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July/August 2021—Vol.44 No.7
O-I VILLOTTA OVERVIEW FUTURE OF FORMING GREENER GLASSMAKING I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
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Contents
www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Assistant Editor: George Lewis Tel: +44 (0)1737 855154 Email: georgelewis@quartzltd.com Designer: Annie Baker
July/August 2021 Vol.44 No 7
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Managing Director Tony Crinion tonycrinion@quartzltd.com Chief Executive Officer: Steve Diprose
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Sustainability: O-I Villotta Creating one of O-I’s most energy-efficient plants
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Future of Forming: Bucher Emhart Glass The journey to digital end-to-end forming solutions
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Future of Forming: Sklostroj All-Electric Plant
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Future of Forming:Heye/Glass Futures In search of a container forming revolution
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Country profile: Pakistan The upward curve of the glass industry in Pakistan
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Hydrogen: Stara Glass The idea of a Total Recovery Glass Furnace and the LIFESUGAR Project
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Environment: Krysteline Cullet production is only part of the challenge
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Environment: Durr Systems Generating electricity using glass production exhaust gas
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Environment: Stoelzle Stoelzle implements holistic CSR strategy
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Environment:Tri-Mer Catalytic filtration in the glass industry
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Automation: futronic futronic wins Taiwan contract
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Country profile: Bangladesh Bangladesh glass industry continues to expand
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Raw materials: Omya Understanding the use of calcium carbonate in glass manufacturing
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Annealing: Vidromecanica Improved the annealing lehrs cycle
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History I’ll drink a glass to that
Chairman: Paul Michael
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International News
GREG MORRIS, EDITOR
Be first with the news! For breaking, up to date news
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Glass packaging bounces back
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Proof, if any was needed, of the public’s thirst for glass was provided by the container glass sector in its recent second quarter financial results. All of the major players in the sector - Vidrala, O-I, Ardagh and Verallia reported strong growth, with production up in the double figures for some compared to the previous year, when the pandemic was at its peak around the world. This was reflected in glass technology supplier Bucher Emhart Glass’ financials where it reported a 75% increase in order intake compared to the year before. This uptake in demand coincided with the widespread opening of the hotels and restaurant sector. It clearly shows the public has an affinity to glass and is their preferred packaging choice during a meal out or overnight stay. Hopefully it means that the messages of campaigns such as Friends of Glass have hit home and the public is recognising the benefits of a material which is inert and endlessly recyclable. So what next for the container glass sector? Perhaps now is the time to remind the public of the benefits of working in the sector. With the arrival of new digital technology in the manufacturing process you could suggest that it has never been a better time than now to secure a job in the sector. For young engineering students, the glass industry, with its increased use of Industry 4.0 technology, is an appealing sector.
Vidrala reports glass sales growth of 11.6%
Spanish container glass manufacturer Vidrala has posted a sales growth of 11.6% in its latest report. Net sales reported by Vidrala during the first six months 2021 amounted to € 529.5 million, representing a growth of 11.6% over the previous year. In its latest financial report it said growth in the second
quarter of this year was partially explained by last year’s low base of comparison. It said: “The results confirmed the strength of its diversified business profile and the bright future glass has as the preferred and most sustainable packaging option for food and beverages. “Demand for glass across
our markets remained solid in the first half of 2021, grounded on the strong underlying fundamentals of food and beverages consumption, the progressive reopening of activities and the continuous support from packagers, brand owners and consumers to glass as the ultimate sustainable packaging material.”
Hydrogen: launch of Italian project to decarbonise the industry An Italian group comprising glass manufacturers, furnace suppliers and energy companies has begun a collaboration aimed at reducing emissions in the glass industry through hydrogen. The group consists of Snam, RINA, Bormioli Luigi, Bormioli Rocco, Stara Glass, UNI.
GE, Stazione Sperimentale del Vetro, IFRF Italia, SGRPRO and RJC SOFT. The ‘Divina’ project (Decarbonisation of the Glass Industry: Hydrogen and New Equipment), co-ordinated by Snam, RINA and Bormioli, aims to reduce emissions in the glass melting stage, which accounts
for more than 50% of total energy consumption throughout the production process. The availability of an energy source such as hydrogen can provide a viable solution by optimising its use in terms of energy and emissions and managing production and transport challenges.
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International News
NEWS IN BRIEF
French manufacturers secure funding
NSG UK is to receive $40 million to finance a greenfield glass production plant in Argentina. The plant, located in Cardales, approximately 70 kilometres north-west of Buenos Aires will have an estimated production of 900 tonnes per day. The plant will develop
NSG’s Industry 4.0 standards and support its decarbonisation ambitions. The International Finance Corporation (IFC) will provide the loan to NSG UK. via its subsidiary in Argentina, Vidriería Argentina S.A. (VASA). It will provide an advisory service to VASA to help identify future energy efficiency
opportunities. David Tinel, IFC’s Regional Manager for the Southern Cone, said: “We are pleased to finance the completion of this project and to strengthen our relationship with NSG UK, a repeat global IFC client with a firm commitment to corporate governance practice and green standards.”
Ardagh reports 7% glass packaging shipments increase Ardagh reported a glass packaging shipment increase of 7% in its latest financial note. The global glass manufacturer said the increase was led by a 10% growth in Europe, which was reflected by a 36% increase in the EBITA of its Eu-
ropean division. It said the strong growth was attributable to increased yearon-year shipments in Europe, a positive contribution from its investments and lower levels of Covid-19 related costs. Total revenues from its Glass
Packaging division increased by 8% at constant exchange rates and by 14% on a reported basis compared with the same period last year. In North American, revenue of $445 million increased by 9% compared with last year.
Balochistan Glass ignites glassmaking furnace Pakistan tableware glass manufacturer Balochistan Glass has ignited a furnace at its Lahore production facility. The refurbished 65 tonnes per day furnace at its Unit III factory in Kot Abdul Malik, Lahore is the second oven at
the site. The company manufacturers a variety of tableware glass, including jugs, vases, fruit sets and water sets. It has three glass manufacturing facilities but two - in Balochistan and in Sheikhupura - have currently
suspended production. In a financial note, management said the expansion project would allow the company to increase its share of the domestic market and tap potential opportunities in the international market.
Glass Futures appoints new Board advisor
Glass Futures has appointed former Chief Executive of Siemens UK Juergen Maier CBE as an advisor to the Board. Mr Maier has joined to champion manufacturing, improving infrastructure and engineering skills and is said to be ‘enthusiastic about the benefit of Industrial Digitalisation to encourage advanced manufacturing and investment in digital technologies’. Alongside his role with Glass Futures, Mr Maier is also Chair of the Digital Catapult and Co-Chair of the UK’s Made Smarter programme.
Encirc to use hydrogen in its furnaces
Glass bottle manufacturer Encirc plans to use hydrogen in its manufacturing furnaces to create billions of ultra-lowcarbon glass bottles. The availability of hydrogen will enable the expansion of Encirc’s Elton facility, which it said would create at least 200 jobs, while futureproofing existing roles. The glass manufacturer aims to produce bottles using hydrogen by 2025. The project has the potential to reduce emissions by 10 million tonnes every year by 2030.
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NSG to receive $40 million for Argentinean greenfield plant
Two French glass manufacturers have secured government funding to help reduce emissions in the production process. O-I’s Vayres site and International Cookware’s Chateauroux facility are among 15 beneficiaries of the French Government’s €28 million funding as part of its France Relance project. It is part of Energy Efficiency and Decarbonisation scheme which aims to cut industrial greenhouse gas emissions by 17% on average at the 15 sites, which represents a total of more than 68,600 tonnes of CO2eq per year.
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International News
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Horn to construct glass furnace for Bastürk Cam Glass melting technology specialist Horn is to build a 560 t/d end fired furnace for Bastürk Cam at its Malatya plant, Turkey. The new furnace is designed with six forehearths for the production of container glass. It will have a melting area
of 185.4 m² to produce flint glass. Heating of the furnace will be by means of Natural Gas or Back-up Diesel oil burners. Horn’s scope of supply includes the engineering of the refractory and steel structure, the Combustion System, Boosting System,
Measuring and Control equipment, a new Horn HVR 600F batch charger, supervision of erection, heat-up and commissioning. Installation is planned to start in the second quarter of 2022.
Schott breaks ground on flat glass processing plant Speciality glass manufacturer Schott has invested €9 million in technology for a flat glass processing plant in Turkey. It said the Schott Irim site in Bolu, Turkey would containe the latest digital production technology when manufacturing starts in
early 2022. The groundbreaking ceremony for the new building took place last month. The investment will increase the production capacity in Bolu by 50% and underlines the importance of the home appliance business to Schott.
The engagement in Turkey is part of Schott’s global growth strategy: For the second year in a row, the group has run a record investment programme, with €350 million being invested this financial year. All projects are on time despite the pandemic.
British Glass publishes industry-wide net zero strategy British Glass has published a strategy that sets out the glass industry’s potential route to net zero carbon emissions. The strategy follows on from the decarbonisation roadmap in 2015 in conjunction with BEIS that was
based on achieving a reduction of 80% CO2 by 2050. Following the government’s agreement to the Paris Agreement, British Glass has worked with members and industry partners to devise a strategy to achieve net zero.
The strategy outlines the options to enable glass manufacturers to reduce combustion and process emissions, as well as improving energy efficiency. It also sets out how glass can support other sectors to decarbonise.
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Don’t just look at it, look into it.
Tiama Xlab – the revolutionary 3D sampling solution Turn virtual reality into reality with the new Tiama Xlab. This highly flexible laboratory module can be installed at the hot end, the cold end or in the laboratory. It loads the container automatically and makes a 3D scan, generating an image composed of millions of facets. The 3D image can be rotated and “dissected” on all sides. Virtual volume, capacity, and vacuity can be measured as well as glass distribution fully mapped. You can also analyse engraving, embossing and much more. Practically all container types and shapes can be inspected and it’s non-destructive because the image (and not the container itself) is “cut” virtually. For an online presentation of the Tiama Xlab please contact us at marketing@tiama.com.
Data – the deciding factor
International News
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Nipro breaks ground on French greenfield site
NiproPharmaPackaging has broken ground on its greenfield glass manufacturing facility in Aumale, France. The site will manufacture glass tubing for pharmaceutical glass packaging products. The new production facility will be housed in a new building adjacent to the current manufacturing site with automated lines which will produce Nipro’s NSV borosilicate type I glass. Last year the pharmaceutical glass packager said it would invest €60 million in its French and US manufacturing facilities.
Noelle + von Campe secures €1.8 million grant
German container glass manufacturer Noelle + von Campe has received a €1.8 million grant to help the development of a new furnace. The glass manufacturer plans to build a new melting furnace at Plant II in Boffzen, Germany. The melting tanks 1 and 3 at the plant location are to be gradually shut down. A new, separate building is to be built for the planned melting tank and the subsequent process units. In addition, a new workshop and social building is to be built and the long halls are to be renovated.
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Ciner Glass unveils UK glass manufacturing plant plans Video: Furnace leak at Indian glass plant Hydrogen: launch of an Italian project to decarbonise the glass industry EME technology for Indian solar glass producer Borosil Ciner Group to invest $100 million in glass raw materials capacity NSG to receive $40 million for Argentinean greenfield glass plant Encirc to use hydrogen in its glass manufacturing furnaces Gerresheimer invests in glass manufacturing furnace expansions O-I and International Cookware secure decarbonisation funding Horn to construct glass manufacturing furnace for Bastürk Cam
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Vitro to construct $120 million float glass furnace at Garcia Mexican glass manufacturer Vitro is to build a $120 million float glass furnace at its García plant near Monterrey, Mexico. It will be the third glass furnace at the plant and is set for construction later this year. The investment will allow
the company to meet the growing market demand in Latin America and provide greater product availability and improved logistics, enabling the company to provide a higher level of service to its customers and markets.
“While the primary purpose of this new line is to meet growing market demand in the Latin American region, the additional capacity will allow us to provide a higher level of service to our customers,” said President Ricardo Maiz.
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Ciner Glass unveils UK glassmaking plant plans
Ciner Glass has unveiled plans for a container glass manufacturing and recycling facility in the UK. The proposed glass packaging site in Ebbw Vale, Wales will create hundreds of jobs and ‘economic benefits for generations to come’, said Ciner Glass’ Board member Didem Ciner. It had submitted an Environmental Impact Assessment and was waiting the results of a scoping report by the local authority, Blaenau Gwent County Borough Council.
Sisecam posts strong financial results for first half of 2021 Sisecam’s 2021 first half-year consolidated net sales totalled TRY 13 billion (US $1.5 billion) with international sales – comprised of exports from Turkey and sales from non-Turkey facilities – accounting for 64% of its total revenue. In its first financial report of 2021, the company also
reported that the company’s capital expenditure was at TRY 838 million (US $97 million), while exports reached TRY 2.8 billion (US $327 million) in the first half of the year. These results meant that Sisecam exceeded the same period of the previous year and in 2019.
