bdf-6-energy-on-glass

ENERGY ON GLASS

WASTE HEAT RECOVERY HEAT EXCHANGER ORC TURBINETOO COGENERATION TRIGENRATION STEAM & SUPERHEATE WATER TREATMENT EMISSION MONITORING SYSTEM ORC TURBINE HEAT EXCHANGER COGENERATION TRIGENRATION DEDUSTING SOx NOx ABATEMENT WATER TREATMEN EMISSION MONITORING CONTROL COMPRESSOR LINE MANAG CERAMIC FILTRATION WASTE HEAT RECOVERY - HEAT EXCHA HEAT EXCHANGER ORC EMISSION STEAM & SUPERHEATED WATER ENERGY EFFICIENCY

GLASS | AUTOMATION | ENERGY

ALL IN ONE

QUALITY IS NEVER AN ACCIDENT. BDF INDUSTRIES, SINCE 1906.

PRODUCT LINES

MELTING

BDF industries Melting product line includes the complete glass melting and conditioning technologies for design and supply of furnaces, working end & forehearths. The range of products includes also the relevant equipment like oil and gas burners and firing system, air and exhaust reverse valve, batch chargers, forehearth glass mixers etc.

BDF Industries furnaces are engineered by high level of customization with focus on energy efficiency and the attention to the environmental impacts.

Long time experience skilled people work together in synergic team with young generation technician in order to offer a wide range in design, manufacture and supply of different furnaces types for production of containers, tableware, lighting ware and technical glassware.

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FORMING

The forming department of BDF Industries is the historical core business.

BDF Industries is able to provide a wide range of machineries with a high level of production flexibility to meet the customers’ requirements. With more than 65 years’ experience in glass forming field, BDF Industries can offer the complete range of IS machine including gob forming and delivery, ware handling, container and variable equipment. The glass forming machineries are fully designed and assembled in house by BDF Industries in Italy, which has relevant knowledge of production process of the most important glass manufacturers in the world (i.e. strong credentials for forming business in O-I, Vetropack, Vitro, Sisecam, Saverglass‌) Our R&D office is focused to find the best solutions applied into IS machines in order to match lower production costs for our Customers thanks to higher reliability and maintainability of our product. We continue to work towards research and innovations that will deliver genuine advantages in productivity and efficiency for our customers glass factories located in different area around the world.

AUTOMATION

The automation division is involved in the engineering process and software, during reconditioning and retrofitting of all part of Glass Factory including: plant designing, installation and startup, network configuration, control, staff training, customer service and remote assistance.

The experienced, qualified, passionate and customer-focused staff is there to add value for customers, partners and suppliers.

As part of its own philosophy, the team believes and operates in the sustainable development: the application of its carefully designed and implemented systems greatly save energy and relevant impact on the environment, thus improving the quality of life and the safety of the operators in the field as well as adding economic and social value to the community.

A fundamental key of success in the automatic control is the interlink with melting and forming teams which makes the final product completely fit with the Glass Factory requirements.

ENERGY

The large BDF Industries Group experience in the glass industry and automation makes BDF Energy division the more qualified counterpart when it comes to improve, re-qualify or re-invent a glass production plant.

To master the challenges of global competition, our customers must minimize costs, continually increase the productivity of their systems and meet ever-stricter environmental regulations.

Our innovative and ecofriendly solutions help to conserve natural resources, improve energy and capital utilization and optimize processes. For our customers, this means lower raw materials consumption, fewer emissions, greater energy efficiency, lower costs and increased output.

BDF Energy division is a natural step of a century-experienced company’s evolution. The experience into demanding environment as the glass industry is our key point to succeed around you.

Resources from waste: heat recovery system of waste gases to produce electric energy via ORC turbine or steam turbine.

Waste gases treatment: dust filtration and waste gases chemical compounds abatement techniques.

These are some package solution examples of what BDF Industries can offer, develop, deliver and install.

SERVICE

The reliable and innovative partner for running glass making plants to maximize productivity, quality, reliability, maintain assets and contain costs.

BDF Industries has a Service organization dedicated to provide a complete spectrum of the highest quality service solutions to satisfy the needs of our clients from a single source. Our services support the entire product value chain from melting glass making to forming, filtering, energy facilities and automation.

The service product line includes installation & startup, upgrades of mechanical equipment and automation, technical assistance for repairing and overhauling, training, performance evaluation & long term service agreement, integrated maintenance management & diagnostic solutions and systems, spare parts.

The BDF Industries service team supports the strategic goals of glass factory by stimulating growth in core skills and providing personalized programs for the glass industry.

The BDF Industries Learning Center in Italy and strategically located Service Centers offer a wide range of programs in technical courses. Our technical courses are presented by field-tested experts combining understanding of theory and practical experience.

The quality training provided is a prerequisite to improve the skills of operating and maintenance personnel, so as to assure knowledge, safety and higher equipment availability.

