Patent Description:
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.

<CIT> describes a glass blowing machine with waste cleaning device comprising a disc.

<CIT> describes a method and apparatus for recovering discrete gobs of molten glass. Recovered gobs are conveyed through a conduit having an entrance and an exit.

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, not independently claimed herein, 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, not independently claimed herein, 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.

The disclosure, together with additional objects, features, advantages and aspects thereof, will be best understood from the following description, the appended claims and the accompanying drawings, in which:.

In accordance with at least one aspect of the disclosure, a glassware manufacturing system contains and recycles process water within the system, limits internal cullet 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 to <FIG>, a glassware manufacturing system <NUM> and glassware manufacturing waste handling system <NUM> are shown in accordance with an illustrative embodiment of the present disclosure. The glassware manufacturing system <NUM> can comprise an architectural installation <NUM>, a glassware forming machine <NUM> carried on a forming floor <NUM> of the installation <NUM>, a glass furnace forehearth <NUM>, and a glassware manufacturing waste handling system <NUM>. Although not shown, the system <NUM> also may include a submerged combustion melting (SCM) furnace or "melter" and a molten glass finer between the melter and the forehearth <NUM>.

Additionally, the architectural installation <NUM> can include a concrete foundation establishing the forming floor <NUM>. The architectural installation <NUM> may 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 floor <NUM>. The architectural installation <NUM> can be configured to support and shelter a compact, single-level glassware manufacturing system <NUM>. For example, the architectural installation <NUM> can be configured to carry glassware forming equipment.

In the embodiment shown in <FIG> and <FIG>, the architectural installation <NUM> has no basement beneath the forming floor <NUM> as 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 system <NUM> disclosed herein because using the glassware manufacturing system <NUM> can 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 installation <NUM> includes a concrete slab with earthen material directly underneath the slab, wherein the slab establishes the forming floor <NUM>.

In some embodiments, and with reference to <FIG>, the forming floor <NUM> can be sloped to direct process water and/or other liquids on the forming floor <NUM> away 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 floor <NUM> can be sloped away from a glassware forming machine <NUM> to a waste liquid trench <NUM>. The forming floor <NUM> can be sloped or crowned such that liquid efficiently flows but does not create a safety hazard within the glassware manufacturing system <NUM>. It is contemplated that the forming floor <NUM> may be sloped or crowned just enough to facilitate runoff of liquids, like water, lubricants, or the like.

With continued reference to <FIG>, the glassware manufacturing system <NUM> can include the glassware forming machine <NUM> carried on the forming floor <NUM>. The glassware forming machine <NUM> can 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 machine <NUM> may 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 machine <NUM> can be completely housed by the architectural installation <NUM>. It will be appreciated that other types of forming machines may be used in the glassware manufacturing system <NUM>.

The glassware manufacturing system <NUM> can include a glass furnace forehearth <NUM> having a molten glass feeder <NUM> configured to provide molten glass <NUM> to the glassware forming machine <NUM>. The glass furnace forehearth <NUM> can be located downstream of a melting furnace (not shown) and may be part of a hot-end subsystem. The glass furnace forehearth <NUM> can 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 to <FIG>, the molten glass feeder <NUM> can be located at a downstream end of the glass furnace forehearth <NUM> and is configured to produce molten glass portions. In the illustrated embodiment, the molten glass feeder <NUM> can receive the molten glass from the glass furnace forehearth <NUM>, 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 feeder <NUM> and gob handling equipment can be configured to provide glass gobs to the glassware forming machine <NUM>.

