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February 2022—Vol.45 No.1
IRAQ CONTAINER PLANT INTERVIEW ARDAGH DECARBONISATION PLAN RENEWABLE GLASS REVIEW I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
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Air Products Celebrates the 2022 International Year of Glass
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Contents
www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Deputy Editor: Jess Mills Tel: +44 (0)1737 855154 Email: jessmills@quartzltd.com Designer: Annie Baker Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com
February 2022 Vol.45 No 2
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Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com Managing Director Tony Crinion tonycrinion@quartzltd.com
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Chief Executive Officer: Steve Diprose Chairman: Paul Michael
Subscriptions: Jack Homewood Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034. Email: glass@quartzltd.com Website: www.glass-international.com
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Official publication of Abividro the Brazilian Technical Association of Automatic Glass Industries
Member of British Glass Manufacturers’ Confederation
22 China National Association for Glass Industry
Editor’s Comment + International news
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Company profile: Royal Can Making Company Iraq container glass plan
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Decarbonisation: Ardagh Opportunities to decarbonise container glass manufacturing
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Decarbonisation: Horn High electric power share in glass melting
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Decarbonisation: Celsian Assessing new raw materials for carbon-lean batches
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Vacuum technology: Pneumofore Modernising Vacuum and Pressure in Hollow Glass Production
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Decarbonisation: Renewable Glass Conference 2021
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Refractories: Refel An update on fused cast AZS exudation
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Refractories: ZCR Thinking outside the box refractory linings by ZCR
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Pharmaceutical glass: IGR Type II-glass for the pharmaceutical industry
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O-I Design Awards O-I awards showcase sustainable printing technology
United National Council of the glass industry (Steklosouz)
Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2020 edition: UK £185, all other countries £195. Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.
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1 Glass International February 2022
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International News
GREG MORRIS, EDITOR
Be first with the news! For breaking, up-to-date news
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Exciting year ahead
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It’s official - 2022 is the United Nations Year of Glass! This once in a lifetime event will focus on all things glass across all sectors. From the more mainstream such as wine and beer, to speciality glass including mobile and tablet technology to more niche sectors such as glass art and history. The celebrations started in some style at the launch event in Geneva, Switzerland earlier this month. A total of 150 delegates were treated to a two-day conference inside the UN’s eye-catching human rights room within the Palace of Nations. Presentation speakers focused on the fundamental role of glass in this glass age and how it has helped facilitate some of the most important technology of our time, such as the aformentioned mobile and tablet technology as well as developments within artificial intelligence and virtual reality. A number of events will take place around the world throughout the year. A glance at the IYOG 2022 website provides all the information with events being added regularly. The only concern is, while sectors such as arts and history have embraced the celebrations, the industrial sector remains relatively quiet. True, big organisations such as Sisecam sponsored the opening ceremony, but elsewhere there is very little activity from the manufacturers. For example it would be good to see a special punt mark to celebrate what is a unique year for the world of glass.
International Year of Glass launched at United Nations
Celebrations for the International Year of Glass started with a two-day Opening Ceremony in Geneva, Switzerland at the UN Palace of Nations. International Year of Glass Chairperson Prof Alicia Duran (pictured) helped launch the celebrations. Bringing together glass communities from across the world, the programme featured 30 speakers who shared the latest scientific and technical insights, and thoughts on how glass will be key to shaping the sustainable society of the future in line with the UN 2030 Agenda. The ceremony in Geneva is the culmination of five years of effort by the International Year of Glass Council to ac-
knowledge the mark glass has made – and continues to make – on civilisation. Glass has accompanied humankind for centuries, as one of the most important, versatile, and transformative materials in history. Used in everything from packaging food and drink in containers, to vaccine distribution, glass is a leading example of sustainable packaging – and its footprint also extends to construction, medicine and dentistry, communication technology, and beyond. Glass is an ideal packaging for adopting sustainable production and consumption patterns including re-use and recycling. International Year of Glass
Council member, John Parker, said: “2022 is the year to recognise glass for its many proven credentials and build on a longstanding cultural heritage for example by advancing glass’ contribution to the UN’s Sustainable Development Goals. “Europe enjoys the world’s highest glass recycling rates, and significant progress has been made in glass manufacturing in recent years to increase sustainable production and consumption.”
For more information on how you can participate in the International Year of Glass celebrations, please visit https:// iyog2022.org.
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International News
NEWS IN BRIEF
Saint-Gobain sells Estonian business
Encirc Italy has supplied sustainable heat energy to meet the needs of the district heating network around its facility in Corsico, Italy. The project, created in partnership with power company Atecc, has reduced the amount of CO2 being released into the atmosphere by more than 3,000 tonnes a year within the region. This has improved air quality in the area, and provided a
sustainable supply of energy for the local population. Atecc, based nearby, partnered with Encirc Italy, previously known in the region as Vidrala Italia, to allow the residual heat from Encirc Italy’s operations to be used to power the local energy grid instead of fossil fuels. The Encirc Italy-led project was supported by technology partner Renovis Energy, which offered an end-to-end service,
supplying the equipment needed while providing ongoing engineering and installation support. The scheme is the first energy supply agreement in the Vidrala group’s history, with the district heating network now able to use 100% of the heat energy created by Encirc Italy throughout winter and 30% of it in the summer.