The contents of service are the following: • Supply local qualified supervisors • Supply of certified end/or upgraded OEM (Original Equipment Manufacturer) spare parts for all maintenance operations • Performance of all equipment maintenance • Repairs using state-of-the-art technology • Optimization of Spare Parts inventory • On the job Training of local maintenance and operation personnel

GLASS | ENERGY | 5

PRODUCT LINES

GLASS CATALOGUES

MELTING FURNACE CONDITIONING WORKING END FOREHEARTH FORMING DELIVERY

FORMING IS MACHINE

WARE HANDLING

ENERGY ON GLASS GATALOGUE

INDUSTRIAL AUTOMATION CATALOGUE

INDEX

ENERGY ENTHALPY RECOVERY ENVIRONMENTAL PROTECTION EMISSION MONITORING

PAG 8 PAG 12 PAG 14

ENTHALPY RECOVERY

ENERGY TOWER CONCEPT WITH LOW FOOT PRINT IMPACT SUITABLE FOR GLASS MANUFACTURING PLANT • Well known technology • Electricity production • Small Installation area required • Important annual energy savings • Quick payback is possible • 20 years lifetime technology • No media high pressure involved in the process • BDF technology is fully suitable and tested for glass manufacturing plant • No interference with the furnace processes • BDF patented system to prevent heat exchanger from fouling • Possible integration with other BDF Energy products

LFP (LOW FOOT PRINT) BDF has developed this Energy tower concept to reduced the required installation area for the glass plant.

8 | GLASS | ENERGY

BDF ENERGY BATCH CHARGER

FURNACE

DEDUSTING MIX BOX

HEAT EXCHANGER

DeSOx

FILTER

DeNOx CEMS

ORC TURBINE

COMPRESSED AIR PRODUCTION It is possible for BDF to generate compressed air with the same plant.

This could be useful for payback reason in some countries.

GLASS | ENERGY | 9

ENTHALPY RECOVERY

HOT WATER PRODUCTION THIS IS BDF BASIC SOLUTION FOR ENTHALPY RECOVERY. HEAT EXCHANGER COULD EASY GENERATE AN HIGH AMOUNT OF STEAM OF HOT WATER. Short payback time, high efficiency.

Some uses for this hot water/steam are: • Office heating • District heating • Sanitary water • Food industry usage • Cullet washing • Steam industrial usage

FUMES COOLING SYSTEM

GLASS FURNACE

HEAT EXCHANGER

HOT WATER

CHILLED WATER PRODUCTION

BY USING ABSORPTION UNIT IS POSSIBLE TO EXPLOIT THE HEAT IN THE FUMES TO PRODUCE CHILLED WATER. Absorption unit technology can determines the chilled water temperature, 4-5 °C for Br-Li or 0°C from ammonia based absorption unit.

The chilled water can be used for: • Air conditioning • Food industry • Store temperature control • Cooling for IS cooling system Br-Li absorption unit need heat exchanger and evaporating tower installation to operate.

10 | GLASS | ENERGY

CEMS

ENTHALPY RECOVERY

COGENERATION TRIGENERATION OPTION BDF CAN OFFERS THE COMBINATION BETWEEN ELECTRICITY GENERATION, HOT WATER AND CHILLED WATER PRODUCTION. IN THIS WAY IS POSSIBLE TO BOOST THE PAYBACK. USING ELECTRICITY, STEAM AND CHILLED WATER PRODUCED IN YOUR OWN PLANT CAN REDUCE MOREOVER THE PAYBACK TIME. FOR THESE REASONS THE BIGGER INVESTMENT IN INSTALLATION COSTS COULD BRING TO A SHORTER PAYBACK THAN A NORMAL ENERGY TOWER SOLUTION. Other option that BDF engineering can offer are: • Distillation unit to produce distilled water exploiting the heat in the fumes.

• Seawater cooling system that can produce bags of salt ready for selling.

GLASS | ENERGY | 11

ENVIRONMENTAL PROTECTION

N N

O N O

O

O

N O N

O

ON

O

O

NO N N

O

N O

O

O

N

O O O Nitrogen Oxides -N NOxO O O H

MAIN GLASS PLANT POLLUTANTS

S

S O N F

S O O O

S O N OS O O

O O

O

O

O S O O

O

O

H FOxides - SOx Sulfur H H H

F Cl S H Cl O O Cl

O S

ChloridesO - HClO H

F

H

Cl

Fluorides - HF

N N

O

O

NOx AND SOx BDF SYSTEM ABATEMENT

ECOLOGIC GLASS PLANT

POLLUTANTS ABATMENT, NOx AND SOx ABATEMENT SELECTED CATALYTIC REDUCTION SCR

SELECTED NON-CATALYTIC REDUCTION SNCR

DRY OR SEMI-DRY SCRUBBER HYDRATED LIME

Involves reacting NOx with ammonia(NH3) or urea(CH4N2O) in a catalytic bed at the appropriate temperature. According with temperature windows there are several catalysts available. The most common are vanadium and titanium oxides(TiO2 and V2O5) embedded in ceramic or metallic substrate, or zeolites. The catalyst units are modular honeycomb structures. The operating temperature of the system are usually from 200°C to 500°C with the optimum between 300°C and 450°C.