Sisecam CEO Görkem Elverici said: “Despite the climate of uncertainty and extraordinary conditions created by the global pandemic, we continued our investments without interruption in line with our priority to meet our customers’ glass demand and to create value for the economies.”
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VMA launches new corporate identity
German non-contact measuring specialist VMA has launched a new corporate identity with a revised logo as well as a relaunched website. The new logo-design more than ever represents the four VMA business divisions: container glass, flat glass, laboratory measuring equipment and special solutions. It distinctly communicates the company’s core competence and reflects the solution-oriented approach with its straightforward and pragmatic design. “We remain dedicated to be a persistent quality partner for our customer in the glass industry. With its timeless design, the logo is the perfect companion for new, groundbreaking projects,” said Nico Thomae, Managing Director of VMA. In the course of changing the logo, the VMA-website was fundamentally revised. The four business divisions are clearly at focus. The updated content and new layout provide a quick and comprehensive overview of the company, product range and services.
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FIC UK provides hydrogen clarification
During the presentation by F.I.C. (UK) Limited on the theme of ‘Hydrogen in Glassmaking’ on the 16th June reference was made to FEVE project (F4F). The slide in the presentation read ‘FEVE project with Ardagh and Heineken’ this may have given the impression that Heineken was part of FEVE. It is unequivocably not. FEVE is the grouping of around 19 containers manufacturers, many of them international. The F4F project by FEVE does not involve Heineken or any other customer. It is a project by the industry for the future of the glass industry and is collaborative. FIC apologise for any confusion that may have occurred.
Gerresheimer invests in glass furnace expansions German glass manufacturer and packager Gerresheimer has invested in furnace expansions at two production facilities. The group invested €50.1 million in its Primary Packaging Glass division in the six
months between December 2020 and May 2021, which was related mainly to the investments at its Kosamba, India and Lohr, Germany facilities. It also invested in expanding its production capacity for
injection vials, in its plants in North America and Europe. In its half year financial results, the pharmaceutical and cosmetics glass packager reported revenue increase of 3.6% to €320.1 million in its glass division.
AGC completes sale of NA architectural glass business AGC has completed the sale of its North American architectural glass business to Cardinal Glass. The deal is reportedly worth $450 million and will see AGC
sell all three of its plants in Kansas, Tennessee and Virginia, which altogether has three flat glass furnaces and two coaters. The transaction is expect-
ed to generate a profit of approximately 25 billion yen ($227,000), which is expected to be recorded as other income in the consolidated financial results for the Q3 of 2021.
Asahi India Glass plots Indian solar glass manufacturing plant Asahi India Glass Limited (AIS) is to help set up a solar glass manufacturing plant in Mundra, India. It has partnered with Ahmedabad-based Vishakha Group to form what is says is India’s largest solar glass manufacturing plant.
The greenfield site at Mundra, Gujarat will have a phase-1 capacity of up to 3GW. The plant is expected to be commissioned within 18-24 months and AIS will take a minority stake in the business. Vishakha Group is a man-
ufacturer of flexible polymer packaging. It also has manufacturing facilities for other key components in the entire solar panel value chain such as solar backsheets, EVA encapsulant sheets and solar module aluminium frames.
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Sustainability: O-I Villotta
� Alessandro Lanzellotto.
� Ludovic Valette.
“Sustainability is at the core of what we do. We are selecting the right plant at the right time with the right purpose.
”
Ludovic Valette
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Creating one of O-I’s most energy-efficient plants O-I Villotta in Italy is now one of the glass container manufacturer’s most energy-efficient plants. George Lewis spoke to Alessandro Lanzellotto* and Ludovic Valette** about the investments at the production facility.
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Sustainability: O-I Villotta
“We currently use approximately 80-85% recycled content for our coloured glass and approximately 70-75% for flint glass.
”
But we want to increase that percentage due to the benefits of recycled glass
T
he world’s largest container glass manufacturer O-I recently completed a series of investments at its plant in Villotta, Italy, transforming it into one of its most energy-efficient glass packaging plants. O-I Villotta produces container glass used for wine in the north east area of Italy, the predominant area where prosecco is produced. It also provides bottles for olive oil for the Italian market along with some spirits for international - geographies. Many investments were made, but none more so than to upgrade both
of Villotta’s furnaces to use gas-oxy combustion technology, giving O-I the ideal scenario to convert the entire site in a short amount of time in order to make the biggest sustainable impact. Gas-oxy combustion is said to increase the energy efficiency of glass melting furnaces by using oxygen created onsite, instead of air, and has reduced nitrous oxide (NOx) emissions by more than 75%. The idea of the investments at Villotta first came nearly nine years ago in 2012 with the first furnace rebuild completed in 2015. Ludovic Valette, Vice-President of
Global Technology and Engineering at O-I said even in 2012 there was already a strong emphasis on sustainability and environmental matters. He said that Europe was already in the driving seat for these sustainable efforts, so when the possibility of a complete upgrade at Villotta presented itself due to the furnaces coming to the end of their life, the company knew it had the opportunity to make some big environmental changes.
Continued>>
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Alessandro Lanzellotto
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Sustainability: O-I Villotta
He explained: “Sustainability is at the core of what we do. We are selecting the right plant at the right time with the right purpose and Villotta is a very important aspect for O-I.” Gas-oxy-fuelled furnaces were not new to O-I, with rebuilds in other plants in Europe and in the US already in operation. Alessandro Lanzellotto, who was the Villotta Plant Manager at the time of the investments, said the reasons for rebuilding with an oxy-fuel furnace include that it was the best solution to move to newer, more energy efficient technology. He said: “We have always has been an energy efficient plant, but we reached the best solution (with oxy-fuel) in terms of energy consumption.” Mr Valette added: “Oxy fuel is a very important technology for O-I to advance our sustainability roadmap and achieve our sustainability objectives.” The investments also included combining the cullet feeder to the furnace to increase the use of recycled glass or cullet. The use of cullet instead of using virgin raw materials in the manufacturing process requires less energy to melt and decreases emissions. “We currently use approximately 8085% recycled content for our coloured glass and approximately 70-75% for flint glass. But we want to increase that percentage due to the benefits of recycled glass,” Mr Lanzellotto explained. Mr Valette added that this high cullet use at the plant was another reason for Villotta being chosen to make such big investments on over a short amount of time. He said: “Villotta is used to using a high amount of cullet and it was an opportunity for O-I to show “how good is good” – and when we combine gas-oxy with energy recovery solutions with high cullet content we have one of the most energy efficient container glass factories in the world.” The recycled glass comes from several recycling plants around the North East of Italy, and in 2020 O-I allocated funding to a number of environmental projects from its Green Bond scheme to help improve cullet used at plants including Villotta. Villotta’s cullet pre-heating system creates even more energy savings because it captures exhaust heat from the furnaces and reuses it to raise the temperature of incoming cullet. Pre-heated cullet is said to require less energy from the furnace
down the line. Mr Lanzellotto feels that it is imperative that O-I continually look at ways to be more sustainable, and he believes that push is coming from all sides, including O-I’s customers and investors. “For sure sustainability is becoming important for our customers. We feel it is important to show how much we care for sustainability”, he said. O-I Villotta also invested in an Organic Rankine Cycle (ORC), which is an electric generator that transforms waste heat into electricity for use on systems throughout the facility. Mr Lanzellotto explained that hot water from the compressor room is recovered to heat parts of the plant floor such as the cold end. The heating system has reportedly provided 845 MWh of thermal energy since January 2017 and has saved O-I money in not having to provide additional heat for its workers. Villotta also captures waste heat from some of the annealing lehrs and reuses the heat later in the cold end. LED lighting has also been installed across the plant to become even more energy-efficient. O-I said it would leverage skills and experience from Mr Lanzellotto and his colleagues at Villotta to move a similar project forward at other locations all over the world, having already developed and worked with O-I on other projects in the past. He believes that Villotta was chosen to make these improvements as it has an excellent knowledge base within the plant with a lot of experience and a strong capacity to solve any problems that may arise once the investments were made. Mr Lanzellotto also felt that the drive coming out of Villotta gave a lot of confidence to O-I to make these big investments. Mr Valette concurred, saying the reason for Villotta being chosen because ‘the local team has strong capabilities and is well connected with their customers and community. There is a very strong cando attitude and a willingness to embrace change, make things work, and improve the performance of their plant’. He added: “Innovation is ‘in their genes’ and they have a very long history of technology development.”
A career on the plant floor at O-I Mr Lanzellotto has been at O-I since 2008, where he started out as an engineer before becoming the Plant Manager at O-I’s San
Gemini Plant in the middle of Italy before taking up the same role at Villotta in 2017. “I found O-I and felt it was a great opportunity and I became in love with glass”, he said. Mr Lanzellotto now works as the Manufacturing Excellence Leader for O-I, focusing on the regions of Italy and Hungary. Mr Lanzellotto said the investments made at Villotta were certainly one of the biggest projects he has worked on in his career so far. He said: “I was very proud to be part of this project, especially seeing it was something new, something that would help improve things here and something that can help our company. It is also good to have worked on something that makes Villotta more sustainable.”
Future thinking O-I said that with all the investments that have been made at Villotta, the upgrades have translated to a melter energy reduction of more than 40% annually, almost 45% reduction of melter CO2 emissions, and an increase of production by more than 30%. The Villotta plant is still running well with all these new investments according to Mr Lanzellotto and last year, Italy’s Ministry of Economic Development and the National Research Council of Pisa recognised O-I Villotta as possessing the requirements of an experimental research and development project, meaning the investments have been worthwhile. He said that Villotta will now be working on ‘improving what we have already done’, with no more major investments being thought about at the moment. Mr Valette added that due to the success of Villotta, it meant that O-I has the opportunity to replicate the technology used there to improve its furnaces at other locations where appropriate. He said O-I has proven it has a history of innovation and invention and it is ‘continuing the tradition initiated by Michael Owens in the 1900s’ with the technology implemented at Villotta. �
*Manufacturing Excellence Leader – Hungary & Italy ** Vice-President, Global Technology and Engineering www.o-i.com
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Future of Forming
The journey to digital end-to-end forming solutions It is clear that digitisation is the future of glass forming. But what will it look like, and how will we get there? Bucher Emhart Glass explains.
W
ithout a doubt, the future of glass forming is digital. In the glass-container factory of the future, the forming process will be controlled and optimised automatically by digital technology, with little or no intervention from human operators. For the moment, however, that vision has yet to be made a reality. To achieve it, two things will need to be working hand in hand. The first is a way to analyse and interpret the production data from different sources like sensors, machines etc. to find out what needs to change. And the second is actuators that can change parameters accordingly.
From operators to mission controllers
� Emhart’s traceability brochure.
equipment suppliers. If there is a problem, the supplier’s technicians can log into the system remotely to analyse problems and run optimisations as required.
Correlated data is the key Any digital technology improvement starts with data. The more data you can access, the greater the potential to transform your production process. However, it’s not enough just to amass data for its own sake. First, your data has to be cleaned – that is, a true representation of reality. Second, your data points must be correlated – that is, you have to be able to match them up with the time, article or section they refer to. What are the most valuable types of
data on the forming process? The most obvious candidates are furnace and forehearth data, machine data from forming and inspection, sensor data and data from auxiliary equipment. There are also some other sources that may be less obvious, but are still essential. They include video camera data, to detect human interactions with the machine, and intelligent tooling data, which recognises which tools are used and when they are changed. Finally, there is also environmental data, which records ambient changes in temperature and humidity.
Continued>>
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Let’s take a look at how things work today. Instead of automated data processors and actuators, humans are doing both: data analytics and actuation. This needs operators and managers that have a long experience in glass making. First, they analyse readings and user interfaces to find out what is going on within the forming line. Then they draw on their own experience to make the right changes. At the same time, they collect data for other purposes – for example, they keep track of wear and tear to moulds and do a lot of time for repetitive tasks like mould swabbing. Now let’s fast-forward into the future. Operators have moved up from the factory floor to the control room, where they make decisions aided by multiple sensors, cameras and digital assistants. They’ve become mission controllers – rather like air traffic controllers at airports. However, these mission controllers don’t work alone. They can call on assistance from an expert team at their
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Future of Forming
� The FlexIS Data Interface.
How data helps Having gathered our data, what will we be able to do with it? First and foremost, cameras and sensors will be able to detect anomalies in the operation of the machine. They can then pre-warn operators about deviations, and propose an action to return to an optimal process. Detailed data analysis will also lead to a deeper process understanding of the interactions between different process steps. For example, we will be able to see how changes in the batch house influence the furnace, the IS machine and ultimately the quality of the finished container. For larger businesses, productivity will be boosted still further as benchmarking and data-based best practices can be rolled out across multiple sites.
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The holy grail of automation The ultimate goal of digitisation is automatic process change, where digital systems analyse sensor data and automatically alter process parameters with no human intervention at all. The main areas where this could be possible are furnaces and forming. Indeed, some automatic controls are already in use – for example, model predictive forehearth controls and closedloop controls on IS machines. In the future, we’ll see these areas joined up, so the system combines multiple controls across more than one machine – for example, managing the IS machine and the forehearth at the same time.