O-I reports increased glass production volumes Sales and production volumes surpassed pre-Covid levels, O-I outlined in its latest financial report. In its fourth quarter earnings report the world’s largest container glass manufacturer said the increased volumes underscored consumer preference for premium and sustain-
able glass packaging. Andres Lopez, CEO of O-I, reported a 1.1% increase in shipments compared to 2019 levels. Year on year there was a 5.3% increase in shipments and a 7.3% increase in production levels. Shipments in tons in Europe increased 13.2% primarily due
to strong growth in the wine category across southern Europe. In the Americas, shipments decreased 1.7% which reflected increased engineering project activity that restricted production amid record low inventories.
Arc offers virtual tours Tableware manufacturer Arc is offering a virtual tour of its glass factory in Arques, France. The platform was created to allow customers and partners to visit Arc’s production sites
in spite of the pandemic. For the factory, there are over 40 on-site locations available with 360° views, which have also been integrated with animations of the company’s
daily operations. For the latest version of the platform, visit: https://cloud.3dvista.com/ hosting/7357289/0/index. htm
Emhart reports increased demand
Exceptionally high demand helped boost Bucher Emhart Glass sales in 2021. The container glass technology supplier said it experienced a rapid upturn in demand from the slump of the previous year. In its latest financial note the Swiss technology supplier said container glass customers had stared investing again. The investment was in glass manufacturing facility’s modernisation and expansions, as well as completely new production locations. Order intake for the year was up by 64.7% to CHF522 million ($562.5 million) compared to CHF317 million ($341.6 million) the year before. Major challenges were posed by bottlenecks for raw materials, components and in logistics as well as the severe government-imposed Covid-19 restrictions in Malaysia. All of these caused sales to decline slightly on the previous year. The operating profit margin is likely to see another marked increase over the first half of 2021 thanks to the favourable product mix and the cost base, which was low for the entire reporting period.
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Encirc supplies heat energy to Italian neighbourhood
Saint-Gobain is to sell its Estonian glass processing business Baltiklaas. The regional unit will be divested to Polar Glass, a subsidiary of Barrus, a glued laminated timber manufacturer in Estonia and supplier to window and door producers. Baltiklaas employs more than 200 people across two sites, in Tartu and Mäo, with sales of around €25 million in 2021. This transaction follows a number of other divestments in glass processing by the group since 2018 in Europe with total sales of around €300 million sold.
3 Glass International February 2022
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Cleanfire® HRx™ Synchronized Boosting System All the boost you need, perfectly synchronized Need to boost energy input to your air-fuelfired regenerative glass melting furnace? Air Products’ Cleanfire® HRx™ Synchronized Boosting System is an innovative and costeffective solution. This patent pending, commercially-proven technology is added to your furnace and synchronized with air-fuel flame reversals for optimal flame stability and luminosity. Benefits includes: • Ultra-low NOx emissions • Reduced energy consumption • Higher glass quality • Enhanced productivity • Increased furnace capacity • Remote performance monitoring
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February news NO.indd 3
Verescence in electric furnace plan Perfumery and cosmetics glass manufacturer Verescence plans to electrify its furnaces. Its Furnace 1 at the Mers-les-Bains production plant in France will be the group’s first furnace to use this technology in 2025. In 2020 Verescence committed to the carbon neutral glass Vercane project which aimed to identify the different energy sources capable of powering glass
production in a sustainable way, including electricity. The progressive electrification of its seven melting furnaces in France, Spain, the United States and South Korea is a key step towards achieving Verescence’s objective of reducing its CO2 emissions by 40% by 2034 (scopes 1 and 2). The project will start during the reconstruction of furnace 1 of the Mers-lesBains plant in three years.
Helene Marchand, General Manager France, said: “I’m pleased to announce this major development which will allow us to decrease by half our CO2 emissions in less than 10 years in France and bring us even closer to our zero-carbon ambition by 2050. “Our new electric furnace 1 on which we have been working for more than a year will be the group’s pilot furnace.”
Sisecam acquires Refel Italian refractory manufacturer Sisecam will acquire the Italian company Refel, one of the world’s leading refractory materials manufacturers. With this acquisition, Sisecam aims to secure its refractory supply and avert supply chain-based risks for its new investment plans. The unavailability of refractory materials can double the time required to complete cold repairs in glass melting furnaces. Sisecam Chairman, Professor Ahmet Kırman, said the investment would allow
Sisecam to become a major player in the ever developing and growing refractory industry: “The acquisition of refractory manufacturer Refel will play a major role in eliminating supply risks that Sisecam may face in its future glass manufacturing investments.” Refel, headquartered near Venice, Italy, is a globally leading producer of AZS fused cast refractory materials, mainly used in building furnaces for the glass manufacturing in-
dustry. With a workforce of approximately 160 highly skilled employees, Refel has an annual production capacity of over 6,000 tons. Excluding Chinese producers, Refel holds nearly 20% of the global AZS refractory capacity which is used in the furnaces of glass manufacturing facilities and had annual sales of €45 million. The transaction was advised by the renowned glass industry advisor Dr. Diane Nicklas.
Glass International February 2022
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International News
NEWS IN BRIEF
Gerresheimer’s Wertheim expansion
Gerresheimer is to expand its glass vial production at its Wertheim, Germany manufacturing facility. The company said it was to invest in production in Wertheim to increase vials capacity by 150 million vials per year. It also plans to create 70 new jobs for this purpose. Until now, the company had served European demand for vials from its plants in Boleslawiec, Poland and Chalon, France.