In another embodiment, not presently illustrated, the molten glass feeder <NUM> can receive the molten glass from the glass furnace forehearth <NUM>, 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 machine <NUM>, 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 feeder <NUM> can receive the molten glass from the glass furnace forehearth <NUM>, 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 to <FIG> and <FIG>, the glassware manufacturing system <NUM> can include the glassware manufacturing waste handling system <NUM>, which can further include a shear spray collection system <NUM> (<FIG>), a sump pit <NUM> (<FIG>), the waste liquid trench <NUM>, and a cullet material handler <NUM>. The glassware manufacturing waste handling system <NUM> can 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 in <FIG>, the glassware manufacturing waste handling system <NUM> can include the sump pit <NUM> in the forming floor <NUM>. The sump pit <NUM> can include a pit or lowest-most volume in the forming floor <NUM> for collecting the process water and other liquid resulting from the forming process. When the forming floor <NUM> is sloped or crowned, the sump pit <NUM> can be located at a low portion of the forming floor <NUM> so that the liquid can generally flow from the glassware forming machine <NUM> and equipment to the sump pit <NUM>. The sump pit <NUM> may 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 pit <NUM> can be transferred for treatment, for example, using a pump, and then can be recycled. In some instances, the sump pit <NUM> may include an oil-water separator (e.g., an API oil-water separator) and/or other treatment means. In this way, the glassware manufacturing system <NUM> can 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 system <NUM> can include a waste liquid trench <NUM> substantially surrounding the glassware forming machine <NUM> and flowing to the sump pit <NUM>. As used herein, the phrase "substantially surround" means extending between <NUM> and <NUM> angular degrees around including all ranges, sub-ranges, and values including endpoints of that range. The waste liquid trench <NUM> can be carried by and integrally formed in the forming floor <NUM>. When the forming floor <NUM> is sloped, the liquid can fall onto the forming floor <NUM> from the glassware forming machine <NUM>, flow down the sloped forming floor <NUM> to the waste liquid trench <NUM>, and flow through the waste liquid trench <NUM> to the sump pit <NUM>. In <FIG>, the waste liquid trench <NUM> forms a rectangle and completely surrounds the glassware forming machine <NUM>. It will be appreciated that the waste liquid trench <NUM> may include other configurations and may include more than one trench that flows to the sump pit <NUM>. For example, the waste liquid trench <NUM> may also substantially surround and/or be located adjacent to other equipment within the glassware manufacturing system <NUM>, for example steam removal ductwork <NUM>.

Shown in <FIG>, the glassware manufacturing waste handling system <NUM> can include the cullet material handler <NUM> configured to receive discrete molten glass portions and unused molten glass streams from the molten glass feeder <NUM>. Although not illustrated, the handler <NUM> also 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 handler <NUM>. The handler <NUM> is also configured to receive hot glassware rejects from the glassware forming machine <NUM>, cold glassware rejects from a cold cullet return conveyor <NUM>, and the like. The cullet material handler <NUM> may 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 handler <NUM> can 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 of <FIG>, as the molten glass feeder <NUM> distributes glass gobs to the glassware forming machine <NUM>, 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 feeder <NUM> and/or the glassware forming machine <NUM> to the cullet material handler <NUM> by way of a waste molten glass chute <NUM>. The waste molten glass chute <NUM> may include a chute or sloping channel or enclosure through which rejected mold charges can fall and be directed to the cullet material handler <NUM>. The waste molten glass chute <NUM> may include material suitable for handling high temperatures and/or corrosion. In some instances, the waste molten glass chute <NUM> may be enclosed and/or cooled.

Additionally, and with reference to <FIG>, as the glassware forming machine <NUM> forms the glassware, some of the hot glassware may be rejected due to commercial variations. A reject conveyor <NUM> can be configured to transport hot glassware rejects from the glassware forming machine <NUM> and/or a glassware conveyor <NUM> to the cullet material handler <NUM>. The reject conveyor <NUM> can be located downstream from the glassware forming machine <NUM> and upstream from an annealing lehr <NUM>. The reject conveyor <NUM> may include a belt conveyor, a chain conveyor, and the like. In some instances, the reject conveyor <NUM> may be covered and/or enclosed for containing the cullet to the reject conveyor <NUM>. Additionally, the reject conveyor <NUM> may include an air assist plate and/or may include high temperature plating. When glassware from the glassware forming machine <NUM> is rejected, the rejected glassware can be blown from the glassware conveyor <NUM> and to the reject conveyor <NUM> upstream from the annealing lehr <NUM>.