Robots, cobots and more Robots will be closely integrated – both mechanically, to the machines, and electronically, into the controls. That will allow them to act as ‘go-betweens’,
� Examples of value created from changes to procedures.
bridging the physical and digital worlds. In this role, they could be automatically deployed to carry out adjustments that go beyond parameter alterations and require physical intervention – for example, delivery adjustments or changing forming material. However, it’s unlikely that glasscontainer forming will ever be carried out in so-called “dark factories”. There will still be work that can only be done by humans – especially during job changes. However, cobots (collaborative robots) and robotic exoskeletons will be there to lend a hand.
Tomorrow starts today All this might sound far-fetched. But it’s already a reality in other parts of the glass industry. For example, operators in the flat glass sector very seldom leave their air-conditioned control rooms. Of course, forming a complex whisky bottle for a global brand is not the same as
making a windowpane. But the direction of travel is clear. As you read this, operating plants are collecting the first data sets that can be correlated right down to the individual container. At the same time, the first AI models are being trained to predict process outcomes like wall thickness distributions. And meanwhile, out on the floor, robots are swabbing and starting to adjust deflectors based on blank-loading readings. It’s an exciting time to be involved with glass forming. Over the next few years, we’ll start to see different types of data brought together and used in completely new ways. The future is digital – and it has already started! �
Bucher Emhart Glass, Cham, Switzerland https://www.emhartglass.com/
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RAISING PERFORMANCE Celebrate the best in forming technology with the AIS from Bucher Emhart Glass The AIS raises plant performance on every level. From genuine parallel blank and blow mold open and close, to individually controlled blank mold half cooling, to balanced and superior blow mold cooling. Designed for an extended ware range and fast, simple center distance changes, it is stronger than ever, performing at the height of productivity, efficiency, quality and safety to support an even better future.
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Future of forming
All-Electric Plant How forming can enable climate-neutral glass production, reports Mark Ziegler*.
I
Engineering and maintenance Advanced technology needs a backup of trained and motivated staff, supported by data management tools. Often underestimated is the importance of downtime reduction of the IS machine. If the forming process is interrupted, the furnace still consumes a large amount of energy. Sklostroj sees two ways to tackle this challenge. First, preventive maintenance needs to be implemented without compromise. The Siemens-based control platform provides all necessary tools for the machine operator to avoid unexpected maintenance stops. State-of the art servo drives give
clear feedback about deviations in the mechanisms, like a torque increase due to higher friction. Data analysis is on everyone’s lips these days and the Siemens MindSphere platform as leading industrial IoT-as-aservice solution evolves very quickly. The integration of analytics and AI to increase the production performance will become standard within 10 years.
Lightweight production Leading brand owners are ambitious to decarbonise their own production. For example Heineken has called upon the glass industry to decarbonise glass production, as approximately 30% of the emissions come from packaging materials. Sklostroj sees lightweight production for the mass markets a crucial lever. For NNPB productions, the process control with closed-loop options for gob weight and press duration control the tool of choice. To reduce weight in BB processes, Sklostroj sees two solutions. First, the Sklostroj gob watch closed-loop allows a precise determination of the gob weight including an automatic control of the feeder settings. The gob watch works with single weight or multi weight feeders. Second, the patented LPBB solution (Light Production
BB) for the blank side is a robust vacuum system to decrease on the one hand the container weight by approximately 10% through an improved glass distribution. On the other hand, the production speed can be increased by up to 3,5%, states Karel Maruska.
Energy efficient machine Energy must be used extremely sparingly. Energy efficient electric actuators are key, as compressed air is costly and an inefficient energy carrier compared to electricity. By using servo-technology for most of the IS mechanisms, Sklostroj reduces compressed air consumption to the coolings. Even the plunger in NNPB productions is available as servo version. Coming back to the energy management of the servo axis: The brake energy recovery, based on latest Siemens technology is standard. An IS machine with many servo axes following a precise timing and consuming energy in planned sequences, is the ideal application for this concept. 12 section full servo IS machine including feeder and ware handling has an electric consumption of less than 30kW for all actuators. This value cannot be reached by pneumatic machines. Continued>>
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n our industry there is an answer from a technical perspective to the fight against climate change and ensuring sustainable development: the All-Electric Plant. It describes a glass production in which regeneratively generated electrical energy is available as the main form of energy, inexpensive and almost unlimited. The key to implementation is comprehensive electrification, networking and automation of the glass plant and – from a broader perspective – the energy infrastructure. The topics such as hydrogen or electric melting furnace, like the F4F (Furnace for the Future) initiative, have already been widely discussed. Let’s now go deeper into the field of forming. Sklostroj’s vision is to enable glass plants to accelerate the implementation of this transformation on the way to a sustainable world, based on a holistic approach. Precision machines with a hot heart is the mission, which stands for a close connection between technology and people. It is important to not only focus on the technology of the forming lines, but also to combine it with a service portfolio for plant engineering and project management.
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Future of forming
Cobots and mobile robots Currently we see a broad, rising use of the swabbing robot. Basis for the success is a proven rise in productivity and the substitution of a potentially hazardous task. A 2% rise in plant productivity leads to at least 2% less energy consumption. Compared to other industries, the glass industry was quite late to adopt robots. The swabbing robots used today follow a classic concept, as they are mounted on a rail. “This will for sure change”, states Mark Ziegler. Test are carried out for using robots for the exchange of moulds, showing the first promising results. Definitively, the use of cobots and mobile robots will become the standard “power tool” in the next decades. Mobile robots can move between the different production lines, equipped with sensors or gripping tools. In combination with the safety standards of the cobot concept, the mobile robot will become the buddy of the operator, helping him to carry out heavy or potentially dangerous tasks. Autonomously working mobile robots will take the necessary equipment from the tool storage by themselves.
3D printing for sampling Current status of 3D printing shows positive results for glass. Still, it is far away from suitability for high volume production. Researchers at the Massachusetts Institute of Technology (MIT) have developed a 3D printer that works with glass. Fused-Deposition Modeling is the name of the technology the scientists have worked with. A workpiece is produced in layers from a meltable material, here glass. The glass printer itself consists of two different chambers made of ceramic, which are stacked on top of each other. The glass is poured into a crucible before it runs from the first into the second chamber through a separately heated nozzle. The printing platform is then also integrated in the second chamber. The entire crucible is moved during the printing process. The glass itself is heated to a temperature of more than 1,000 degrees. In the second chamber of the 3D printer, temperatures of more than 550 degrees Celsius prevail. Jan Koren, Technical Firector is closely following the development: “Recent trials on the MIT - Massachusetts Institute of Technology show interesting results in 3D printing. “Theoretically, it would be conceivable that a melting tank with the associated IS machines would be replaced by a very large number of 3D printers. However, the research is still in its infancy. The quantities which can be produced by an IS machines far exceed the possible production volume of a 3D printer.”
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CO2-neutral energy will be the key factor in reconciling climate protection and global prosperity. Sklostroj feels obliged to do its part. Already today, the glass production machines are energy efficient. In the future, electricity generated from renewable sources will be the only energy source in the plants. Sklostroj’s highly efficient machines combined with its open automation platform will be the tools of choice for the AllElectric Glass Plant. �
*Regional Manager, Sklostroj Turnov, Prepere, Czech Republic www.sklostroj.cz/
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Conclusion
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THE CLEAN FUTURE OF G L A S S M E LT I N G I S N O W ! ECOFURBISHING 2.0 The future of glass melting has to be energy efficient, sustainable and clean. That’s what we strive for in every little detail of our furnace designs. Any kind of optimisation can contribute to a more sustainable glass melting process. We are facing the global challenges by constantly working on new innovations. All-electric furnaces and hybrid furnaces are only the beginning of the furnace-efficiency-revolution.
Future of forming
In search of a container forming revolution
I
have often asked myself, and many others, about whether we are going to ever see a fundamentally different automatic glass container forming process. When I say a different process, I mean totally unrecognisable from any of the current two-stage process; whether that be Blow-Blow, Press-Blow, or NarrowNeck-Press-Blow (BB, PB, NNPB). Within these original forming approaches, we have seen some radical mechanisation changes over the years that span about a century now. This was started with the BB process where it was made both by hand and semi-automatically by
people effectively making one bottle at a time, aided by moulds and mouth-blown or using compressed air. They used the power in their arms to open and close the moulds as well as collect the glass. Often requiring two people for each single forming station, if I remember correctly, from seeing the old film footages (I am not that old!). After this original manual two-stage, semi-automatic mechanisation of the forming process, there came the full automation of the process via the rotary machine where the whole machine was rotated around an axis. Maybe his is
where the original 360-degree timing came from, even before the 360-degree drum-driven I.S. Machines? This development of the first automatic machine is attributed to Michael J. Owens from the Libbey Glass Company in Toledo, Ohio, USA. Although the machine was a breakthrough at the time, it was effective in the forming process but suffered from productivity issues as the whole machine would have to be stopped to attend to breakdowns or equipment parts changes. Continued>>
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Peter Firth* highlights the evolution of container glass forming and asks if there will be any further revolutionary changes in the forming process or of the machines that implement it.
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� Glass Futures site.
Even though still the same essential process, the next revolution was the change from the rotary machine to what we now know as the I.S. Machine. The letters I.S. is believed to have stood for either the description of the machine as the Individual Section Machine or because of the inventors being named Ingle and Smith. The original patent application being by Henry W. Ingle and Charles Goodwin Smith of the then Hartford-Empire company (now known as Emhart Glass). Maybe it was a bit of both, and both are worthy descriptions. This revolutionary new forming machine was made, marketed and distributed widely under patent protection. As the intellectual property protection expired, competitors using virtually the same mechanisms arrived on the scene to assist in proliferating the provision of such machines all over the world. I can’t even expect myself to name all the different suppliers of such machinery nowadays, although these now differ in many details to the original mechanism by Emhart. There are currently many manufacturers of IS Machines, but to the casual observer, these will still exhibit the fundamentally same characteristics as each other. Decisions on which supplier of a forming machine to choose from often comes down to matters of company standards and price, as well as maybe supply capabilities depending on the specific forming controls required. However, notwithstanding the details, the customer glass plant will still be getting what they could have also obtained from another machine supplier. At least the customers of the glass containers will not be able to recognise any difference in the chosen forming machine. When NNPB was developed by Heye Glass in the 1970s, it was seen as revolutionary, and so it was. Although still within the bounds of the recognisable two-stage forming process, the change they introduced was to press the parison of a narrow neck container rather than
use compressed air to form it. This was revolutionary in that the ‘finish’ (ring or top) of the container was formed last in the blank-side process, rather than first as in the BB process. Nothing fundamentally different to the widemouth PB production process, however, but nonetheless this was revolutionary in narrow-neck container forming thinking at the time. NNPB became a worldwide glass container forming gamechanger. This new container forming process enabled lighter containers to be manufactured for the same capacity than could be achieved with BB. Only many years later are we seeing enhancements in the details in the BB forming process challenge the performance of the NNPB process. Application of blank-side vacuum and attention to forming details and equipment has given rise to containers made with BB which compete with those made from NNPB. But we still have the same three fundamental forming processes. Even if there have been changes in the basic container forming approach since, those approaches have not found the traction and support that means they can compete with the original processes. By competing I mean in terms of productivity and quality. In the combination of these two factors, the I.S. Machine remains the workhorse of the industry. With a few bespoke customisations for making speciality items maybe, but still pretty much based on the original forming processes already mentioned. I am aware of one other fundamental departure from the traditional container forming machine. Again, this was from the team at Heye Glass, which made a container machine known as the H1-2 Machine. This was still in operation at Oberkirchen on C Furnace when I was employed as Technical Director (UK Glass) within the Ardagh Group. (Heye Glass became part of Ardagh, although
the technical and machinery division, Heye International, still stands as a separate company under the Ardagh Group). However, the lack of significant overall benefits of the H1-2 over the IS Machine, and its restriction to wide-mouth production, led to it being shut down about 13 years ago, along with C Furnace itself. Suppliers are now incrementally improving their I.S. Machines with reduced dependency on compressed air as the main motive force. Although compressed air is still exclusively used as the forming air for the containers and as a means of cooling for the plungers. Most of the basic standard sizes of the machine still remain as well, such as the 21” width of the section boxes and the centre distances between the moulds on the machine, typically being 4.25”, 5.0”, 5.5” and 6.25”, as well as many other different more recent centre distances for triple and quad gob production. Unsurprisingly, general industrial technology developments have been the recent driver for the changes in the I.S. Machine. Although this is more of a continuous improvement route, rather than a radical departure from an established forming process or machine concept. The more common such applications being the servomechanisation of section mechanisms, which followed the earlier servo developments in the ancillary drives and mechanisms such as the feeder, shears, scoop, ware pushers, conveyor drives, ware transfer and lehr-stacker. We are now also seeing many thirdparty suppliers that specialise in certain aspects of the forming process and who look to interface with the forming machine; whether that is directly by connection and control, or indirectly through the provision of information to the Machine operator.