Top 10 stories in the news Our most popular news over the past month, as determined by our website traffic. All full stories can be found on our website. � � � � � � � � � �
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Iraqi glass container plant plan unveiled Verallia unveils electric glassmaking plan Wiegand-Glas postpones furnace start up CO2 neutral container glass production Vidroporto selects Sorg furnace Sisecam acquires Refel refractory group China takes ownership of Kazakh float facility Emhart reports exceptional demand O-I reports increased production GPI refutes glass shortage claims
AGI glaspac opens plant
Indian container glass manufacturer AGI glaspac has inaugurated its new manufacturing facility in Bhongir, Telangana, India. With an aim to cater to the growing demand in the speciality glass segment, the new 154 TPD (Tonnes per day) glass plant has initiated the production of clear glass products as vials, nail polish bottles. The facility will provide direct employment to 350+ people and will serve foreign markets along with the Indian markets. Rajesh Khosla, President & CEO, said: “We are closer to our vision of building a centre of excellence in the container glass packaging in India, using globally-benchmarked manufacturing systems and practices.”
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Vidroporto selects carbonreducing furnace from Sorg
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HSIL Limited boosted by wine success
Increased demand for beer and wine glass bottles helped boost Indian glass packaging company HSIL Limited’s income by 18%. In its latest financial note to the quarter ending December 31, 2021, it reported total income of 645 crore compared to 548 crore in the same quarter last year. The company registered Y-o-Y revenue growth despite a high base of a comparative quarter in last year which saw pent-up demand post Covid-19.
Sorg is to supply a high-boosted 480/day furnace to Brazilian glass packager Vidroporto’s Porto Ferreira plant in Sao Paulo state. Vidroporto is a container glass producer for alcoholic beverages and food markets. It chose Sorg as its technological partner for the new end-fired regenerative furnace. Looking to reduce its carbon footprint, the end-fired furnace will be the first one in South America to comprise
a high-amount of electrical heating (boosting). It will incorporate Sorg innovations to produce high-quality glass while achieving high thermal efficiency, lower CO2 emissions and a long furnace campaign. As well as the engineering, supervision, steel structure, equipment and technical support for the furnace, Sorg will also deliver the glass conditioning system to feed three Tandem machines with the latest solutions, including
Sorg STW for the distributor and SORG 340+ design for the forehearths. Vidroporto has two production sites with four furnaces in operation. Sorg said it was proud to be chosen for the new project, in which it will dedicate its efforts to deliver the topmost technical solutions and to support the Vidroporto team during the project, construction, commissioning and furnace operation.
6 Glass International February 2022
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International News
NEWS IN BRIEF
Applied Vision secures GCA inspection contract
Applied Vision Corporation will install its Volcano Glass Inspection Systems at GCA’s new furnace projects in 2022. GCA, based in Kutahya, Turkey, will use the Volcano systems to inspect the sealing surface, base and sidewall of its glass containers. Dr Abdullah Gayret, general manager of GCA, said: “We chose Applied Vision for these projects not only because of its leading edge technologies, but also its responsiveness to our needs as a consistent and growing glassmaker.” “GCA has been instrumental and such a positive influence on the evolution of our Volcano product family,” said Jeff Hartung, Applied Vision’s vice president, sales and customer service. “We have been able to translate their technical needs and feedback into value by adding machine functionality in order for both GCA and Applied Vision to benefit.”
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Verallia’s €65 million French plant investment
Verallia is to invest €65 million in its Chalon-sur-Saone production facility, France. About €60 million will be used to equip the site with three furnaces to replace the current ones. The remaining €5 million will be used to increase the site’s production capacity, improve its industrial performance, and reduce its environmental footprint and that of its customers. This investment will also reinforce the programme to lighten the weight of certain bottles, in response to growing demand from customers who want to reduce their environmental footprint. The Chalon sur Saône plant is the largest of the group’s 32 plants, both in size and production capacity. It can produce 1 billion bottles per year. The group said at the end of 2021 of its intention to build two new 100% electric furnaces at its Cognac site.
Glass Futures breaks ground on £54 million development
Glass Futures has broken ground on its £54 million development in St Helens, UK. The 165,000ft2 global glass research and innovation facility is expected to complete in January 2023. Glass Futures will manage the building to deliver industry and government-backed
research, as well as development projects focused on decarbonising glass production. It will also provide a platform for the industry to access an experimental scale furnace to test and run trials for implementation at commercial scale, both collaboratively and individually.
Guests from Glass Futures, Network Space Developments, St Helens Borough Council, Liverpool City Region, MPs Marie Rimmer and Connor McGinn welcomed UKRI to the site to mark the ground-breaking of the Centre of Excellence.
Bormioli Pharma takes part in sustainable glass research Bormioli Pharma is participating in a number of research projects to achieve performance and sustainability aims. The company has collaborated with Italian research
centre IMEM-CNR to develop external and internal coatings able to increase glass performance. It is also experimenting a treatment to make soda-lime glass bottles more resistant to aggressive phar-
maceutical formulations. Bormioli Pharma has also joined the Glass Futures industrial research project, which aims to identify new low-emission technologies for glass production.
HFT formalises leadership team HFT has restructured its senior leadership team to better align with its corporate strategy goals. The speciality engineers and contractors believe the adjustment will allow the company to focus on its core capabilities and further enhance its services to clients. HFT will focus on global engineering, procurement and construction, while contin-
uing its emphasis on project solutions. Mark Piedmonte will continue to lead as president and CEO, with additional responsibilities, whilst Kevin Yung has been promoted to Chief Revenue Officer. Brad Hall and Jordan Baker join HFT in other leadership roles, serving respectively as Chief Operations Officer and Chief Financial Officer.