A cullet trench <NUM> may be formed integrally and within the forming floor <NUM> and may be located proximate to the glassware forming machine <NUM>. 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 handler <NUM> can be partially recessed in the cullet trench <NUM> or can be fully recessed in the cullet trench <NUM>. Placing the cullet material handler <NUM> at least partially recessed in a cullet trench <NUM> can improve access and safety around the glassware forming machine <NUM>. In some instances, the cullet material handler <NUM> may be mounted to and disposed at or above a level of the forming floor <NUM>.

With reference to <FIG>, the cullet material handler <NUM> can include an enclosure <NUM> over the cullet trench <NUM> to establish a cullet trench conduit <NUM>. The enclosure <NUM> can include a cover (e.g., stainless steel cover) that covers at least the top portion of the cullet material handler <NUM> and can be configured to contain glass cullet to the cullet material handler <NUM> and contain steam within the cullet trench conduit <NUM>. The steam may be produced from water-cooling jackets, evaporated process water, and from other forming processes.

With reference to <FIG> and <FIG>, steam removal ductwork <NUM> can be in fluid communication with the cullet trench conduit <NUM> to remove the steam from the cullet trench conduit <NUM>. The steam removal ductwork <NUM> can include ducting (e.g., stainless steel sheet metal and the like) and/or other conduit that couples to the enclosure <NUM> and/or steam removal fans (not shown) for moving the steam and/or other gases from the cullet trench conduit <NUM> to outside the glassware manufacturing system <NUM>. It will be appreciated that the steam removal ductwork <NUM> can 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 to <FIG>, the shear spray collection system <NUM> can include a shear spray collector <NUM> under the feeder <NUM> to collect shear spray water. In one embodiment, the shear spray collector <NUM> may 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 system <NUM> may 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 to <FIG>, an annealing lehr <NUM> can be disposed downstream of the glassware forming machine <NUM> and can be configured for annealing glassware formed by the glassware forming machine <NUM>. The annealing lehr <NUM> can include a gas-fired oven where the glassware conveyor <NUM> transports glassware from the glassware forming machine <NUM> and extends longitudinally through the oven. Additionally, a pusher (not shown) can be configured to push long, transversely extending rows of glassware into the annealing lehr <NUM>.

The glassware manufacturing system <NUM> can include a cold cullet return conveyor <NUM> configured to receive cold glassware rejects and cullet from the glassware conveyor <NUM> and/or a lehr reject conveyor <NUM> at a location downstream from the annealing lehr <NUM>. The lehr reject conveyor <NUM> and/or the cold cullet return conveyor <NUM> may 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 handler <NUM>.

The glassware manufacturing system <NUM> may include a cullet crusher <NUM> on the forming floor <NUM> and disposed between the cullet material handler <NUM> and the cold cullet return conveyor <NUM>. The cullet crusher <NUM> can be configured to crush and further break rejected glassware and cullet received from the cold cullet return conveyor <NUM> and can direct the resulting cullet to the cullet material handler <NUM>. The cullet crusher <NUM> can 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 system <NUM>, 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 system <NUM> may include an operator pitch chute <NUM> with bottle crushing equipment <NUM> configured to receive hot glassware rejects from the glassware forming machine <NUM>. The operator pitch chute <NUM> and/or the bottle crushing equipment <NUM> can be disposed adjacent, or proximate, to the glassware forming machine <NUM>. Glassware rejected by an operator can be placed into the operator pitch chute <NUM> and crushed by the bottle crushing equipment <NUM>. The bottle crushing equipment <NUM> may include a bottle or cullet crusher, and the resulting cullet can be recycled. Similar to the cullet crusher <NUM>, the bottle crushing equipment <NUM> may 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 to <FIG>, a waste glass handling sluice <NUM> is 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 <NUM> to <NUM> degrees Celsius and may be conveyed at a temperature in the range of <NUM> to <NUM> degrees Celsius, and may be discharged from the equipment at a temperature in the range of <NUM> to <NUM> degrees Celsius.

In the illustrated embodiment, the sluice <NUM> is 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 sluice <NUM> represents 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 sluice <NUM> could be located in the basement of a conventional glass factory architectural installation. In any case, the construction and arrangement of the sluice <NUM> represents a significant departure from conventional waste molten glass quenching tanks, as described below.