Continued>>
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Future of forming
Typical examples here being infrared vision or sensing systems to detect the heat in the glass or from the mould gear, or simply vision to visually assess the position of motions including the gob delivery to the blank-side. Further, priordeveloped robotic technology is now being deployed in the forming process to replace previous human operator machine interventions. The point being here that nothing is fundamentally changing anymore, and back to my question about whether we will see any further revolutionary changes in the forming process or the machines that implement it. I, for one, would be happy to hear of some new changes that can revolutionise the way we make glass containers, even though I cannot currently conceive of what that might be myself. Maybe the last major spark of mechanical and forming genius from the inventors Ingle and Smith is what mankind is left with for the basics of the glass-container forming process for time to come? Or maybe the next generation of Ingle and Smith is reading this article or even working away on it secretly ready to surprise us all. Only time will tell. By way of encouragement and assistance for supporting the future possible developments, whether incremental or revolutionary, I have been pleased to be working as part of the design team for the Glass Futures St Helens project. This
� The Heye H1-2 machine
is a glass Research & Development (R&D) plant for all kinds of glass production, but starting with a forming focus on glass containers. Very soon in the plant design process, we will be looking at the specification of a small R&D I.S. Machine, which will be made available for experimentation and development work. Maybe this might help support the future of glass container forming and eventually lead to a revolution. It could even be a gamechanger such as we have seen in the past, or maybe that is just wishful thinking? No matter what, there will at least be one facility in the world that is absolutely open to any ideas and happy to put those ideas under glass as soon as possible. By working on this project, I am currently proposing that we consider a 6-Section Machine Bed, with just four installed sections. In this way, we will have two vacant section stations able to be tailored to customer R&D requirements. This would therefore allow those two additional stations to be loaded with glass and also to feed onto the machine conveyor, together with any other production at the time from the installed sections. The width of any proposed development section would not be a restriction as there is a 2 x 21” (42”) in space to work with. The remaining space to the side of the outer potential ‘test
section’ location would enable relatively easy access to the internals of any new sectional development work. If, however, it was a totally different machine concept that needed to be put under glass, there is a space for a future as yet unknown forming machine from an additional future foreheath we are allowing for in the design of the facility. If you, your company, or your employer have an interest using such test facilities for taking the forming process to the next level, please get in touch with us to discuss. You also still have a chance to influence the proposed R&D plant layout (which I covered in brief in an article in April 2021 in Glass International). Do this simply by making contact and presenting your suggestions. We are open to any constructive input during this design phase of the St Helens R&D Glass Plant.�
*Private Consultant (Glass Container Production), working with Glass Futures on the GFL St Helens Project Contact: Via LinkedIn Profile (search ‘Peter J Firth’) or email peterjfirth@gmail.com Glass Futures, https://www.glass-futures.org/ Heye International, www.heye-international.com
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Country profile: Pakistan
The upward curve of the glass industry in Pakistan
Pakistan has performed better than its peers in the region on multiple fronts in the last 12 months. The country didn’t suffer as much as some of the other countries in the region due to Covid-19. Glass International presents an overview of the container and flat glass in the country.
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C
omprising of five major glass producers (three container glass and two float glass producers) the Pakistani glass industry has posted more than average growth rates in the last four years. However, despite the mammoth size of the country’s population (estimated at 220 million at the end of 2020), glass industry in the country has not been able to achieve a higher scale of capacity and output. Per capita consumption of container and flat glass in the country is low compared to other countries in the region. Total installed capacity of glass containers is about 1,200 tonnes per day. For flat glass the installed capacity is 2,050 tonnes per day. Out of the 1,200 tonnes container glass capacity, nearly 30% is not operational as one of the container glass’s (Balochistan Glass) two production units
are currently not operational. Non-alcoholic beverages, food and pharma packaging dominate the container glass consumption in the country. Alcoholic beverages account for a mere 7% of container glass consumption in Pakistan. Demand of container glass for the alcoholic beverage subsegment is met by the glass division of Murree Brewery (Murree Glass). There has not been any major investment in the container glass sub-segment in recent years due to subdued demand. Import of container and flat glass from China and Iran has also been a major obstacle for the growth of domestic glass industry. Both the countries export about 20% of the total glass demand in Pakistan.
Healthy economic indicators Healthy economic indicators point to good growth prospects for Pakistani container and flat glass to achieve steady growth rates in the forthcoming financial year. Pakistan’s government has set a 4.8% GDP growth target for the financial year starting on July 1st. For the financial year ending on 30th June, 2021, Pakistan has said it is on course to achieve 3.94% GDP - more than double the IMF’s view and roughly triple the World Bank’s projection. The IMF is estimating GDP growth for 2020/21 at 1.5%, while the World Bank puts the expected expansion at 1.3%. Ratings agency Fitch said Pakistan’s economy appeared to have weathered the pandemic shock well relative to its peers. It said provisional data pointed to GDP growth of 3.9% in the current
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Country profile: Pakistan
Committee on Housing Construction and Development (NCHCD) in July. The Committee’s objectives include monitoring the construction sector and ensuring that any hurdles that arise are overcome to ensure that construction activities continue to increase rapidly.
Glass Manufacturers Ghani Glass
Flat glass growth The flat glass industry will be the key driver of overall glass industry in Pakistan in future. Covid 19 had a major impact on Pakistani economy between March and June 2020. To counter the dwindling economy, the government announced a PKR 100 billion relief package for the construction industry in April 2020 Although formally, on average, the construction sector has contributed between 2.3% and 2.85% in the last five fiscal years to Pakistan’s GDP (it was valued at PKR 316 billion in the Pakistan Economic Survey 2019-20), most economists estimate its value significantly higher in the total GDP. The package’s objectives are two-fold. The first is to bridge the affordable housing gap through the Naya Pakistan Housing Program (NPHP) which was initiated in April 2019 with the goal of building five million houses in five years. To ensure these goals are met, the government set up the National
“For the financial year ending on 30th June, 2021, Pakistan has said it is on course to achieve 3.94% GDP more than double the IMF’s view and roughly triple the World Bank’s projection.
”
Tariq Glass Tariq Glass made its name in Pakistani glass industry as a glass tableware producer. In 2013 it entered into float glass production and eight years later, is the largest float glass producer in the country. It commenced commercial production from its second float glass line in April 2021 to become the largest float glass producer in Pakistan. The company has an installed capacity of 1,050 tonnes of float glass products from two production lines. The company is also the largest tableware glass producer in the country with a production capacity of nearly 300 tonnes per day of tableware glass. The company produces its tableware products on single and double gob press machines as well as H-28 (press & blow) and stretch machines. The company has an onsite mould workshop, modern warehousing, advanced laboratory and Tecno 5 decorating machines at its production facility. During the first nine months ( July 2020- March 2021) of the current financial year 2020-21, Tariq Glass registered a robust growth of 23.61%, with sales revenue of PKR 14,059 million as compared to PKR 11,374 million of the corresponding period of the last year. According to company’s management: “With the induction of added production from the float glass plant unit II, wide-variety of float glass products will be available not only in clear and coloured float glass (i.e., green, blue, bronze), mirror and reflective glass but also the float glass of Continued>>
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financial year, after a contraction of 0.5% last year. The overall industrial sector has witnessed a positive growth of 3.57 % in the current fiscal year as against a negative growth of 3.77 % last year. The large-scale manufacturing (LSM) sector, which is driven primarily by QIM data (from July 2020 to March 2021), showed an unprecedented growth of 9.29 %. Among major glass consumers, food beverage & tobacco (11.73 %), pharmaceuticals (12.57 %) and automotive sector grew by 23.38 %. Flat glass consumption was spurred by construction activities, which has increased by 8.34 % mainly due to an increase in general government expenditure and private sector construction-related expenditures.
Ghani Glass is the largest glass producing company in terms of sales revenue. The company operates in both the major sub-segments- container and float glass. Ghani Glass operates four glass plants in the country ( Plant 1 at Haripur Taxila Road, District Haripur; plant 2 at Landhi Industrial Area, Karachi; plant 3 at Lahore Sheikupura Road, District Sheikupura; and plant at Lahore Gujranwala road, Tehsil Kamonke, District Gujrawala). Sales revenue of Ghani Glass grew more than 14 % in the first nine months ( July 2020- March 2021) of the current financial year. The company achieved sales revenue of PKR 16,178 million compared to sales revenue of PKR 14,159 during the same period in 2019-20. Both sub-segments contributed almost equally to the increase in sales revenue.
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T hi si snotas ol arecl i ps e
Wi r eEdgedet ect i on
wi t hz er ocompr omi seby
Country profile: Pakistan
varied thicknesses in the range of 2 mm to 12 mm will be available for the customers. The availability of effective sales mix will ultimately result in higher sales and further improved profitability of the company.”
Balochistan Glass About a decade ago, Balochistan Glass was the largest glass producer in Pakistan. The company has three production plants (Unit –I at district Lasbella, Balochistan, Unit- II at Sheikhupura Road, Sheikhupura and Unit III at Kot Abdul Malik, Lahore). Until 2018, Unit I was a glass tableware production facilty, while unit number II and III were container glass facilities. In a rejig in that year, the company shifted tableware glass production to unit III and container glass production to unit I and II. Currently, unit I and II are not operational. The company underwent an expansion at Unit – III (second furnace for tableware glass). The refurbished furnace was fired successfully on 23rd June. In the light of enhanced production capacity, the management is continuously exploring further market options and making concerted efforts to increase its share in local market and tape the promotional opportunities in the international market. The company has also made strategic decision to introduce another brand with completely new range of tableware glass products.
Company profile Pakistan.indd 3
After a gap of many years, Balochistan finally registered profits during the first nine months of the current financial year. Though, total sales of the company declined during these nine months as compared to the same period last years. Major reason behind the declined sales was suspension of the operations at Units I & Unit II. Sales revenue during the first nine months of the current financial year stood at PKR 953 million as compared to sales revenue of PKR 1,265 million during the same period in the last financial year.
Murree Glass Murree Glass is the container glass division of the only brewery in the country, Murree Brewery. With an installed capacity of about 160 tonnes per day, Murree Glass meets the entire demand of Murree Brewery and Tops Food, a subsidiary of Murree Brewery. During the first nine months of the current financial year, Murree Glass’s output declined by more than 14 % ( 33,551 tonnes in 2020-21 from 39,454 tonnes in 2019-20) as compared to the same period in the financial year 2019-20. �
https://www.ghaniglass.com/ https://www.tariqglass.com/ https://www.balochistanglass.com/
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Hydrogen
� � Giorgio Minestrini, dissemination manager, and Ernesto Cattaneo, coordinator of the LIFE SUGAR project, inside Stara Glass offices.
The idea of a Total Recovery Glass Furnace and the LIFE SUGAR Project Ernesto Cattaneo* discusses a consortium which aims to launch a glass manufacturing furnace that can decrease energy and NOX emissions of a regenerative furnace. fuel efficiency of electrical energy production is 45%. Regenerative furnaces, can easily have a 65% fuel efficiency. Therefore, in the countries where energy production is not mostly renewable, glass furnace electrification causes a world increase of CO2, not a decrease. � Alternative fuels: they make sense when all the process is sustainable. Hydrogen is indeed interesting, since is does not contain carbon, but nowadays 95% of the hydrogen in the world is produced by steam reforming, it is therefore grey and very far from carbon neutrality. � Carbon Capture and Storage (CCS): it does not seem to be applicable everywhere, and anyway, as said, we need to deal with 10.000.000.000kg/year of CO2. � Efficiency increase: even if regenerative furnace chambers have a
tremendous temperature efficiency, in fact they heat air up to 1300°C with a flow of 1500°C waste gas, still about 30% of the burned fuel is wasted with the 500600°C fumes. This direction for carbon containment is indeed the most virtuous one, because it involves all others as a cascade. Stara Glass, as a furnace design company, has always aimed at utilising the residual waste gas heat that, depending on the furnace size, might even be 2MW. The idea is to cool down the waste gas up to the coldest level allowed by the filter, which is commonly about 200°C for bag filters, and reintegrate in the process the saved thermal power. Stara Glass, with its Centauro technology (Fig 1), has already been able Continued>>
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uropean Union aims for carbon neutrality by 2050. This ambitious and well due goal has put the glass industry under an unprecedented negative spotlight. We used to be thought about for the total recyclability of our products, or for their unmatchable chemical inertia. Now the glass industry means a ratio 3.5:1 between glass and CO2 production. In fact, Europe produces 35 Mtonne/ year of glass and 10 Mton/year of CO2 for its melting. If some glass researchers had had a magic trick in the sleeve to solve the CO2 issue, at this point it would have already come out. But it did not, so it appears we will have to start paving all the hard roads in front of us, and analyse all possible contributions to CO2 containment, one by one: � Electrification: in Italy, the average
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Hydrogen
� Fig 1. Stara Glass Centauro.
