Optimal demand response operation of electric boosting glass furnaces

Abstract

The glass industry is highly energy-intensive, accounting for 1% of total industrial energy consumption in the United States. Most of the energy consumption in the glass manufacturing process is attributable to the significant heat required to melt raw materials. An electric boosting system which can transfer extra heat (5%–20% of total energy) to the glass melt in addition to the energy from natural gas combustion can be implemented in a glass furnace. Electric boosting is thermally efficient, reduces direct pollutant emissions, and prolongs furnace superstructure lifespan. However, a high level of electric boost is not always economically desirable, considering the volatility of electricity prices. Balancing between natural gas and electricity consumption in a demand response strategy can reduce the energy cost and mitigate strain on the electrical grid. In this paper, a physics-based model is developed to describe the dynamic behavior of a prototype electric boosting glass furnace. We present a dynamic optimization strategy to optimally balance between using natural gas and electric power under electricity price fluctuations. Case studies on the effect of varying energy prices and emissions regulations are analyzed.