The sluice <NUM> extends along a longitudinal axis, and includes a base <NUM> configured to be carried on or by a forming floor of an architectural installation, and a table or platform <NUM> carried above the base and configured to convey waste glass from an upstream location to a downstream location. The sluice <NUM> also includes an upstream inlet <NUM> to receive hot molten glass, and a downstream outlet <NUM> to transmit cooled, preferably solidified, glass. The sluice <NUM> also may include vibrators <NUM> operatively coupled to the platform <NUM> to vibrate the platform <NUM> for assisting with moving waste glass in a downstream direction, and vibration isolators <NUM> operatively coupled between the base <NUM> and the platform <NUM> to reduce transmission of vibrations outside of the sluice <NUM>.

The base <NUM> may include a rectangular frame, as illustrated, and may be fastened or otherwise coupled directly to the forming floor. In other embodiments, the base <NUM> may include four or more pedestals; one at each corner of the sluice platform. In any embodiment, the base <NUM> may be adjustable to adjust an angle of declination of the platform <NUM>. For example, the base <NUM> may include adjustable legs <NUM>, 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 platform <NUM>.

The platform <NUM> includes an upper wall <NUM> to support, distribute, and convey glass in a downstream direction, and side walls <NUM> extending in a direction upwardly away from the upper wall <NUM> to guide and retain glass along and on the upper wall <NUM>. The platform <NUM> also may include a cover <NUM> extending between the side walls <NUM> and spaced above the platform <NUM>, and also the steam removal ductwork and related equipment described above with respect to <FIG> and <FIG>. The upper wall <NUM> has a plurality of apertures <NUM> to allow fluid to flow therethrough from a location below the upper wall <NUM> to a location above the upper wall <NUM>. The apertures <NUM> may be straight cylindrical in shape, tapered with larger upper ends, chamfered at upper ends, or provided in any other suitable configuration.

The platform <NUM> also includes one or more fluid ducts 76a,b,c beneath the upper wall <NUM> of the platform <NUM> to communicate fluid to the plurality of apertures <NUM>. In the illustrated embodiment, the fluid duct(s) 76a,b,c may be constituted by a space between the upper wall <NUM>, a lower wall <NUM> beneath the upper wall <NUM>, and side walls <NUM> and end walls <NUM> extending therebetween. In other embodiments, the fluid duct(s) 76a,b,c may 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 ducts 76a,b,c beneath the upper wall <NUM> of the platform <NUM> can communicate fluid to the plurality of apertures <NUM> according to a plurality of different parameter values. For example, an upstream fluid duct 76a may be supplied with a fluid at a first pressure and flow rate, a downstream fluid duct 76c may be supplied with a fluid at a second pressure and flow rate, and so on. Likewise, in this regard, the apertures <NUM> corresponding 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 inlet <NUM> includes a deflector panel <NUM> having an upstream end 82a and a downstream end 82b at a lower elevation than the upstream end 82a such that the deflector panel <NUM> is declined at an oblique angle with respect to horizontal. The deflector panel <NUM> may be a fluid-cooled panel including a molten glass contact wall <NUM> to receive molten glass and convey the molten glass downwardly toward the upper wall <NUM> of the platform <NUM>. The deflector panel <NUM> also may include a plurality of other walls including side walls <NUM> and a lower wall <NUM> to 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 nozzles <NUM> directed toward the molten glass contact wall <NUM> of the deflector panel <NUM> to provide external cooling to the deflector panel <NUM>. The upstream inlet <NUM> also includes inlet side walls <NUM> on opposite sides of the deflector panel <NUM> and an inlet front wall <NUM> extending between the side walls <NUM> and spaced downstream of the downstream end of the deflector panel <NUM>.

The vibrators <NUM> may be mounted to a lower surface of the platform <NUM>, or to any other portions of the platform <NUM> suitable to impart vibrations to the platform <NUM> to facilitate conveyance of molten glass in a downstream direction along the sluice <NUM>. The vibrators <NUM> may 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 sluice <NUM>.