Mr Piedmonte, CEO, said: “One attribute of every successful organisation is a willingness to evolve as necessary to more effectively address tasks at hand. “I believe we’ve done exactly that by formalising the structure of our senior leadership. “I’m confident about our direction and I’m eager for the journey ahead.”
8 Glass International February 2022
February news NO.indd 6
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Company profile: Royal Can Making Co
Royal Can Making Company unveils Iraq container glass plan
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I
raq-based holding company Royal Can Making Company plans to set up a greenfield container glass factory with a capacity of about 1200 tons per day. The plant, south of Baghdad, will be built over the next three years with a first flint furnace of 520 tons per day operational by Aug 2023. Established in 1995 in Iraq, Royal Can Making Company investor is a holding company involved in several areas of business encompassing manufacturing, distribution, and marketing. The company, owned by Mr Saad Kola, has diversified into several segments ranging from hospitality, pharma and FMCG. Having a strong and efficient distribution network, knowledge of local market and resources which are one of its most important assets in its business in Iraq they fully own, manufacture, and distribute the following brands: Pioneer Pharma, Royal Can Making Co and Middle East for manufacturing packing Materials Co. Founded in June 2012, Royal Can Making is based in the Sulaymaniyah -Kurdistan region of Iraq, while Middle East for Manufacturing Packing Materials was founded in November 2017 and is based in Baghdad, Iraq. Both companies are specialist aluminium can manufacturers in Iraq, with two facilities, one in Sulaymaniyah and the second one in Baghdad. RCMC has a combined production capacity of 4
billion cans annually. Having had a majority stake in can supply in Iraq, Mr Kola said the RCMC group sees a logical extension to its business and an opportunity to supply glass bottles to the domestic market. He said: “Our clients have been asking for Glass. About 30% of our clients use it for beverages such as Pepsi and juices etc. “There is currently no container glass factory today in Iraq. There are 40 milion people in Iraq so there are huge demands for glass, particularly now with the focus on the environment and efforts to minimise plastic consumption. “Glass use is expected to grow more in future. Glass is currently imported into Iraq from neighbouring countries and transportation costs are extremely high, as well as customs costs. “This has pushed us to accelerate the construction of the glass plant.” The food industry is gaining importance from the Government and is expected to be one of the most important components of the national economy in the near future. The majority of glass manufactureed at the site will be for domestic use but the company may export in future. Royal Can will have a new company for the glass business.The English name is AL-Malakeya Glass manufacturing company. Royal Can has collaborated with German engineering company cm.project.ing as its
10 Glass International February 2022
Company profile Iraq.indd 1
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Engineering Procurement and Construction Management (EPCM) contractor. The EPCM contract was signed in August 2021. With no established major container glass manufacturer in Iraq the supply chain gap and potential restrictions from government for importing container glass places an opportunity to establish a new production facility. The current market needs about 1000 t/d of glass. However, the trend, the same as elsewhere in Europe and in the Middle East, is to move to nonreturnable glass. About 90% of the bottles will be non-returnable. RCMC plans to supply about 90% of the domestic market demand for container bottles The project owners have defined a target to sell 1000 tons per day of glass by 2024. RCMC has acquired about 520,500m2 of land near Baghdad. The location will have its independent power generation facility to supply electricity to the proposed glass plant and for future expansion. The design capacity of the plant in the first phase will be 520 tons/day through one oven. A second furnace will be built in February 2024, which will increase production capacity to about 700 tons per day. The second furance is a 150tpd furance primarily catering the pharmacy market. The third furnace with a capacity of about 520tpd is scheduled to go in production in Jan 2026. This is a flint and green furnace.
� Saad Kola, owner of Royal Can Making Co and Daniel Schippan, Managing partner of cm.project.ing, signed an EPCM last August.
The facility will have best available technology (BAT) from the industry. The raw material sourcing and sand processing plant is being considered to be built inside the facility to ensure security of raw materials. A 40,000m2 warehouse and a residential building to accommodate about 400 employees is also considered on the plot. A decoration line is also considered as most of the container bottles sold in the region comes with decoration. The site and the layout are designed to further expand the factory into three additional furnaces (totaling up to six furnaces). CMP has been given the direction to plan the utilities and infrastructure to plan for future expansion. In addition, the industrial complex is planned for future expansion of a steel factory and a power generation plant to generate power up to 150MW is also foreseen in the layout. Mr Kola said the security situation in Iraq is now stable. The company has used overseas companies from Europe and the USA to install equipment at its can making sites in the past. In addition it will build a modern residential building on the site of the glass plant for 250 overseas suppliers to stay in during the construction phase. It means suppliers will not have to be hosted in hotels and be required to use transportation every day to reach the site. The EPCM contract was signed between RCMC and CMP in Aug 2021. The concept engineering is completed and currently the detail civil and architectural engineering is under progress at CMP HQ. The tenders for the core technology equipment are already out and the offers are being reviewed with leading equipment suppliers. By Q1 of 2022, all core technology contracting, and civil contractor (GC) will be completed. A groundbreaking ceremony for the first furnace is planned for June 2022. �
* Owner, Royal Can Making Company, Iraq www.royalcanco.com **Managing Partner, cm.project.ing, Aachen, Germany www.cmprojecting.de
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A greenfield container glass plant in Iraq will supply the domestic glass needs of the Middle Eastern country. Its owner has apointed cm.project.ing as EPCM contractor. Greg Morris spoke to Saad Kola* and Daniel Schippan**.
11 Glass International February 2022
Company profile Iraq.indd 2
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THREE INDUSTRY-LEADING SERVICES, ADVANCING AS ONE. The SORG Group is more than just one company. It is three unique forces powered by experience, reliability and innovation, providing a single source to support glassmakers with optimal design and seamless delivery throughout the furnace lifetime.