Also known as thermal DeNOx, the oxides of nitrogen in the waste gases are reduced by reaction with ammonia or urea. The chemical reactions are the same of SCR system but take place at higher temperatures without the need for a catalyst. The operating temperature is in the range 900-1050°C and the optimum is around 950°C for ammonia and 1000°C for urea. For this reason in SNCR the reagent injection is closer to the furnace than SCR. 1-2 seconds are required to obtain a good efficiency from the reaction.

An absorbent reagent is introduced and dispersed in the waste gas stream. this material reacts with SOx (but also metals and acid species HF and HCl) to form a solid, which has to be removed by a filtration system. Is possible to inject the reagent directly in the fumes ducting or in a reaction tower or chamber for a more efficient process. This absorbent reagent is a powder (usually Ca(OH)2, NaHCO3, or Na2CO3)for dry scrubber, or a water solution of NaCO3 or Ca(OH)2 for semidry scrubber. In the glass industry the most common is the dry application that use Ca(OH)2 namely hydrated lime.

12 | GLASS | ENERGY

ENVIRONMENTAL PROTECTION

FILTRATION - DEDUSTING BAG FILTERS SLEEVES Basic principle is to select a fabric membrane which is permeable to gas but retain the dust. Initially dust is deposited both on the surface fibers and within the depth of the fabric, but as the surface layer builds up, it itself become the dominating filter medium.

This “cake” of dust increase also the resistance to gas flow, so periodic cleaning of the filter are mandatory to prevent the pressure drops.

HIGH TEMPERATURE FILTER MEDIA CERAMIC CANDLES Same principles of bag filter but the filter material is ceramic (or stone wool in some cases) that can resist to higher temperatures: this device is called candle. Further technologies combine NOx removal by the embedding of catalyst in this ceramic candles.

Dust efficiency removal

SLEEVE

CERAMIC CANDLE

Very high Capture metals

High also with high dust loading, but low with small particles

Possible re-use of collected dust Yes Collected in dry conditions

Pressure drop High if not cleaned

Reaction to Temperature moisture of Exercise

Moderate

Investment cost

Safety issue

Size

Re-heating for DeNOx

€

None

Small

Yes

€€

difficult explosion relief for flammable materials

Small

No

Bad

Max 220 °C

Low, unless high pressure drops

Good

Over 500°C

Low, unless high pressure drops

Yes Collected in dry conditions

Energy use

Flue gas volume (Nm3/h)

High Temperature Technology CERAMIC CANDLE

Low Temperature Technology FABRIC SLEEVE

10000-15000

C1

S1

15000-20000

C2

S2

20000-25000

C3

S3

25000-30000

C4

S4

30000-35000

C5

S5

35000-40000

C6

S6

FILTRATION PROPOSED FILTER SIZE According to heat exchanger models we can find 12 different filers that can be used with the same volume of the waste gasses.

GLASS | ENERGY | 13

ENVIRONMENTAL EMISSION MONITORING

BDF CEMS 87 • Devices for extractive and in-situ emission measurement • Measuring technologies (e.g. NDIR, UV, electrochemical or paramagnetic principle, filter correlation, scattering light) • Single and multi-component analyzers, on customer request • Certified system by government agency • CEMS system can be integrated in plant control scada system • Low maintenance costs • Possible integration with process control.

• Possible supervision integration with other glass plant controls.

• Possible installation at ground level (fast-loop option).

IN -IN SITU - SITU

FAST FAST LOOP LOOP

BDF CEMS 87 IN-SITU

BDF CEMS 87 FAST LOOP

14 | GLASS | ENERGY

INSTALLATION, COMMISSIONING, MAINTENANCE • Audit • Spare parts • Repairs • Hardware & Software up date • Electrical & mechanical installation services for turn key projects • Start up • Government Agency’s rules compliance service and counseling • Maintenance activities and preventing maintenance scheduling

GLASS | ENERGY | 15

BDF ALL IN ONE MELTING FURNACE CONDITIONING WORKING END FOREHEARTH FORMING DELIVERY FORMING IS MACHINE WARE HANDLING ENERGY ON GLASS INDUSTRIAL AUTOMATION

BRANCHES REPRESENTATIVES WHERE BDF INDUSTRIES IS ACTIVE

www.bdf.it BDF INDUSTRIES S.p.A. Headquarter Viale dell’Industria, 40 36100 Vicenza - Italy phone +39 0444.286.100

BDF SHANGHAI TRADING Co.,Ltd. Room 1301/2, 818 Nanjing West Road, Shanghai (China) phone +86.02162108237

BDF INDUSTRIES North America LLC 800 Town and Country Boulevard - Suite 300 770261 Houston - TEXAS phone +1 832 404 2292

BDF INDUSTRIES South America Ltda Av. Paulista, 854 10° andar sala 1020 Bela Vista 01310-100 São Paulo SP - Brasil phone: +55 11 21860262

BDF SERVIS D.O.O. Hum Na Sutli 107/4, 49231 Hum Na Sutli - Croatia phone + 385 (0)49 382 222