The vibration isolators <NUM> may be coupled to a lower surface of the base <NUM>, or to any other portions of the base <NUM> suitable to promote confine the vibrations from the vibrators <NUM> to the platform <NUM>. The vibration isolators <NUM> may 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 vibrators <NUM> to the platform <NUM>.

With reference to <FIG> and <FIG>, and although not specifically illustrated in <FIG> and <FIG>, the sluice <NUM> of <FIG> may be positioned between the waste liquid trench <NUM> and the cullet trench <NUM>, alongside the cullet trench <NUM>. In another embodiment, the sluice <NUM> may be positioned alongside the cullet trench <NUM> on a side of the cullet trench <NUM> opposite that of the waste liquid trench <NUM>. In a further embodiment, the sluice <NUM> may be positioned above and parallel to the cullet trench <NUM>. In an additional embodiment, the sluice <NUM> may replace the cullet trench <NUM>. In any embodiment, the waste molten glass chute <NUM> is positioned such that its downstream outlet transmits molten glass to the upstream inlet <NUM> of the sluice <NUM> and, more particularly, to the deflector <NUM> of the sluice <NUM>.

<FIG> illustrate another illustrative embodiment of a waste glass handling sluice <NUM>. This embodiment is similar in many respects to the embodiment of <FIG> and 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 to <FIG>, the sluice <NUM> is elongate or oblong and extends along a longitudinal axis, and includes a base <NUM> configured to be carried on or by a forming floor of an architectural installation. The sluice <NUM> also includes a platform <NUM> carried above the base <NUM> and configured to convey waste glass from an upstream location to a downstream location, and also includes an upstream inlet <NUM> to receive hot molten glass, and a downstream outlet <NUM> to transmit cooled, preferably solidified, glass. As will be discussed in more detail below, the sluice <NUM> also may include one or more vibrators <NUM> (<FIG>) operatively coupled to the platform <NUM> to vibrate the platform <NUM> for assisting with moving waste glass in a downstream direction, and vibration isolators <NUM> operatively coupled between the base <NUM> and the platform <NUM> to reduce transmission of vibrations outside of the sluice <NUM>.

With continued reference to <FIG>, the platform <NUM> includes an upper wall <NUM> to support, distribute, and convey glass in a downstream direction, and side walls <NUM> extending in a direction upwardly away from the upper wall <NUM> to guide and retain glass along and on the upper wall <NUM>. The platform <NUM> also may include a cover <NUM> extending between the side walls <NUM> and spaced above the platform <NUM>. The upper wall <NUM> has a plurality of apertures <NUM> to allow fluid to flow therethrough from a location below the upper wall <NUM> to a location above the upper wall <NUM>. The apertures <NUM> convey fluid so as to cool and levitate molten glass and prevent adhesion of the molten glass to the upper wall <NUM> of the platform <NUM>. The apertures <NUM> may 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 sluice <NUM> still may operate to one degree or another. Therefore, gas pressure may be applied through the apertures <NUM>, for example, from <NUM> to <NUM> PSI including all ranges, sub-ranges, values, and endpoints of that range. With reference now to <FIG>, the platform <NUM> also includes one or more fluid ducts 176a,b,c coupled to a lower wall <NUM> of the platform <NUM> to communicate fluid to the plurality of apertures <NUM>.

In the illustrated embodiment, and with reference to <FIG>, the fluid duct(s) 176a,b,c communicate with a space between the upper wall <NUM>, the lower wall <NUM> beneath the upper wall <NUM>, and side walls <NUM> and end walls <NUM> extending therebetween. The walls <NUM>, <NUM>, <NUM>, <NUM> may be welded together in an airtight manner. Preferably, the upper wall <NUM> is welded to the side walls <NUM> and then the lower wall <NUM> is welded to the side walls <NUM>. As also shown in <FIG>, the fluid duct(s) 176a,b,c may be laterally offset from a longitudinally extending centerline of the sluice <NUM> to accommodate various structural elements of the vibratory equipment.