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Decarbonisation
Opportunities to decarbonise container glass manufacturing While work continues to develop breakthrough decarbonisation technologies in container glass manufacturing, Sven-Roger Kahl, Manager of Furnace Operations and Innovations at Ardagh Glass Packaging discusses alternative routes to reduce CO2. � AGP’s Sven-Roger Kahl, Manager of Furnace
C
ontainer glass manufacturing is an energy-intensive process that currently uses fossil fuel as its main energy source. For a sustainable future, the industry must develop breakthrough and alternative technologies to address carbon emissions – the only downside to the packaging material beloved of the food and beverage industry. Reducing the industry’s carbon emissions to net zero by 2050 is the goal and, unsurprisingly, there are several ways to get there. Presenting to the industry at Glass Trend in December 2021, Sven-Roger Kahl, discussed how alternative technologies can reduce the carbon footprint of the container glass industry. He explained how AGP has proven that carbon savings can be achieved through using more recycled cullet, alternative recycled raw materials, batch pre-heating and cullet drying, and talks about the challenges of each different route.
Each of these methods impacts energy consumption, which in turn impacts the CO2 footprint. Where alternative recycled raw materials do not directly reduce the carbon footprint they always contribute to the circular economy.
Recycled cullet Using high quality recycled glass cullet to make new glass containers requires less energy in the furnace. Every 10% of cullet used in place of raw materials reduces energy consumption by 2.53% and reduces the use of primary raw materials. Plus, the more cullet re-used in the furnace means less goes to landfill. The challenges around using more cullet are quality, availability and price. In terms of quality, any organic contamination within the cullet can cause discolouration and blistering in the glass. Contamination such as CSP (ceramic, stone, porcelain) can lead to
inclusions in the final product, and any metal contamination can shorten the lifetime of furnaces. Ardagh has been working with cullet suppliers for many years to agree higher cullet quality standards across the industry. Its Cullet Task Force, formed in 2009, has led to a change from a local to a centralised cullet process across all of Ardagh’s 20 European plants. An approved cullet specification and cullet quality monitoring system have been instrumental in ensuring consistency and reliability of cullet quality, while an internal cullet database enables live trend monitoring of cullet quality on factors such as pollution and colour. Most aspects of this specification are summarised in the German Industry Standard T120 issued by BV Glas. Continued>>
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Operations and Innovations.
13 Glass International February 2022
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Decarbonisation
AGP uses up to 90% recycled cullet in its European furnaces, but availability is a challenge. The Close the Glass Loop multistakeholder platform created by FEVE, the European container glass federation, has set out to achieve a post-consumer glass container collection target of 90% in Europe by 2030, and to ensure that this is recycled into the container glass bottleto-bottle production loop. This will be achieved through close cooperation between the whole glass packaging value chain, sharing best practices on innovative and tailored collection models, high quality sorting and recycling, and consumer communication campaigns. Data recently released by the Close the Glass Loop platform confirms that glass collection and recycling in Europe increased in 2019 to reach an average rate of 78%, representing a growth of 2% compared to the previous year’s performance and an all-time record high. See the latest glass recycling map and discover more on closetheglassloop.eu The fluctuating price of recycled cullet also impacts the amount that can be used; adding more cullet to the batch recipe must still be financially sustainable.
� The Cullet Team at AGP, working on improvements in recycled cullet strategy.
Close the Glass Loop Case Study: Zero Waste Leeds
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Alternative recycled raw materials
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Most raw materials are carbonates: soda ash, limestone and dolomite, which all release CO2 during the melting process when making new glass containers. However, there are alternative raw materials from waste streams that are carbon neutral, or are circular materials, and AGP has proven they can be used effectively in place of specific raw materials in the furnace: � Slags from blast furnaces can be used to produce all glass colours, replacing up to 20% of sand weight. Aluminium and steel smelting slags show similar potential based on theoretical calculations but are not yet used in industry. � Fly ashes: Sodium Carbonate can be used to produce flint and amber glass colours, replacing up to 30% of soda ash. � Water treatment waste: Calcium carbonate, Sodium sulphate and Iron (hydr)oxide can be used to produce flint and emerald glass colours, replacing up to 80% of limestone. The impact of using these alternative raw materials can be substantial. For example, by using Calumite (blast furnace slags) in place of the standard batch, process CO2 is reduced from 46.8
In summer 2021, AGP supported a local social enterprise: ‘Zero Waste Leeds’ to encourage the people of the City of Leeds in Yorkshire, UK, to keep recycling glass. This campaign involved a 12 week-long communication and community engagement campaign and included the installation of three new glass recycling banks around the city. Local children created colourful designs for each new glass bank, to make recycling a more fun and enjoyable experience. The campaign showed residents where to recycle their glass with an interactive map and explained how it is recycled within Yorkshire in a true circular economy, saving both natural resources and CO2. The outcome was in impressive 43% increase in glass collected from the new banks across the three sites, compared with the same period in the base year of 2019.
kg per ton of glass, to 37.6kg per ton of glass. This reduces process emissions from the batch by 20% and overall CO2 emissions by 4%. By using aluminium and steel slagbased batch in place of the standard batch, process CO2 is theoretically reduced from 27.8 kg per ton of glass, to 7.7kg per ton of glass. This potentially reduces process
emissions from the batch by 70% and overall CO2 emissions by 10%. There are challenges when using waste stream materials which require the knowledge of experienced glass technologists: � chemical composition and stability Continued>>
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Decarbonisation
� Calumite can be used to produce all glass colours and can replace up to 20% of sand weight
� Difference in conditions in the furnace, without and with a pre-heater. Red and blue lines indicate the
in the batch.
batch line in the furnace.