� Fig 2. An example Centauro furnace with its flows, its temperatures and
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its heat recovery system split in.
to extract the residual waste gas heat, in form of hot clean air, but this was used outside the glass production process, for example to produce hot water or to heat the factory during winter time, but, while the factory gas bill decreases, the furnace specific consumption (kcal/kg) of a Centauro furnace is the same of an equivalent end-port. In the simplest words, Centauro is an end-port furnace where the low temperature part of the chambers, about 3-4 m of checkers in height, is substituted by a metal heat recovery system thus: � Solving important layout restrictions. � Allowing the utilisation of the SNCR technology for NOx removal (that is applied in the about 800°C zone between chambers and recuperators). � Allowing the said extra-process heat recovery.
out we would waste more than 2/3 of it. Heat is not a noble source of energy like mechanical or electrical power, heat is convenient to be used to heat up, not to create motion. So, what can we heat? � Air: end-port and Centauro furnaces have already heat recovery systems dimensioned to their upper limit. � Glass batch or cullet: it is possible, and some glass producers do it, but it involves potential carry-over and dioxins issues, and it is technically unfeasible to transfer to this flow all the heat we intend to recover. � Fuel: natural gas has such a lower volume, compared to waste gas, that it cannot physically store all the thermal power we want to recover. But methane can be made react, in a very endothermic chemical reaction, to convert be converted into a fuel of a much higher calorific value: hydrogen.
Fig 2 shows an example Centauro furnace with its flows, its temperatures and its heat recovery system split in: � Regenerative chambers � Radiating heat exchangers (double shell counterflow metal recuperators) � Convective heat exchanger (crossflow with large air-flow)
The LIFE SUGAR Project
Oversizing the flow in the metal part allows extracting all extractable heat from waste gas. You can see that, in front of 11.000 Sm3/h of air needed from the combustion, more than 27.000 are sent to the first exchanger, and 13.000 Sm3/h @ 150°C + 3.400 @ 500°C are extracted to be used in the factory. When all heat is constantly utilised a saving of about 1MW is achieved. But it would be much more interesting to bring that thermal power inside the process. How? It is possible to produce electrical energy, but Carnot points
CH4 + H2O
SUstainable Glass: Architecture of a furnace heat recovery system including a steam Reformer The idea of the LIFE SUGAR project is utilising the waste gas heat to convert the natural gas methane into hydrogen by a steam reforming reaction. 3H2 + CO
This reaction is strongly endothermic and our theoretical evaluation is that the reforming of about 1/3 of the fuel, which will be reintroduced in the furnace as syngas, is enough to saturate the process and allow an about 15% energy and therefore CO2 saving. Since the reaction happens at temperatures higher than a regular end-port waste gas, we will utilise the particular structure of the Centauro system heat recovery and extract the waste gas between the metal and ceramic
parts of the heat recovery system, as shown in Fig 3. Hydrogen combustion will raise the NOx levels but the effective SCNR system included in Centauro furnaces will contain the issue under NOx emission law limits. The LIFE SUGAR project has been financed by the LIFE instrument of European Community and it involves several specialised companies: � SG - Stara Glass: project leader specialised in glass furnace design and innovation, based in Genova, Italy. � PRO - SGRPRO: a start-up dedicated to measure, computing and research, controlled by Stara Glass. � JM - Johnson Matthey: a global science and chemicals company, and a sustainable technologies specialist including catalysts and processes for steam reforming, based in Reading, England. � KT - Kinetics Technology, an international technology licensor and EPC contractor with a track record in steam reforming. Based in Roma, Italy. � SSV - Stazione Sperimentale del Vetro is a research centre and analytical laboratory specialised in glass science and technology, with a strong experience in on-site process and emissions measurements. Based in Murano, Italy. � UNIGE - Università degli Studi di Genova- the reference research centre for modelling and testing glass production industrial solutions. The project features the following activities: 1. Design, construction and installation in the UNIGE facilities of a mock-up component to test the catalyst. 2. Recruitment of a glass producer to test the solution on the field; this activity is already concluded; the prototype will Continued>> 37
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studiobrand.it
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Hydrogen
� Fig 3. Centauro + SUGAR technology.
� Fig 4. the locations of the LIFE SUGAR project.
be installed in the new Centauro furnace of the Castellana Grotte (Bari – Italy) Vetrerie Meridionali O-I plant. 3. Design and construction of a SUGAR prototype module, about 1:5 scaled (foreseen energy saving: 2-5%). 4. Test, tuning and field demonstration of the technology. 5. Design of the final full-scaled product. 6. Business development, dissemination.
The final goal of the project is to launch on the glass market what we call a total recovery furnace, that can decrease the energy consumption (and NOx production as well) of regenerative furnaces in a very significant way – target 15% – and, with it, CO2 emission and glass production cost, to match the increasing demand of production sustainability. While this idea is not applicable to regenerative furnaces, it is to other types like unit melter or oxy-gas furnaces, with different levels of efficiency. Once the
externally heated steam reformer unit and process for glass furnaces are developed, we will work for an even wider application of this technology. �
*LIFE SUGAR project coordinator, Stara Glass head of innovation projects, Stara Glass, Genoa, Italy www.staraglass.it/ LIFE SUGAR project https://www.lifesugarproject.com/
Air Products is blazing a new trail for oxy-fuel burner technology . . . Boost your performance and productivity for better glass with the Cleanfire® HRx™ burner! Upgrading your oxy-fuel burners, adding burners to boost production, or converting your air-fuel furnace to oxy-fuel? The patent pending Cleanfire HRx burner offers you expanded functionality and flexibility with unmatched performance. It can deliver: Increased flame radiation for high fuel efficiency Ultra-low NOx emissions Foam reduction capability for higher-quality glass Enhanced productivity Optional remote performance monitoring feature
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37 Glass International July/August 2021
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Environment
Cullet production is only part of the challenge
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ore than 50 million tonnes of glass is produced a year globally but less than 40% is used for new glass production due to limited furnace capacity, quality, colour disparity, location, and economics. Sustainable low CO2 solutions are needed for the glass which is unsuitable for use in new glass production. Considering the commercial viability of this global problem requires a more inclusive approach, one not necessarily structured solely for glass cullet, but one where markets are driving the recycling, rather than legislation or recycling determining its use in markets offering CO2 savings over more traditional products.
All markets must offer environmental and economic benefits, focusing on the needs of each individual client and establishing an inclusive strategy ensures commercial viability of glass recycling no matter its location or traditional constraints. Innovative technologies to recover all types of glass no matter its type, size or quality offer challenges, in all cases it is clear that the true market potential and value of recycled glass is determined by the level of processing. Our experience shows innovation enhanced by effective knowledge transfer partnerships and collaborations, working with governments, universities, and other technologies to develop low CO2
solutions have long term benefits. Cooperation with universities has established innovations spanning agriculture, horticulture, composites and pozzolans, each research project assessing and developing the market, creating credible data, and enhancing technology for their cost-effective production. As markets evolve demands for thermal cleansing and ever finer materials drives innovation, improves productivity and enhances market viability of materials previously only suitable for landfill. Krysteline’s global Distributor and Sales agents are the eyes and ears of our marketplace, offering guidance on market Continued>>
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Steve Whettingsteel* discusses the increased importance of cullet as the glass industry tackles its CO2 footprint.
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* CEO & Managing Director, Krysteline Technologies, Southampton, UK www.krysteline.com Glass International July/August 2021
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* latest swabbing-robot installed in July 2017 in Germany
demand, creating and developing relationships with end users and providing solutions which not only meet commercial goals but offer enhanced knowledge transfer. International universities are playing a substantial role in Krysteline’s evolution, providing credible R&D activities while disseminating knowledge across markets, growing interest, and stimulating demand. When coupled to tangible CO2 valuation, glass starts to take on a new look, offering value across all sizes, colours and compositions. The British Government and the EU continue to play a key role in the evolution of sustainable glass recycling, investing in R&D of new technologies and supporting market development as well as providing clarity on how CO2 in the waste industry should be quantified and qualified. Our dealer network is often supported by the British High Commission (DIT) offices around the world which has brought together a greater level of global cohesion, bringing together businesses of all types, not just those in the waste sector, creating a unified mixed glass solution no matter its location. These technological innovations and the creation of high value end products are changing the way people view glass recycling. Gone are the days of glass being seen as the poor relation, a clear path is evolving. Recent work has seen a major resort chain moving away from traditional waste disposal to one of resource recovering, engaging clients, moving to an open policy, demonstrating the resorts capability to recover, segregate and repurpose many of the waste streams generated on site, utilising the natural elements of rainwater harvesting and solar generation, but always closing the loop on how each of these technologies is recycled at the end of their life. Opening up the onsite recycling facility to clients and seeking to dramatically decrease its own CO2 footprint is an important factor in seeking to achieve carbon neutral status. By challenging the common viewpoint of waste glass being only truly recycled when converted into cullet a clearer strategy has gradually evolved. At no point is it suggested that cullet should not be the primary market where it is both economic and its CO2 value demonstrable. The economic future of cullet use is determined by making the whole glass recycling landscape one which has more transparency, offering the recycler the opportunity to choose its market based on local and financial conditions, not being constrained by a market which is challenged by its economics. Efficient and effective alternative markets for the glass destined for landfill or low value aggregate offers market stability to the whole glass recycling industry, creating a confidence in glass, which has been lacking for decades. As the world’s recycling industry understands more clearly the CO2 footprint of its products at each part of the collection and repurposing process it is likely to play a more significant role in its use or value. Krysteline is well placed to provide sustainable markets across a broad spectrum of locations, all considerate of their CO2 footprint. �
11/08/2021 15:01:56
Autoclave-free Lamination System for Flat Glass Production Energy- and cost-efficient inline production of laminated glass
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Environment
Generating electricity using glass production exhaust gas Matthias Hagen* and Sven Jensen** explore the obstacles and opportunities of using excess heat from flue gases to aide improve sustainable glass manufacturing.
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Exhaust gas volume flow
Recoverable electricity
30.000 Nm³/h
250 to 420 kW
45.000 Nm³/h
375 to 630 kW
60.000 Nm³/h
500 to 840 kW
� Fig 2. Recoverable electric energy depending on
� Fig 1. Chart of the heat recovery over air volume.
can be extracted and transferred to warm water or thermal fluid. But many glass factories do not have a direct use for it. The own requirement for hot water is small and in rare cases it is possible to feed into a district heating
2
Evaporator Heat transfer from heat source to working media
3
Turbogenerator Thermal power is partially converted into electric power
network nearby. The ideal solution is the conversion of thermal energy into electric power. This is possible with an Organic Rankine Cycle Continued>>
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Power generation Electric power feed line to the grid
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Condenser Condensation of working media vapor
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6
Heat supply Heat transfer medium flows from the heat source into the ORC Module
Heat extraction Condensation heat, that can be utilised for follow-up processes
7 Pump Recirculation of the working media
� Fig 3. Principles of the ORC technology.
the volume flow.
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ajor glass companies are currently looking for possibilities to reduce CO2 emissions. As glass production is an energy intensive process, the main target is to reduce or replace the use of fossil fuels. Kiln suppliers are shifting from fossil to electric firing and the use of hydrogen is an ongoing discussion. Regardless of the type of fuel used in the kiln, all furnaces will create flue gases with temperatures between 280 °C and 550 °C. This temperature range depends on the installed heat recovery with recuperators or in most cases regenerators. Experience shows that the composition of the flue gases and the dust content poses a constant threat to the equipment. Internals of the regenerators, refractory parts called checkers, will clog and so the recovery of heat will be reduced. Although periodical thermal cleaning helps to reduce deposits manual cleaning is required in the long term. This illustrates the difficulties in handling dust containing flue gases. However, the exhaust gases represent a huge potential for energy recovery. In most cases it is not utilised today (Fig.1). Typically, the thermal energy is dissipated to ambient due to cooling requirements for the flue gas treatment with a bag filter and sent to the atmosphere through the stack. By installing a heat exchanger in the flue gas flow, valuable thermal energy
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� Fig 4. Best combination for CCF and ORC technologies.