With reference to <FIG>, the plurality of fluid ducts 176a,b,c beneath the upper wall <NUM> of the platform <NUM> can communicate fluid to the plurality of apertures <NUM> according to a plurality of different parameter values. For example, an upstream fluid duct 176a may be supplied with a fluid at a first pressure and flow rate, a downstream fluid duct 176c may be supplied with a fluid at a second pressure and flow rate, and so on. Likewise, in this regard, the apertures <NUM> corresponding to any given fluid duct of the plurality of fluid ducts 176a,b,c may be different in quantity and/or size to convey fluid according to different parameter values. The apertures <NUM> may be <NUM> to <NUM> in diameter including all ranges, sub-ranges, values, and endpoints of that range. The apertures <NUM> may 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 <NUM> to <NUM> 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 apertures <NUM> and air pressure through the apertures <NUM> may 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 to <FIG>, the fluid supplied to the platform <NUM> of the sluice <NUM> 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. Preferably, however, no cooling liquid is used, such that neither the bottom wall <NUM> of the inlet <NUM> nor the rest of the lower wall <NUM> need be liquid-cooled. The platform <NUM> may be composed of AISI <NUM>, <NUM>, <NUM>, and/or any other suitable carbon steel, <NUM> stainless steel, Inconel <NUM>, and/or any other suitable metal, and/or any other material suitable for use with molten glass. Likewise, although the sluice <NUM> may be configured to receive process water with the molten glass, preferably the sluice <NUM> operates 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 sluice <NUM> may be waterless in one or more respects. Although not separately illustrated, those of ordinary skill in the art would recognize that the sluice <NUM> may 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 sluice <NUM>. Likewise, although not separately illustrated, those of ordinary skill in the art would recognize that the vibrators <NUM> may 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 vibrators <NUM>.

The upstream inlet <NUM> includes inlet side walls <NUM> on opposite lateral sides, an inlet front wall <NUM> extending between the side walls <NUM> at downstream ends of the side walls <NUM>, and an inlet rear wall <NUM> that may have an upper edge that is vertically recessed from corresponding upper edges of the side walls <NUM> and front wall <NUM>. The inlet rear wall <NUM> may be shorter than the side walls <NUM>, for example, to accommodate a molten glass chute (not shown) cooperating with the sluice <NUM> to deliver molten glass to the inlet <NUM>. The inlet <NUM> also includes a bottom wall <NUM> extending between the side walls <NUM> and supporting the platform <NUM> thereon, and a top wall <NUM> extending between the side walls <NUM> and forward from the front wall <NUM>. The top wall <NUM> has an aperture <NUM> that 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 sluice <NUM>.

The base <NUM> may include a rectangular frame that may include four or more legs or pedestals <NUM> at each corner of the base <NUM>, longitudinally extending side rails <NUM> extending between the pedestals <NUM>, and laterally extending end rails <NUM> extending between the pedestals <NUM>.

Finally, the sluice <NUM> may be equipped with one or more sensors <NUM>, for example, proximate the outlet <NUM> of the sluice <NUM> to sense presence of glass, temperature of the glass, and/or any other characteristics suitable for use as feedback in adjusting performance characteristics of the sluice <NUM> such as air flow, air pressure, vibration frequency, vibration intensity, and/or the like. For example, the sensor(s) <NUM> may include an IFM TW2000 infrared sensor to measure temperature of the glass as it exits the sluice <NUM>. Those of ordinary skill in the art would recognize that the sensor(s) <NUM> can 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 sluice <NUM> and which may be coupled to and controlled by such controllers.

With reference to <FIG>, the cradle <NUM> is carried by the base <NUM> and, in turn, carries the sluice <NUM>. The cradle <NUM> includes a base wall <NUM>, rear flanges <NUM> extending laterally outwardly from the base wall <NUM> at a rear end of the cradle <NUM>, and front flanges <NUM> extending laterally outwardly from the base wall <NUM> at a front end of the cradle <NUM>. The flanges <NUM>, <NUM> may extend upwardly along the sidewalls <NUM> of the sluice <NUM> to laterally restrain the sluice <NUM> and may be welded, fastened, or otherwise coupled thereto. Also, the flanges <NUM>, <NUM> may be welded, fastened, or otherwise coupled onto the isolators <NUM>. The cradle <NUM> also includes one or more webs <NUM> (<FIG>) extending downwardly from and longitudinally along the base wall <NUM> and may be welded, fastened, or otherwise coupled thereto.