� contamination by heavy metals and volatile elements (chlorine and fluorine) � grain size distribution (some are very fine) � unexpected chemical reactions from waste materials and stability of supply.
The challenges of using pre-heaters are: � the CAPEX required - payback is between three and seven years � the installation requires space, which can sometimes require a complete footprint reconfiguration � companies require knowhow, from design through to operation, to achieve the optimum benefits.
hall � weather-induced operational problems are solved � CO2 is reduced by 334 tons per year due to using residual heat from the production hall instead of using additional energy to dry the cullet in the furnace. This is equivalent to the annual CO2 emissions of 208 cars.
Cullet drying and pre-heating
This system is also known as ‘Frozen Cullet’, a program supported by the German Ministry of Environmental Affairs. The challenges of using the heat exchangers are: � the CAPEX required – payback is between one and three years � the installation requires space � companies require knowhow to realise the full benefits.
The glass technologist must work together with the waste material producer, to decide which fraction can be used in glass melting and what additional processing steps may be necessary to make the waste material fit for glass melting. Traditionally the glass industry has been hesitant to use alternative raw materials due to concerns over the resulting bottle quality, but AGP has proven that if your alternative materials are high quality, the end result is as good as using traditional raw materials.
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Batch and cullet pre-heating AGP first installed a batch pre-heater at its Nienburg plant in Germany in 1987 and thanks to their multiple benefits, has increased that to six installations with a seventh currently in construction. The pre-heater heats the batch and cullet, which means less energy is required to melt materials in the furnace. Our example shows the difference in conditions in the furnace, with and without a pre-heater. The blue line indicates the amount of batch ingredients yet to be melted thanks to the difference in temperature. In terms of performance, pre-heating: � reduces flue gas volume and CO2 by 15% � increases the melting capacity by 10% � reduces energy costs by 15% � there is little maintenance required and as the pre-heater installed in 1987 is still in operation, its lifetime is at least 34 years.
During winter, snow, water and ice accumulate on cullet in open storage. As water in all its forms causes obstacles in operation and increases energy consumption, it makes sense to dry it out and pre-heat the cullet before it goes into the production process. The way we do this is to blow warm air from the plant’s production hall into a heat exchanger, which heats up the air further. A second heat exchanger transfers the energy from the hot air to the wet or frozen cullet, which defrosts and dries it, leaving high quality cullet. The system can process 457 tons of wet or frozen cullet per day. The benefits are: � 190 kW of thermal energy is gained from the heat generated in the production
To read more about Ardagh Group’s sustainability progress and to read our 2021 Sustainability Report, please visit ardaghgroup.com/pdf/sustainabilityreport-2021. �
Ardagh Glass Packaging, www.ardaghgroup.com
� The AGP facility in Neuenhagen, Germany where a batch pre-heater is installed between the batch plant and the furnace.
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Decarbonisation
High electric power share in glass melting Max Kallert* describes concepts for substituting fossil fuels for electric power, which could aid in achieving climate neutrality within the glass industry.
� A classic end-fired furnace including regenerator, distributor and forehearths furnace.
restrictions (e.g. for cullet, pull changes, etc.) applying for a full electric melter. Furthermore, the standard for electric furnaces right now (<200 tonnes per day) is still on the lower end needed in the container glass segment. This is why Horn is developing several hybrid concepts as an alternative. These concepts combine an increased electric power share and the well-known principle of horizontal melting. The word hybrid is an often-used buzzword in this context, but there are varying definitions. Does hybrid mean: � The simple existence of both kinds of power in the furnace? � Equal contribution from electric and fossil sources? � High flexibility ranging from predominantly fossil to predominantly electric contribution? Horn defines a furnace as hybrid if both forms of power, electric and fossil, are needed for sufficient operation. Therefore, an end-fired furnace with
electrical boosting up to 10-15% would not be considered a hybrid furnace, whereas a 50/50 contribution from both fossil and electric sources would clearly be a hybrid furnace.
Considerations For hybrid furnaces, some current working standards (for fossil furnaces) have to be reconsidered. The incorporation of a higher amount of electric power makes it necessary to increase the number of electrodes in the melting basin too. Each bottom electrode creates locally a strong vertical flow that interferes with the main horizontal convection, known from the horizontal melting process. If a high number of electrodes are positioned evenly and extensively over the basin bottom, a broad disruption of the typical convection flow is a probable consequence. That is why Horn prefers a certain positioning of Continued>>
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I
n times of global warming, the push to reduce carbon dioxide emissions and reach climate neutrality is also influencing the glass industry. Right now, fossil fuels are still covering the majority of the energy consumption in the production of glass. Current measures to cut down fuel consumption include heat recovery for batch, cullet and gas preheating as well as direct substitutions with more sustainable fuels (like hydrogen or bio gas). However, the incorporation of green electric power into the glass production could be the way to go. Compared with green fuels, electricity in the melting process has the advantage of higher availability and lower prices (due to better efficiency). A logical, but radical, step now would be to completely switch to electric energy and use a full electrical vertical melter. This would mean huge changes in operating compared to the current fossil furnaces and their horizontal melting principle. This is due to different
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Decarbonisation
� All-electric melter (100% electric power; VEM). The furnaces from the hybrid-fossil category represent the evolutionary step from the classic-fossil furnaces in container glass towards more electric power, while the super-hybrid furnaces continue this concept to an even higher electric share.