(ORC) system, which is essentially an “upside down” fridge. � Fig 5. Modular components In a fridge you put in electricity of the ORC system. and get out cold. In an ORC you put in heat and receive electricity (Fig. 2). The ORC is a thermodynamic process similar to the wellknown water-steam cycle, which forms the basis of conventional electricity generation in power plants (Fig.3). The main difference is that the ORC uses an organic fluid with a low boiling point. Consequently, ORC is a key technology for generating electricity from heat sources with medium and low temperature levels. In the glass industry in principle heat recovery systems can be installed heat source with temperatures up to 90 °C in two different positions in the flue gas if needed. flow: one position is downstream of a This secondary heat can make up to bag house filter which usually operates at 80% of the primary heat and creates around 200 °C. additional value for the owner when used The other position is right downstream for heating purposes on site or when fed the regenerator where the exhaust gas to a local district heating network. temperatures are between 400 °C and The major disadvantage of positioning 550°C. Each position is characterised by a heat recovery system at the position specific conditions. The position downstream of bag filters yields the advantage of an almost dustfree environment. Dust deposition and fouling of heat transfer surfaces can be largely avoided. At the same time several disadvantages must be named: The relatively low exhaust gas temperature leads to large heat exchangers with high costs. Additionally, the conversion to electricity runs at a relatively low efficiency at around 6 % to 9%. In contrast, exhaust gases in the range between 400 °C and 550 °C enable ORC systems to deliver around 15% to 18% of the heat as electric energy. Moreover, the residual heat of the condensing of the ORC working media after the turbine can be used as secondary
upstream the filter is the high dust amount. Similar to well-known problems of fouling and clogging of regenerators the heat exchanger will suffer and the performance will degrade rapidly. Continuous intensive cleaning cycles are necessary or the installation of sophisticated but expensive additional equipment is required, such as a shot cleaning system. Steel balls pass through the heat transfer area from top to the bottom and, thus, maintain the surface area clean. In many cases the investment in the heat extraction and cleaning system exceeds the investment in the ORC system that leads to an unattractive business case. In this context, the innovative catalytic candle filter technology (CCF) combined with a heat recovery by means of an ORC system offers new possibilities (Fig.4). Continued>>
� Fig 6. CCF with assembly studs for the ORC.
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* Sales Manager for Clean Technology Systems, Dürr Systems **Sales and Business Development Manager for the product Cyplan ORC, Dürr Systems Goldkronach Germany www.durr.com Glass International July/August 2021
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* latest swabbing-robot installed in July 2017 in Germany
The advantage of the position of the ORC downstream the filter is combined with the advantage of high temperatures. The CCF can remove dust particles from hot flue gases at temperatures up to 420°C. In addition, the ceramic material can be enriched with catalyst – so that it can remove NOX as well – in one step. The very low dust content down-stream the CCF enables the application of the direct evaporation technology. The clean but hot exhaust gas is introduced to an evaporator which represents the primary heat exchanger of the ORC system. The heat is directly transferred from the hot gas to the ORC working media. No further intermediary heat transfer loop, e.g. thermal oil, is required, which leads to reduced investment costs. Due to the almost dust-free environment the heat transfer surface of the direct evaporator is maintained clean and no expensive cleaning equipment is necessary. Direct evaporation Cyplan ORC systems (Fig. 5) are available modular in different sizes classified by electrical output: 220 kW, 330 kW and 500 kW. One ORC system consists of three major components: evaporator, ORC base module and dry cooler. The components are pre-assembled and pressure tested in the factory, shipped to the customer and connected at site. Depending on the amount of waste heat available, more ORC systems could operate in parallel. In many current projects, the CCF is already equipped with connection flanges for integration of an ORC system at a later date (Fig. 6). This shows that there is a common thread running through the system to ensure maximum flexibility for the customer. In summary, it is possible to react to varying conditions with little effort and therefore the process can be adapted. A rough economic calculation shows that an investment in an ORC system yields interesting financial returns. An installation for 45,000 Nm3/h waste gas stream produces around 3,600 MWh electricity per year what corresponds to a pay-back time of approximately five years. In actual projects this value is often reduced because in many countries investments in energy efficiency are supported by governments in form of tax brakes or direct financial aid. In the case of Germany the payback time is reduced to less than four years. Additionally, the company’s CO2 balance is improved. The electric power produced through waste heat recovery and conversion is classified as CO2-free electricity. Based on the average carbon dioxide emission in Germany for 1 kWh in the electricity grid, the glass manufacturer with an ORC system can reduce his CO2 footprint by approx. 1,500 tonnes per year. The technology described above helps customers on their way to zero CO2 emissions and supports their goals for a sustainable production and positive contribution to society and environment. �
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Environment
Stoelzle implements holistic CSR strategy www.glass-international.com
Stoelzle Glass Group has been awarded for its sustainability strategy initiatives across all its production sites. Doris Marka* reports.
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ore than ever before, people and companies need to rethink their impact on nature. The European Green Deal has set ambitious goals for all industries and companies aimed to reduce CO2 their emissions and mitigate the greenhouse effect. As part of an energy intensive industry, Stoelzle is well aware of this challenging task and launched comprehensive sustainability initiatives on a group level at all production sites a couple of years ago.
Sustainability award This year Stoelzle Oberglas, the Austrian
production site and headquarters of the Stoelzle Glass Group gained recognition for its commitment to corporate social responsibility. The glass manufacturer was awarded with the regional TRIGOS, which is the most important Austrian award for responsible management. The award recognises companies for their excellent leadership roles and as a role model for responsible management and sustainability. Those companies clearly contribute to the future growth of the Austrian economy, society and the environment. Stoelzle Oberglas was the winner in
the climate protection category for two reasons: the successful implementation of a holistic sustainability strategy on a group level and for its ambitious prestige recycling glass project at the Austrian production plant. The jury was also impressed by the Green Knowledge initiative, a series of virtual workshops, aimed at raising awareness for climate protection throughout the Stoelzle Glass Group. In six virtual workshops, more than 100 interested Stoelzle employees learned from external lecturers with regard to the topic of Climate Change - Myth, Risks and Opportunities and
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be increased in future.
Decoration technique with 77% less CO2
In its three decoration sites in UK, Poland and France, Stoelzle sets steps as a role model for decoration techniques. A special powder coating technique, the Quali Glass Coat 2.0 helps save up to 77% of CO2 emissions compared to standard lacquering. Thanks to the use of less raw material and completely solvent-free colours, this method is sustainable and also creates bottle surfaces, which are highly resistant to mechanical impacts.
and made it much more sustainable. After several trial productions in 2020, the Austrian site Stoelzle Oberglas, which focuses on Pharma and consumer glass, is ready to manufacture its EcoSecur Pharma glass, a new generation of Type II glass. Compared to commonly known Type II production processes, the new Ecosecur bottles receive their inner surface treatment in from of a precisely dosed liquid agent. The liquid agent can be applied in exact doses to small to large glass containers. The manufacturing process guarantees a stable and high product quality, while being much safer to humans and the environment compared to other treatments with gas or solid agents.
In-house glass lab
Powder coated bottles are most suitable for a second decoration step in order to achieve valuable branding.
Type II Glass Sustainability ranks highly at the Stoelzle Glass Group. A dedicated R&D team doesn’t only focus on saving energy and reducing CO2 emissions but also thrives to develop ecofriendly processes and improve product quality. With regard to Type II Pharma glass, Stoelzle reinvented a commonly known production process
*PR Manager, Stoelzle Glass Group, Austria https://www.stoelzle.com/
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worked on finding new perspectives and necessary measures combined with the implementation of new processes and structures. Birgit Schalk, Sustainability Manager at the Stoelzle Glass Group, describes the winning project Prestige Recycling Glass as follows: “The main challenge in the glass industry is to continuously improve the energy-intensive process of glass production and at the same time to keep glass quality at a consistently high level. “With our new batch formula, we have managed to produce a sustainable, brilliant, colour-stable white glass with at least 20% PCR whilst maintaining a high level of quality. After a trial campaign in 2020, we successfully implemented the new batch formula in autumn and have been saving since then 20% of natural raw materials, 4% energy and around 16% CO2.” The increased use of cullet was accompanied by the implementation of a quality assurance concept, which monitors and ensures a consistent high level of glass quality and glass colour, even if the amount of cullet will gradually
One of the pillars in the quality assurance concept is Stoelzle’s in-house glass lab, which was installed recently at the Austrian headquarters. With the increased use of post-consumer recycled cullet, constant monitoring of the glass composition and colour is a necessity. The glass composition is checked regularly via X-ray fluorescence measurements. This method allows a rapid and reliable determination of a variety of glass components, which is crucial to optimise the glass batch for the forming process and to ensure that the content of heavy metals, such as lead are below the mandated limits. Furthermore, the concentrations of metal ions, which influence the glass colour, can also be determined. Complimentary, the glass colour is measured using UVVis spectroscopy to ensure a colourless appearance of all flint glass products. �
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Environment
Catalytic filtration in the glass industry Martin Schroeter* explains how the versatility of catalytic filtration can become the recognised technology for stack emissions control within the glass industry.
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oday, catalytic filtration is a widely accepted technology for control of stack emissions in the glass industry. Both in Europe and the USA, it holds a status of Best Available Control Technology (BAT / BACT) and became the preferred solution for control of NOx, SO2 and PM emission in Asia. While the implementation of the catalytic filtration technology in the glass industry has been installed due to a variety of drivers across different geographies, this paper summarises the versatility of the technology to address those drivers and inspire upgrading solutions.
Versatility of the technology One of the major characteristics of the catalytic filtration technology is its adaptability to accommodate different regulatory requirements. The track record of the catalytic filtration technology began in Europe in the late 2000’s as an alternative solution to add NOx removal efficiency up to 95% with negligible ammonia slip. This was a major concern for regenerative furnaces during flow reversal.
Four years later, the catalytic filtration technology was adopted for the glass industry in the USA, while it took further three years for the first catalytic filtration system start-up in Asia. At the heart of the technology is a filter candle made of ceramic fibres, which allows operation at elevated temperature of up to 900°C (1,650°F). The dust separation follows the principles of surface filtration on a conditioned layer, the “filter cake”. While dust removal is achieved with back pulse air, only part of the filter cake is detached and removed to the hopper section of the filter house. Since the ceramic filter does not expand during back pulsing, a residual dust cake will always remain on the filter. The residual dust cake prevents any constituent of the particulate matter to penetrate into the filter wall and thus makes the filter wall the ideal location to place a finely dispersed DeNOx catalyst as it will be entirely protected from particulate blinding. In combination with dry sorbent injection, typically using hydrated lime
as the sorbent, the catalytic filter is now capable to control both filterable and condensable particulate matter, NOx and acid gas precursors, like SO2, SO3, HCl or HF, together with metals and HAPs falling in the category of acid type components. While the catalytic filtration technology provides a high removal efficiency for all targeted emissions, geographies with moderate regulatory requirements may still consider catalytic filtration as a forward-thinking solution, which will still meet present regulations and be prepared for future requirements. This technology can also be used in combination with pre-existing emission control equipment -- adding emissions reduction capabilities by installing a partial flow treatment with catalytic filtration provides clients with a CAPEXefficient solution. At the other end of the spectrum, combination with traditional technology, like an SCR DeNOx slip reactor downstream of the catalytic filter system, can provide highest removal efficiencies Continued>>
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� Different regulatory requirements (removal efficiency/system availability) in different geographies.
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� CFD simulation of the mixing patterns and residence time profile of high jet injection technology.
while keeping operational expenditures at a moderate level. The desire to control operational expenditures did also inspire a number of technologies to minimise consumption of injected sorbent. These technologies, like booster air assisted injection or waste recirculation technologies, target improving the sorbent utilisation, which is hindered by diffusion limiting scale formation of the reaction product, by increasing mixing, dispersion, and residence time. Upgrading the overall system with these technologies can allow SO2 removal efficiencies exceeding 97%, and/or reduction in sorbent usage exceeding 20%. Availability has become another important factor when designing an emission control system. Driven by very limited permitted time for bypass operation of untreated exhaust gas in the USA, development of a cost-efficient modular concept delivered the potential to full redundancy of the complete emission control system. Today, filter housing maintenance can be done “online”, isolating one housing by closing inlet and outlet dampers. The remaining filter housings are designed to allow operation at full capacity for a limited period of time. Additionally, by equipping all subsystems in a redundant way, like 3 half-flow ID-fans, maintenance of the emission control system becomes independent from furnace operation. At the centre of the newest development is the filter candle itself. Larger exhaust flows and footprint restrictions have driven the development towards longer filter elements.
While shorter filter elements offer a cost-effective solution at lower exhaust gas volume flows, longer filter elements become the preferential choice at larger exhaust gas volume flows. Longer filter elements also allow filter house design to accommodate future conditions, such as additional exhaust gas treatment for future capacity increase. This could be achieved by adjusting the filtration area at the time of capacity increase.
Conclusion The catalytic filtration technology has developed flexible design solutions to address varying regulatory requirements for the glass industry worldwide. The technology has achieved a state of maturity allowing for the implementation of consequential design improvements for optimum total cost of ownership. While the lifetime of the filter elements
for the first industrial systems was predicted to be much shorter, experience has shown that the filter elements can operate for more than 10 years. New developments are focusing on operation and maintenance, striving for reduction of consumables and preventing mass filter breakage events with novel technology to prevent broken filter elements from sliding out of position. In summary, the glass industry has fully adopted the catalytic filtration technology as a means to meet present emission control requirements, while also allowing clients to upgrade their systems to meet future requirements with reduced effort and cost. �
*Sales - Ceramics Technology Group (CTG) Tri-Mer Corporation, Owosso, USA https://tri-mer.com/
� Relative cost of filter housings depending on exhaust gas flow for different filter length.