As best shown in <FIG>, the cradle <NUM> further includes one or more crossmembers <NUM> that extends laterally between the webs <NUM> and that may be welded, fastened, or otherwise coupled thereto. In the illustrated embodiment, there are three webs <NUM>; one centrally located and two on lateral outboard sides of the centrally located one. The cradle <NUM> further includes a vibrator mounting plate <NUM> that may be welded, fastened, or otherwise coupled to upstream ends of the webs <NUM> for mounting the vibrators <NUM> thereto, and a reinforcement strut <NUM> that may be welded, fastened, or otherwise coupled to the base wall <NUM>, and to the vibrator mounting plate <NUM> and extending upstream therefrom to a rear wall <NUM>, which may be welded, fastened, or otherwise coupled to and extending downwardly from the base wall <NUM> at the rear end of the cradle <NUM>. Of course, the vibrators <NUM> may be fastened, welded, or otherwise coupled to the mounting plate <NUM> in any suitable manner.

Although the illustrated embodiment shows the sluice <NUM> supported by the base <NUM> resting on a factory floor, in other embodiments, the sluice <NUM> may be suspended from overhead, for example, from girders, trusses, and/or any other suitable overhead structure of a building in which the sluice <NUM> is 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 cradle <NUM> to such building overhead structure. Likewise, the vibration isolators <NUM> may be configured to be coupled between such overhead structure and the cradle <NUM> in any suitable manner
The sluice <NUM> and its ancillary equipment like the sensor(s) <NUM>, a fluid fan or pump to supply fluid through the apertures <NUM>, and the vibrators <NUM> may be instrumented and/or communicated with one or more controllers for closed loop control of rate of flow of molten glass through the sluice <NUM>. For instance, a temperature of the glass can be sensed or monitored by one or more of the sensors <NUM>, for example, at or proximate the end of the platform <NUM> as it exits the sluice <NUM>. 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 apertures <NUM> can be increased to increase cooling of the glass.

<FIG> illustrates an example of a method <NUM> for handling glassware manufacturing waste using the glassware manufacturing system <NUM> and glassware manufacturing waste handling system <NUM> described herein. For purposes of illustration and clarity, method <NUM> will be described in the context of the glassware manufacturing system <NUM> described above and generally illustrated in <FIG>. 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 method <NUM> may find application with any number of arrangements (i.e., steps of method <NUM> may be performed by components of the glassware manufacturing system <NUM> other than those described below, or arrangements of the glassware manufacturing system <NUM> other than that described above).

Method <NUM> comprises a step <NUM> of providing process water to the glassware forming machine <NUM> carried by the forming floor <NUM>, where the process water drains from the glassware forming machine <NUM> to the forming floor <NUM>. 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 chute <NUM>, and/or any other liquid to the glassware forming machine <NUM>. In an example, process water can be provided to the glassware forming machine <NUM> by 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 chute <NUM>), and so forth. The process water can be provided to the glassware forming machine <NUM> and can then drain by gravity from the glassware forming machine <NUM> to the forming floor <NUM>. 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 pit <NUM>.

Method <NUM> comprises a step <NUM> of collecting the process water from the forming floor <NUM> using a waste liquid trench <NUM> and a sump pit <NUM> formed in the forming floor <NUM>. After the process water drains from the glassware forming machine <NUM> to the forming floor <NUM>, the water can flow to the waste liquid trench <NUM>. In instances when the forming floor <NUM> has a pitch or is sloped or crowned, the pitch, slope or crown of the forming floor <NUM> can assist with providing and directing the process water flow. As the water flows to and is collected by the water liquid trench <NUM>, the water liquid trench <NUM> can carry and direct the water to the sump pit <NUM>, 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 machine <NUM>, for example the cullet material handler <NUM>.