End-fired hybrid � CFD model of an hybrid end fired furnace running with a 30/70 share of electric and
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fossil power fired furnace.
bottom electrodes, combined with the use of side electrodes, to preserve the typical horizontal convection. This way, the melting process in the batch layer can be supported and the disruption by the vertical flow around the electrodes is minimised. A declining share of fossil power reduces the temperature in the crown and superstructure, regardless which kind of combustion is used. This can lead to problems for some of the common materials currently used, for example standard silica should be used above 1470 °C. Depending on the wanted range of energy flexibility, this problem can be intensified due to high temperature differences. Additionally, the chemical atmosphere from combustion (air fuel; oxy fuel; hydrogen firing) has to be taken into account. The refractory producers are working on options (e.g. lime free silica), but the refractory concept has to be chosen carefully for the desired hybrid furnace. Another consequence of reduced fossil consumption is a decrease in the volume flow of the fuel itself and the oxidant as well. For end-fired furnaces, this will lead to a state of underload in the regenerators and lower velocities at the burner port, which can result in instabilities in flame formation and a generally shorter flame length. This contributes to an unfavourable temperature distribution in the superstructure and has negative influence on the glass quality. For new furnaces with limited fossil energy flexibility this is no issue, as the regenerator and superstructure can be designed accordingly. However, for existing furnaces (which should be retrofitted for a higher electric share) and furnaces with a high electric flexibility, this can be problematic. In both cases, the volume flows differ significantly from the original state and
the issues noted above will occur. As a countermeasure, the recirculation of flue gas is a possible solution. Part of the flue gas from the exhaust regenerator is added to the combustion air on the corresponding air regenerator. Therefore, the volume flow and the velocities at the burner port increase and proper flame formation is restored. Additionally, the NOx-concentration can be reduced with this measure. By controlling the recirculated volume, the flame length and position of the hot spot can be influenced as well.
Categories To meet the needs of the customer, Horn developed the following furnace categories varying in overall electric share, energy flexibility and basic principle. Key: end-fired furnace (EFF), cross-fired furnace (CFF), oxyfuel furnace (OXY) and vertical electric melting (VEM). � Classic-fossil furnace (up to 20% electric power; EFF; CFF; OXY). � Hybrid furnace (20 to 40/50% electric power; EFF;OXY). � Super-hybrid furnace (up to 80% electric power; OXY). (Future concept.)
Currently the standard for the production of container glass is the end-fired furnace. Therefore, a lot of knowledge and routine in operating exists at the majority of glass producers. To combine this wellknown principle with the possibility of an increased electric power share, Horn developed the hybrid end-fired furnace with from 20% to 40% of electric power. Two mechanisms ensure proper operating conditions for energy flexibility. The first one is the already mentioned recirculation of flue gas, which influences the hot spot in the combustion space (necessity depends on wanted flexibility). The second one is the individually adjustable boosting systems. As a result, the power distribution in the glass melt can be changed to correspond with the settings in the combustion space to further influence and stabilise the hot spot. Compared to a completely fossil fuelled end-fired furnace, the CO2-emissions regarding the melting can be reduced up to 45% (not including CO2 from batch gases).
Oxyfuel hybrid Today, oxygen for gas combustion is mostly used for high quality and special glass. This can largely be traced back
� CFD model of an hybrid oxyfuel furnace running with a 50/50 share of electric and fossil power oxyfuel furnace.
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Decarbonisation
to the high price of oxygen. A cleaner combustion (especially regarding NOx) and a higher efficiency are also on the plus side. Depending on the furnace size, even some form of heat recovery from the exhaust gas is possible (preheating gas, cullet, batch, etc.). For hybrid furnaces, firing from the side has a huge advantage. Whilst recirculation in an end-fired furnace changes the temperature distribution to a desired setting, at an oxyfuel furnace the gas distribution can be precisely adjusted. Therefore, it is easier to influence the hot spot to find ideal melting conditions. For a high share of electric power, the gas distribution can be shifted more towards the refining area, whilst the energy in the melting area is predominantly provided via the electrodes. If the electric share is lower, the gas can be distributed more evenly along the furnace. A recent, successful start-up of a Horn hybrid oxyfuel furnace, with an electric share of 50%, has turned the concept into a reality. The oxyfuel hybrid increases the energy flexibility even more, compared to the end-fired hybrid furnace. Starting from a continuous combustion space,
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the furnace can be operated with up to 50% electric power, with a minimum of around 20%. Compared to a completely fossil oxyfuel furnace, the CO2-emissions regarding the melting can be reduced up to 50%.
Oxyfuel super-hybrid For creating an even higher degree of flexibility (up to 80%) Horn is developing the super-hybrid oxyfuel furnace. Based on the hybrid oxyfuel furnace, additional features were added. A refining area with a depth of over 2.5m, and additional side electrodes to ensure proper refining, are provided in the glass melt. In the combustion space, a socalled ‘shadow wall’ can be implemented to separate it into two parts: a cold section, where low fossil heating takes place and the batch is ideally covering the glass surface, and a hot area where the majority of gas is combusted. The hot flue gases are discharged over the batch, to enable heat recovery onto the cold batch layer. The necessity of this shadow wall and the position inside the surface are highly dependent on the operating of the furnace. If the flexibility should be used
to its highest degree, a shadow wall will definitely be necessary. If the goal is to maintain a certain energy ratio (such as 30% fossil and 70% electric) with minor deviations, the superstructure design can be adjusted accordingly and a shadow wall is not needed. The potential for reducing CO2-emissions is even higher for this concept; up to 80% of CO2-emissions from combustion.
