles or other devices for use as shear water (e.g., to cool shears), cooling water (e.g., to cool the waste molten glass chute34), and so forth. The process water can be provided to the glassware forming machine16and can then drain by gravity from the glassware forming machine16to the forming floor18. In some instances, the provided process water can be recycled from water previously used in a glassware manufacturing process, and may be treated and recycled from the sump pit28.

Method300comprises a step320of collecting the process water from the forming floor16using a waste liquid trench22and a sump pit28formed in the forming floor16. After the process water drains from the glassware forming machine16to the forming floor18, the water can flow to the waste liquid trench22. In instances when the forming floor16has a pitch or is sloped or crowned, the pitch, slope or crown of the forming floor16can assist with providing and directing the process water flow. As the water flows to and is collected by the water liquid trench22, the water liquid trench22can carry and direct the water to the sump pit28, where the water can be collected and contained for treatment, further use and recycling, and/or disposal. In some instances, collecting the water can include collecting the water from other equipment in addition to the glassware forming machine16, for example the cullet material handler30.

Method300comprises a step330of collecting cullet from the glassware forming machine16. In one embodiment, the method includes using the cullet material handler30to collect the cullet, where the cullet material handler30is disposed adjacent, or proximate, to the glassware forming machine16. The cullet can be provided to the cullet material handler30using the waste molten glass chute34, a reject conveyor36, and/or other equipment used in the industry for handling cullet. In another embodiment, the method also or instead includes using the sluice56,156to collect the cullet, where the sluice56,156is disposed adjacent, or proximate, to the glassware forming machine16. The cullet can be provided to the sluice56,156using the waste molten glass chute34, a reject conveyor36, and/or other equipment used in the industry for handling cullet.

Method300comprises a step340of recycling the process water from the sump pit28to the glassware forming machine16. In this step, the water in the sump pit28can be pumped/provided to the glassware forming machine16using a pump (not shown) or other means. For example, the water can be pumped through plumbing to the glassware forming machine16including at least one spray nozzle. In some implementations, additional water can be added to the process water for compensating for process water losses, for example due to evaporation. In this way, the glassware manufacturing system10can be generally a closed loop with regard to providing the recycled process water.

In some instances, method300may comprise a step350of treating the process water from the sump pit28. Process water collected by the sump pit28may include materials and/or debris (e.g., oil, dirt, small glass pieces, suspended solids, and the like) from the glassware forming process that may be undesirable. In these cases, the collected process water may be treated so that cleaner water may be recycled to the glassware forming machine16. For example, the sump pit28may include an API oil-water separator. Treating the process water with an API oil-water separator can include separating gross amounts of oil and/or suspended solids from the collected water. Other methods for treating the process water may include filtration using a filter. It is contemplated that the water collected by the sump pit28may be treated using other equipment and processes.

FIG. 16illustrates an example of a method400for handling waste molten glass using the sluices56,156and their ancillary equipment described herein. For purposes of illustration and clarity, method400will be described in the context of the sluices56,156generally illustrated inFIGS. 4-14. It will be appreciated, however, that the application of the present methodology is not meant to be limited solely to such an arrangement, but rather method400may find application with any number of arrangements (i.e., steps of method400may be performed by components of the sluices56,156and ancillary equipment other than those described below, or arrangements of the sluices56,156and ancillary equipment other than that described above).

Method400comprises a step410of receiving waste molten glass on a cushion of gas on a platform. For example, discrete gobs or charges of waste molten glass, or streams of waste molten glass may be received on cushions of gas supplied by the platforms60,160illustrated inFIGS. 4 and 5, or on any other platform suitable to have a cushion of gas thereon and to receive molten glass thereon.

Method400also comprises a step420of conveying waste molten glass in a downstream direction on a cushion of gas on a platform. For example, the platforms60,160may be declined along a downstream direction, and the cushion of gas may be configured to push the molten glass in a downstream direction.

Method400further comprises a step430of adjusting one or more characteristics of gas to affect a flow of waste molten glass along a platform. For example, the gas can be supplied at an upstream end of the platforms60,160at a higher pressure and/or flow rate compared to gas supplied at a downstream end of the platforms60,160.

Method400also comprises a step440of vibrating a platform to assist with conveying waste molten glass in a downstream direction. For example, the platforms60,160may be coupled to the one or more vibrators66,166to produce relative movement in an lateral and/or longitudinal direction between an upper surface of the platforms60,160and a lower surface of the molten glass.

Method400additionally comprises a step450of adjusting one or more characteristics of vibration of step440to affect a flow of waste molten glass along a platform. For instance, a temperature of the glass can be sensed or monitored by one or more of the sensors209, for example, at or proximate the end of the platform160as it exits the sluice156. In response to such glass temperature sensing, when the glass temperature is determined to be in excess of some temperature threshold, and in one example, the vibration energy can be decreased to slow the glass flow rate across or along the platform thereby allowing more time for the glass to cool down more, and/or, in another example, air pressure supplied through the apertures174can be increased to increase cooling of the glass.

The presently disclosed equipment and/or methods may facilitate reception and conveying of hot molten glass in a manner that may eliminate the need for a basement, may be compact, may be waterless, and/or may reduce or eliminate chute-clogging of waste glass.

FIG. 17illustrates a prior art glassware manufacturing system, including an architectural installation having a forming floor and abasement beneath the forming floor. A glassware forming machine is carried on the forming floor, and an annealing lehr is carried on the forming floor downstream of the forming machine. A forehearth is located above the forming machine and is coupled to a molten glass feeder configured to provide glass gobs to the glassware forming machine. A glassware manufacturing waste handling system includes a hot gob chute extending from the feeder, through the forming floor, and into a gondola in the basement, and a shear spray collection pan for dumping shear spray into the basement via the hot gob chute or otherwise. The waste handling system also includes a hot cullet return chute extending from a hot container conveyor, through the forming floor, and into a gondola in the basement, and a cold cullet return chute extending from a cold container conveyor, through the forming floor, and into another gondola in the basement. The waste handling system also includes floor drains extending from an upper surface of the forming floor to the basement for draining waste liquids onto the basement floor and into an American Petroleum Institute (API) pit for oil/water separation.

There thus has been disclosed a glassware manufacturing system, a glassware manufacturing waste handling system, and a method for containing and recycling process water and limiting cullet handling to the forming floor. The disclosure has been presented in conjunction with several illustrative embodiments, and additional modifications and variations have been discussed. Other modifications and variations readily will suggest themselves to persons of ordinary skill in the art in view of the foregoing discussion. For example, the subject matter of each of the embodiments is hereby incorporated by reference into each of the other embodiments, for expedience. The disclosure is intended to embrace all such modifications and variations as fall within the spirit and broad scope of the appended claims.