Method <NUM> comprises a step <NUM> of collecting cullet from the glassware forming machine <NUM>. In one embodiment, the method includes using the cullet material handler <NUM> to collect the cullet, where the cullet material handler <NUM> is disposed adjacent, or proximate, to the glassware forming machine <NUM>. The cullet can be provided to the cullet material handler <NUM> using the waste molten glass chute <NUM>, a reject conveyor <NUM>, and/or other equipment used in the industry for handling cullet. In another embodiment, the method also or instead includes using the sluice <NUM>, <NUM> to collect the cullet, where the sluice <NUM>, <NUM> is disposed adjacent, or proximate, to the glassware forming machine <NUM>. The cullet can be provided to the sluice <NUM>, <NUM> using the waste molten glass chute <NUM>, a reject conveyor <NUM>, and/or other equipment used in the industry for handling cullet.

Method <NUM> comprises a step <NUM> of recycling the process water from the sump pit <NUM> to the glassware forming machine <NUM>. In this step, the water in the sump pit <NUM> can be pumped/provided to the glassware forming machine <NUM> using a pump (not shown) or other means. For example, the water can be pumped through plumbing to the glassware forming machine <NUM> including 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 system <NUM> can be generally a closed loop with regard to providing the recycled process water.

In some instances, method <NUM> may comprise a step <NUM> of treating the process water from the sump pit <NUM>. Process water collected by the sump pit <NUM> may 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 machine <NUM>. For example, the sump pit <NUM> may 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 pit <NUM> may be treated using other equipment and processes.

<FIG> illustrates an example of a method <NUM> for handling waste molten glass using the sluices <NUM>, <NUM> and their ancillary equipment described herein. For purposes of illustration and clarity, method <NUM> will be described in the context of the sluices <NUM>, <NUM> generally illustrated in <FIG>. 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 method <NUM> may find application with any number of arrangements (i.e., steps of method <NUM> may be performed by components of the sluices <NUM>, <NUM> and ancillary equipment other than those described below, or arrangements of the sluices <NUM>, <NUM> and ancillary equipment other than that described above).

Method <NUM> comprises a step <NUM> of 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 platforms <NUM>, <NUM> illustrated in <FIG> and <FIG>, or on any other platform suitable to have a cushion of gas thereon and to receive molten glass thereon.

Method <NUM> also comprises a step <NUM> of conveying waste molten glass in a downstream direction on a cushion of gas on a platform. For example, the platforms <NUM>, <NUM> may be declined along a downstream direction, and the cushion of gas may be configured to push the molten glass in a downstream direction.

Method <NUM> further comprises a step <NUM> of 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 platforms <NUM>, <NUM> at a higher pressure and/or flow rate compared to gas supplied at a downstream end of the platforms <NUM>, <NUM>.

Method <NUM> also comprises a step <NUM> of vibrating a platform to assist with conveying waste molten glass in a downstream direction. For example, the platforms <NUM>, <NUM> may be coupled to the one or more vibrators <NUM>, <NUM> to produce relative movement in an lateral and/or longitudinal direction between an upper surface of the platforms <NUM>, <NUM> and a lower surface of the molten glass.

Method <NUM> additionally comprises a step <NUM> of adjusting one or more characteristics of vibration of step <NUM> to 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 sensors <NUM>, for example, at or proximate the end of the platform <NUM> as it exits the sluice <NUM>. 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 apertures <NUM> can 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> illustrates a prior art glassware manufacturing system, including an architectural installation having a forming floor and a basement 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.

Claim 1:
A glassware manufacturing system (<NUM>), comprising:
an architectural installation (<NUM>) having a forming floor <NUM> and no basement beneath the forming floor (<NUM>);
a glassware forming machine (<NUM>) carried on the forming floor (<NUM>);
a molten glass feeder (<NUM>) configured to provide molten glass (<NUM>) to the glassware forming machine (<NUM>); and
a glassware manufacturing waste handling system (<NUM>), including:
a sump pit (<NUM>) in the forming floor (<NUM>);
a waste liquid trench (<NUM>) substantially surrounding the glassware forming machine (<NUM>) and flowing to the sump pit (<NUM>); and
at least one of a cullet material handler (<NUM>) or a molten waste glass sluice (<NUM>), configured to receive molten glass (<NUM>) from the molten glass feeder <NUM> and hot glassware rejects from the glassware forming machine (<NUM>).