50 0 Glass International July/August 2021
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Automation
futronic wins Taiwan contract � futronic will supply a complete machine control system and servo technology to its Taiwanese customer in September 2021.
The German automation supplier will provide the machine control system and servo technology and will work alongside a European plant and equipment manufacturer on glassworks modernisation.
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A
s part of the project to modernise the glassworks at the Taiwan Tobacco and Liquor Corporation (TTL), an unnamed European plant and equipment manufacturer will supply a completely new IS machine. This will be accompanied by machine control system and servo technology, provided by futronic. The new machine is scheduled for commission in September 2021. The customer is a state-owned conglomeration which owns some of the country’s biggest breweries and distilleries under one roof. The company is modernising one of the two production lines in its glassworks. The project centres around the hot and cold ends; and amongst other things, the line’s eight-section IS machine, which is to be completely replaced. The new glass machine will be built by a European plant and equipment manufacturer. But despite the firm’s portfolio including machine controls and drives of its own, the customer has insisted on futronic technology.
� Sales Engineer Murat Yolaçan is responsible for
� futronic’s FMT24S control system will be part of
the project in Taiwan.
the installation.
Competitive edge
furnished by the control system specialist and housed in a total of five control cabinets. Lastly, an FMT training module will double as a supply of spare parts. futronic has scheduled installation and commissioning for January 2022. The plan is for several representatives from the customer’s organisation to travel to Tettnang in parallel for training at futronic, the pandemic permitting. The two parties have agreed not to disclose any details regarding the order volume.
“We’re very proud to have succeeded in convincing the customer of our products and our expertise”, says Murat Yolaçan, Sales Engineer at futronic and the man responsible for the project. futronic is well-connected in Asia, with many EPRO controls and other models from older generations still in use. The two production lines at TTL have also worked with EPRO control systems until now. “We have an excellent reputation there”, Mr Yolaçan confirmed. “All the same, it’s not every day that we can gain a competitive edge over such big players in such an extensive refurbishment project.”
Almost the entire futronic portfolio The order comprises almost the entire futronic portfolio of control and drive systems for IS machines with up to 24 sections: the package’s core items are a futronic FMT24S machine control system and an FDU24S servo drive. The drives for the servo take-outs (STO24S), 2-axis pushers (PDU24S) and servo inverts (SIU24S) will likewise be
Lighthouse contract Mr Yolaçan is now hoping that the project will have a lighthouse effect throughout the Asian market. He said: “There are an awful lot of glassworks that are due to be modernised in the next few years. “This contract is a chance to show how our controls are ideal for controlling machines from different manufacturers.” He added: “that our product portfolio will become very attractive for more and more potential customers as a result.” �
futronic, Tettnang, Germany www.futronic.de
52 0 Glass International July/August 2021
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Vacuum Control System VCS
Photos: O-I Germany
Zero defect quality in the vacuum process
Inexpensive reject system Early detection of manufacturing and system problems Reduced error rate Significantly improved quality of products and production
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automation in a new dimension
11-12 MAY
Monterrey, Mexico
GLASSMAN LATIN AMERICA RETURNS TO MEXICO Glassman events are where the hollow glass industry does business. Join us in Mexico to meet thousands of buyers looking for innovative manufacturing solutions for energy efficiency, quality control, packaging, logistics and decoration.
INTERNATIONAL EXHIBITION 2-DAY CONFERENCE NETWORKING EVENTS
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Country profile: Bangladesh
Bangladesh glass industry continues to expand S
outh Asia is home to some of the most populated countries in the world. India, Pakistan and Bangladesh - three major countries of the region feature in world’s top ten most populated countries. It has been one of the biggest economic development success stories of recent decades. Despite high poverty levels since its independence in 1971, Bangladesh is on course to graduate from the United Nations least-developed countries list in 2026. Annual gross domestic product (GDP) growth has accelerated in every decade, reaching over 8% in 2019. However, the economic development has not translated into big gains for the country’s glass industry. Per capita consumption of glass products in both the major sub-segments is low when
compared to many other Asian countries. The flat and container glass industry in Bangladesh comprises of four producers in each category. Contrary to the general trend of the container glass industry having higher output than the flat glass, it is in fact the country’s flat glass industry that has higher output as compared to the container glass industry. Compared to nearby Pakistan, which is also covered in this issue, Bangladesh has made remarkable performance during the last decade. It could be gauged from the fact that it is no longer among the least developing countries. The volume of Bangladeshi exports is twice as much as Pakistan’s and same is the case with its Continued>>
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Bangladesh’s glass industry has attracted investment and attraction in the last decade. Seema Gahlaut presents an overview of the country’s container and flat glass industry.
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Country profile: Bangladesh
currency, Taka, whose value has nearly doubled than that of Pakistan’s rupee. Bangladesh’s GDP growth rate is 7.9% compared to Pakistan’s 1.5%. The foreign exchange reserves held by Bangladesh are said to be at $41 billion as against Pakistan’s $20 billion. Only on remittances, Pakistan is ahead of Bangladesh.
Flat Glass Industry Bangladesh current has four main flat glass producers. Nasir Glass Industries is located near the capital Dhaka, while PHP Float Glass Industries is situated close to the port city of Chittagong. The two other producers are engaged in sheet glass production. MEB Sheet Glass Factory is located at Chittagong, while government-owned Usmania Sheet Glass Factory has its production unit in Dhaka. Bangladesh’s construction sector has performed adequately during the previous few years, apart from in 2020 due to the Covid-19 pandemic. On average, 3.5 million houses are built annually in the country. The market for residential, commercial and office building stock is projected to increase by USD 72.3 billion by 2025. According to Mohammed Mohsain of the PHP Float Glass, he explained that the ‘demand of flat glass products has been rising in the country due to the rise in infrastructure development’. He said: “The demand has grown significantly over the last few years, which has encouraged us to launch new products. The glass industry has enormous potential, but it is also true that there has not been significant investments in the glass sector for some time.”
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Nasir Group of Industries Nasir Group is one of the two leading float glass producers in Bangladesh. Currently, the company is the largest float glass producer in Bangladesh. Its manufacturing plant is located at a short distance from the capital city Dhaka, at Sripur in Gazipur and has an installed capacity to produce 72,000 tonnes of float glass. The glass factory produces clear and tinted float glass in 2mm to 12mm thickness. The company had commenced float glass production with a designed capacity of 250 tonnes per day in the year 2005. During the start of the last decade, Nasir Glass increased the designed capacity of 400 tonnes per day. In December 2020, Nasir Group signed a general contract with China’s technology supplier CTIEC for the company’s third float glass production line with a designed capacity of 600 tonnes per day. The company has a designed capacity to produce 100 tonnes per day of glass tableware products and 20 tonnes per day of glass tubing for fluorescent tube lamps and CFL lamps from its production facility located at Sohagpur in the Tangail district. Equipped with technology from European suppliers such as Olivotto, JCL and Danner Tubing,
the company has made its mark in manufacturing these types of product. Nasir Group is one of the largest business conglomerates in Bangladesh and in addition to float glass, the group is engaged in production of industrial gases, tobacco, packaging, light engineering, melamine and footwear. Nasir Glass is also among the leading glass processors in Bangladesh. In March 2021, the company installed a set of pre-processing machines from Italian company Bavelloni to increase the capacity of processed glass at its manufacturing facility.
PHP Float Glass Company PHP Float Glass is the second largest float glass producer in Bangladesh. The company has a designed capacity to produce 150 tonnes per day of float glass products from its headquarters in Chattogram. The project was set up with technical assistance from Luoyang Float Glass Technology of China. To expand the product portfolio, the company installed a high-quality silver mirror plant in 2008 from the Chinese technology supplier. In February 2021, PHP Float Glass commenced commercial production from its newly acquired sputtered coater. The company has a designed capacity to produce 1500 tonnes per month of coated glass through the new coater. Amir Hossain Sohel, Managing Director of PHP Float Glass Industries said: “Two colours [blue and green] of imported reflective glass have been controlling the market, but we are going to offer various colours for the consumers and builders. “We are introducing 10 colours of reflective glasses including pink, grey, blue, and silver that vary from 2mm-12mm in thickness.”
Usmania Sheet Glass Usmania was the only flat glass manufacturing company in Bangladesh before its independence, established in 1959 in the Kalurghat industrial area of Chattogram and starting production in 1961. After independence from Pakistan, Usmania Sheet Glass merged with Bangladesh Chemical Industries Corporation under the industries ministry. Although it is known as the pioneer in the domestic glass industry, the company has incurred losses recently. It lost Tk 125.4 million in the 201920 financial year, up from Tk 108.2 million a year before.
Container glass industry Contrary to the neighbouring container glass industries of China and India and despite its large population, Bangladesh lacks a sizable container glass industry.
Continued>>
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EXCELSIUS is member of ROBUR
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Country profile: Bangladesh
Other packaging format and especially PET packaging has been a deterrent in the development of the domestic container glass industry. Demand from the beverage sector has been the largest disappointment for container glass producers. Only carbonated beverage producers demand container glass bottles. There is hardly any use of container glass in the other categories such as juices, energy drinks etc. According to data from the Bangladesh Beverage Manufacturers Association (BBMA), more than 100 companies are involved in the production of soft drinks in Bangladesh. Investment in the sector has been Tk 100 billion during the last fifteen years. Surprisingly, the pharmaceutical sector is the largest segment for container glass producers. Bangladesh’s pharmaceutical sector, which has been growing solidly at more than 15% a year, is currently sized at US$3 billion, and is expected to reach US$5 billion by 2025. Once dependent on imports, the sector is now self-sufficient but is still dominated by domestic companies. The local sector produces 97% of the medicines that are needed in the local economy and is the second largest tax contributor to government revenue. There are more than 150 firms in the industry with the top 20 firms making up around 85% of the total. The industry includes global brands like Square and Incepta. The Bangladeshi pharmaceutical manufacturing firms mostly produce small-molecule generic drugs that are no longer patented in the domestic market. The industry’s low-cost base relative to major exporters such as China and India suggest that there is a potential to increase exports. There is already a move toward a greater focus on exports. Companies from Bangladesh are exporting to more than 127 countries around the world, according to the Bangladesh Association of Pharmaceuticals Industries.
Bengal Glass Works Government-owned Bengal Glass Works is the largest container glass producer in Bangladesh. The company has been involved with container
glass production since 1975, when it began commercial production from a 40 tonnes per day furnace. In subsequent years, two more furnaces (in 1995 and 2011) were added. Currently, the company has a designed capacity to produce 155 tonnes per day of container glass for pharmaceutical, food and beverage products and glass lamp shells which are used for manufacturing incandescent light bulbs.
JMS Glass Industries JMS Glass commenced commercial production in 1985 at its manufacturing facilities, which are located at Siddirgonj, Narayangonj, near Dhaka. JMS Glass Industries operates two furnaces (one for amber glass and other for flint glass) to produce about two million glass bottles per day for pharma, beverage, food and cosmetics industries.
Padma Glass Industries Pharmaceutical glass producer Padma Glass ventured into container glass production in 1988 by setting up a production unit at Barisal district in the country. In 2011, the group setup another container glass plant (Padma Blowing Limited) at Barisal for producing glass ampoules, glass vials and bottles for pharmaceutical industries.
Segway Glass Segway Glass is a subsidiary of leading healthcare products company Jayson Group of Companies. Jayson Group produces pharmaceuticals, herbal medicines, veterinary items and animal feed. Equipped with a modern manufacturing facility from German company Schott, Segway Glass produces glass ampoules for injections. Currently, besides supplying ampoules to the local pharmaceutical industry in Bangladesh, Segway exports some proportion of its output to other South Asian countries. �
http://nasirgroup.com.bd/ https://phpfamily.co/businesses/float-glass/ https://www.ugsflbd.com/ https://www.bengalglass.com/ http://www.jmsglass.net/ https://jaysongroupbd.com/segway/home
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RIM tempering Tempering Lines on spindles
TEMPERING Lines on belt
vidromecanica@vidromecanica.com
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LIGHTENING THE IMPACT OF HEAVY INDUSTRY CALL FOR SPEAKERS NOW OPEN
Application deadline: 30 September 2021 We’re looking for people at the frontier of cleaner industrial manufacturing who can ignite a discussion about the path to net zero on a game-changing scale. If you have ideas on, solutions for, or experience of how manufacturers in hard-to-abate sectors can embrace sustainable technologies, we want to hear from you. WE ARE LOOKING FOR: Presentations that will engage the audience in a highly creative or interactive way Content that is applicable to a broad range of hard-to-abate sectors
Real-world implementations Practical takeaways that attendees can implement, or that drive robust discussions about new ways to improve operations
INTRODUCING THE SIM STEERING COMMITTEE
Nadine Bloxsome Aluminium International Today
Matthew Moggridge Steel Times International
Greg Morris Glass International
Fiacre O’Donnell Vidrala Ltd
Melanie Williams Melanie Williams Consulting
Geoff Matthews EnergyFlex Pty Ltd
Pernelle Nunez International Aluminium Institute
Oscar Verheijen GlassTrend Board
PART OF:
Chris Bayliss Aluminium Stewardship Initiative ORGANISED BY:
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Raw materials
Understanding the use of calcium carbonate in glass manufacturing Harald Scheel* explains why natural mineral calcium carbonate is an ideal raw material to use in the glassmaking process.
O
� Fig 1.
Highest content of calcium carbonate Mono structured grain structure Zero fines Least chemical deviations Free of anthropogenic substances PFC/PFT Constant analytical monitoring Registration to REACH by the producer Constantly low iron of <0.002 % results in whiter glass or enables other raw materials with more iron Constantly low iron content reduces use of decolourisers Consistently low iron content enables greater use of foreign cullet, thus saving raw costs Higher cullet input results in melting energy savings Higher cullet input results in higher furnace capacity, thus higher quantity Low iron content brings more radiant heat due to higher batch transparency Carbon Footprint = 0! (Credit factor flue gas emissions) No dust components, thus 100 % usable raw material Controlled production process, close monitoring intervals Saving resources for green credits No supply bottlenecks due to four sources of supply Long-term supply contract possible Free monthly test reports
Understanding the pellet softening process Fast decarbonisation called crystallisation reactors happens when the water mixed with calcium hydroxide flows upstream through a fluidised bed of seed crystals for precipitation as pellets. In Omya’s case, the seed crystals are a defined sieving of e.g. 0.1-0.3 mm from broken pellets from previous reactor times. The resulting calcium carbonate is deposited in crystalline form of aragonite on the seed crystals; as a result, the grain size of the pellets increases continuously. Continued>>
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mya is a global producer of industrial minerals derived from calcium carbonate and dolomite, and a worldwide distributor of chemical products. As a natural mineral, calcium carbonate has a multitude of characteristics that make it an ideal raw material for a wide variety of uses in various industrial as well as environmental applications. In special cases Onya is processing and marketing the hardness of drinking water as pure calcium carbonate. The by-product from waterworks is so called Stellacarb, a pure material for industrial applications as for the glass industry.
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Raw materials
� Fig 2.
Grain sizes over 2mm reduce the reactivity due to the decreasing surface area in relation to the reactor mass. When the water emerges, the decarbonisation is practically complete. (Fig. 1) Table 1 shows a comparison is shown of natural limestone to hydrated lime. Despite the already very low carbon footprint of natural limestone which is processed by only 62 kg per ton of CaCO3
� Fig 3.
at our plants, there is another one with much less carbon footprint which is called Stellacarb. Hereby the creditable carbon footprint is equal to zero! (Fig. 2) It shows more than a dozen pros listed as able to use Stellacarb as a calcium carbonate raw material for your melting process. Omya understands its role as a networker for the glass industry, not only
in Europe but everywhere where glass is made (Fig. 3). �
Product Manager Water - Environmental Solutions Europe, Omya, Köln, Germany https://www.omya.com/ With support from IGR Institut für Glasund Rohstofftechnologie GmbH, Germany https://igrgmbh.de/ https://igrgmbh.de/
Over 1000 production lines are equipped with Graphoidal Shear Spray Systems. Contact us today to find out how our latest technology can help you. Graphoidal Developments Ltd, Broombank Road, Chesterfield S41 9QJ, England Tel: +44 (0) 1246 266000 Email: sales@graphoidal.com Fax: +44 (0) 1246 269269 Website: www.graphoidal.com Omya raw materials.indd 2
23/08/2021 11:27:02
Incorporating the BIFCA Standards Seminar
ONLINE EVENT 14-15 SEPTEMBER REGISTER TODAY
The future is now when it comes to furnace technology
Manufacturing industries are already seeing the results of the ‘Furnace of the Future’ in reducing CO2 emissions and producing cleaner, more sustainable materials. But how can energy-intensive manufacturers work towards making this future a reality? Are we already seeing the benefits of adopting smarter and more sustainable technologies within furnaces? Could we be doing more? This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and present a collaborative approach to bring the Furnace of the Future to life.
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FROM THE PRODUCERS OF
Topics will focus on: r Industry 4.0 (the Furnace of the Future) r Furnace Maintenance r Heat Treatment r Energy Efficiency r Testing & Measurement r Retrofitting r Emerging Technologies r Operations & Productivity Alongside the two-day virtual conference, participants will also be invited to join live discussions and will have the opportunity to network with new industry contacts, arrange video meetings and exchange resources and information. IN ASSOCIATION WITH
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Annealing
� Vidromecanica’s annealing lehrs.
Improved the annealing lehrs cycle Annealing is an important element of the glass-making process which is more complex than it may first appear. Precisely controlled cooling is required during annealing until a sufficient strain point is reached, reports Vitor Maia.*
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G
lass is described as a mineral product obtained by a melting process that cools without crystallisation and finally takes a solid state. This definition provides the basis of the annealing process. Every glass type (soda lime, borosilicate, etc.) is characterised by a different batch composition and consequently, a different temperature-dependent viscosity and expansion coefficient. During melting, the batch passes continuously from a solid to a liquid state. At forming it is brought back to a solid, passing the various ‘plastic’ stages and characterised by different viscosities.
These define the characteristic points of glass annealing, such as working, softening, annealing and strain points and annealing range (the temperatures between softening, annealing and strain points). Through knowledge of the annealing range, temperature limits for each stage have been established (Fig 1).
Permanent Stresses There are two types of residual stress: Permanent and temporary. Annealing is in fact a cooling process. Glass has poor temperature conductivity and although this property can be advantageous in some instances, it
is an inconvenience in annealing. To explain the origins of stress, consider that glass is made up of a series of distinct layers, lying parallel to the surface. Heat loss from the glass depends on the transfer of heat from layers in the body of the glass to those at the surface. These layers are interdependent and in different states of expansion. As the external surface cools faster, it reaches its final shape while the centre is still in expansion. All the molecules are intimately bound and their reciprocal action will create compression stresses once the inner layers have cooled and contracted.
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Annealing
is determined by time-thickness calculations. Precisely controlled cooling is required during the annealing phase until the strain point is reached. The cooling gradient is given by calculations depending on glass thickness and type. Finally controlled, fast cooling is necessary to bring the glass to ambient temperature. This process must also be maintained within calculated tolerances to avoid breakages resulting from temporary stresses (Fig 2).
Temporary Stresses
� Flexibility is key to getting the right annealing lehr for Vidromecanica.
There is a necessary balance to maintain between compressive and tensile stresses. Imbalances create varying degrees of destruction in the glass thickness but if cooling is achieved sufficiently slowly, the layers will not be submitted to disturbance and stress generation will be avoided. All stresses created at this point remain permanent and annealing is important because mechanical and thermal resistance are conditioned by it.
When being cooled below strain point, glass can still be submitted to thermal influences creating temporary stresses and distortions that disappear slowly. However, unless cooling is controlled, unbalanced stress levels could lead to breakages. Of course, controlled and strong cooling to generate high stresses makes toughening desirable in some instances. Increasing the compression stress on the surface gives the glass high mechanical and thermal resistance.
Annealing Curve Passing through the tunnel of a continuous annealing lehr, glass follows a fixed temperature gradient that is necessary to produce the desired level of stress. Glass must be reheated or cooled to assure homogeneity above the annealing point. The amount of time glass is maintained at this temperature
Annealing is an important element of the glass-making process more complex than it may first appears. Consequently, thorough knowledge of the process is becoming increasingly necessary. A number of scientists have developed theories and established rules that are relatively easy to use, including Adams and Williams (widely used), Shand (Corning Glass); Owens (the most widely used and easy-to-use curves); and Redstone and Stanworth (mainly used for optical glass). Neutral annealing, avoiding the creation of stresses, is not necessarily the ultimate goal to attain. In certain instances, the introduction of controlled stresses to the glass can be advantageous. Design flexibility has certainly been an important requirement for lehr builders such as Vidromecanica over the last three decades, providing customers with readily adjustable heating and cooling equipment. Vidromecanica manufactures thermal equipment (for annealing, decorating and toughening); equipment for coating treatment (hot and cold end coating) and cullet recycling equipment. Development, design and manufacture of machinery, development of control systems, control panel construction and software provision for the production lines are handed by the company’s inhouse specialists. With glass machinery solutions for many applications of the glass industry, equipment and systems from Vidromecanica are used in the glass container, tableware and technical glass sectors (Fig 3 and Fig 4). �
*Technical Director, Vidromecanica, Marinha Grande, Portugal www.vidromecanica.com; Email: vidromecanica@vidromecanica.com
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Conclusions
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History
Prof. John Parker
I’ll drink a glass to that Prof John Parker* and Ella Barrett** discuss Jacobite Wine glasses created during the 18th century.
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N
umerous factors have influenced wine glass design and generated many excellent textbooks on the subject, ranging from the ability of the bowl to capture the wine’s bouquet to the influence of a weight-based glass tax on spiral air-twist stems. Here we focus on politically motivated decoration of 18th century wine glasses. An excellent overview on engraved lettering on glass has been written by David Peace, (Glass Engraving, Lettering and Design, published by Batsford, 1985), himself a noted engraver. He links the constraints of good design to the requirements imposed by the methodologies adopted. His forebears were craftsmen in the metal file industry and their trademark introduced him to the creation of elegant images. Wood engraving then led into glass decoration. His book describes the oldest glass artefact in the British Museum with engraved lettering. Dated from 722 to 705 BC, he suggests the pattern was made using a rotating tool. But by the first century AD, lettering was more often created using engraved moulds as in modern container production. Not until much later did the art of engraved lettering approach the standards demanded now. The wine glasses that this article focuses on are Jacobite glasses made during the 18th century. In 1714 the last Stuart monarch (Queen Anne) died but she had outlasted all 17 of her children and had no natural heir. Some saw her half-brother James III as her legitimate successor but as a devout catholic he was legally prevented from inheriting the crown. A more distant but ‘safer’ relation was George I of Germany (house of Tudor). Another factor was Scotland. The Union with England in 1707 was still raw for many and James III of England was also James VIII of Scotland.
The Jacobite uprisings in support of James VIII centred on Scotland but had many English supporters; the ‘Old Pretender’ was finally defeated in battle in 1746. Such political movements were influential in the increasingly sophisticated culture of the day. Rebellious groups in society were turning to print and engraved glasses were an extension of this cultural trend. Coffee houses provided a catalyst for a more modern form of political discussion and more masculine modes of politeness; freemasonry began during this period. A British identity was being forged through Empire and trade links; indeed, trade alongside links to the Dutch Royal family through marriage meant that Dutch politics was also influencing British thinking. The material objects created during this period provide insights into the prevailing cultural norms and societal values and are widely studied by historians. Objects such as coffee cups, tea sets and wine glasses all symbolise aspects of identity; our ‘Jacobite wine glasses’ are one aspect of this, with images representing the Catholic/Scottish Jacobite cause. Thistles and six petal roses were common images; a bud represented the pretender to the throne. Latin phrases such as ‘Redeat’ (may he return) and ‘Fiat’ (may it happen) were code reinforcing the visual messages. Our Jacobite glasses were probably decorated by rotating wheel using techniques developed by Dutch artists during the previous century and would have been smuggled into the country, their message being seditious and illegal. Glass engraving went on to be widely developed in this century by the Dutch and indeed Jacobite Glasses continued to be produced after 1746. By the end of the 1700s fine pieces with an international reputation were being created.
The engraver aims to use surface damage over a controlled area to scatter light and create a visible but translucent image. One of the simplest methods uses a hand-held tool with a diamond or silicon carbide point to produce stippling by tapping or to draw lines. Rotating drill heads of different shapes impregnated with an abrasive, like that in the dentist’s toolkit, now offer more flexibility. They are also hand-held and used on a fixed glass piece. A rotating ‘copper’ wheel often powered by a foot treddle uses an abrasive (e.g. carborundum) introduced as a suspension in a liquid lubricant/coolant (water). The artist must bring the piece to the wheel but can divide letters into individual steps and use pressure to vary the width and depth of the line created so imitating the action of an ink pen writing italics. The latter method dates back to Roman times but now is sadly on the UK red list of endangered skills. UK artists like David Peace developed the skills of calligraphy to a level where their work is much sought after in a variety of settings. Prof Turner’s second wife, Helen Munro Turner, was herself a noted glass engraver. Albert Harland gifted the Turner Museum of Glass its collection of wine glasses in 1943. A Member of Parliament for Ecclesall, Sheffield and a member of the University Council, his collection spans different historical periods. We hope, Covid-19 permitting, to open our collection to visitors in September during the Annual National Heritage Days and feature the Jacobite cups as a highlight, without re-igniting earlier conflicts. �
*Curator of the Turner Museum of Glass, ** Research Assistant and Digital Curator at Turner Museum of Glass The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk
66 Glass International July/August 2021
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