Conclusion The glass industry is a very traditional branch and a furnace represents a high investment for the manufacturer. Therefore, it absolutely makes sense to do an evolutionary, intermediate step between the classic and the super-hybrid furnace categories with Horn’s hybrid end-fired furnaces and Horn’s hybrid oxyfuel furnaces. If glass producers are willing to take it ‘all the way’ and go full electric, Horn is the right partner for large all-electric furnaces as well. �
*CFD Modelling at Horn Glass Industries, Plössberg, Germany, https://www.hornglass.com/
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Decarbonisation
Assessing new raw materials for carbon-lean batches With decarbonisation at the forefront of the glass industry, Corinne Claireaux1, Mathi Rongen2, Luuk Thielen3 and Johan van der Dennen4 discuss how using alternative raw materials in batches could reduce direct CO2 emissions.
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L
ike every other energy-intensive industry, decarbonisation is the major challenge facing glass. It’s everywhere - on the news and on the desks of many technical, marketing, legal, and financial teams. Consequently, great initiatives all are pulling the industry towards the use of less carbonised energy sources and raw materials, such as GlassTrend projects, Glass Futures, furnace for the future and the Dutch-funded TKI project for hydrogen combustion piloting. Using hydrogen combustion and melters with a higher share of electrical energy is no longer a distant dream. Fossil fuel combustion is the first source of direct (Scope 1) CO2 emission, followed by the decarbonisation of the batch. Additionally, the CO2 footprint of the raw materials constituting the batch contributes to indirect (Scope 3) emissions. A step-by-step approach is proposed to help the glass industry progress towards a carbon-lean batch and glass production.
Batch-to-melt kinetics Finding undissolved particles in a final product is rather seldom. This high quality is achieved by careful optimisation of the residence time and the temperatures in the melter. Increasing the residence time or the temperature of the melt would degrade the overall energy performance of the melter, which is an absolute no-go. Therefore, any new raw material should not worsen the melting kinetics of the batch. Lab-scale evaluations consist in interrupting the melting of the batch at different times before completion of the conversion. The residual crystalline part of the batch is quantified by X-ray powder diffraction (XRD). This experiment allows the melting rate comparison and the identification of the nature of the residual defects. The effect of raw materials’ nature, particle size, cullet size and quality can be assessed in view of melting rate.
Fining and foaming Raw materials must not generate excessive
foaming, as this will have a negative impact on the process efficiency or alter the fining of the melt - leading to seeds, bubbles and other quality issues. In the High-Temperature Melting Observation System (HTMOS), coupled to the Evolved Gas Analysis (EGA) set-up, the entire melting process is filmed and gases arising from the gas-forming reactions are analysed. The atmosphere above the batch in the set-up is tuned to match the combustion atmosphere in the furnace. Undesired phenomena such as foaming, delayed or incomplete fining are directly observed while the gas analysis enables monitoring of the fining process and quantification of the batch emissions. This information is crucial to ensure that raw materials contribute to the attainment of a homogeneous, bubblefree melt.
Energy demand The purpose of a glass furnace is to provide the energy required to convert
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energy demand of industrial glass batches. The energy demand set-up is based on the principle of a drop calorimeter. Validation measurements have been performed on silica sand, sapphire and glasses; the results have been compared with thermodynamic data. The set-up has 5% accuracy and 3% reproducibility. It operates between 1000 and 1400°C. This temperature is high enough to fully convert most batches into a melt. Depending on its foaming behaviour, the maximum batch sample size ranges between 200g and 600g. Therefore, it is very easy to test representative industrial batches including cullet pieces as big as 40mm.
Lab to plant
� Using burnt lime can decrease CO2 emissions from a batch and save on energy costs.
the batch into a bubble-free melt. Part of the quantity of energy required is the sum of the energy needed for heating the raw materials to the reaction temperature, sustaining the endothermic reactions leading to the formation of a melt, and further heating up of the melt to their respective exit temperature. For an industrial glass-melting furnace, the total energy required for batch melting is between 25 and 50% of the total required energy. Commercial thermal analysis equipment (DTA / DSC) is available to measure the energy required. Such machines use extremely small quantities of raw materials, which may cause representativity issues in batches containing multiple raw materials. These machines also do not allow the use of real-size cullet due to this limited sample size. These issues are overcome in a new experimental set-up, developed and built at CelSian, which measures the overall
Lab assessment allows the observation, quantification and understanding of the behaviour of the batch raw materials. Information such as the presence of foam (both primary and secondary), the temperature at which a first liquid phase is formed, the redox of the final glass and the energy requirement of the batch are easily obtained. This data can be used in computer models of the full-scale furnace to calculate the coverage of the batch blanket, the energy transfer, the quality of the glass and the energy consumption of the furnace. Calculation of the energy consumption of the furnace does not require advanced CFD modelling and can be obtained by simpler, faster models such as CelSian’s Energy Balance Model. This model simulates the energy consumption and CO2 emissions of a furnace as a function of its design, process input and settings. Therefore, it can be used to evaluate the energy and CO2 savings, which could be generated at the plant scale by the substitution of one or more raw materials.
Application The use of burnt lime CaO instead of limestone CaCO3 is a well-known way to decrease the CO2 emissions from the batch and to save on energy costs. CaO is a reactive raw material that allows for quicker batch-to-melt conversion. Since it is a decarbonised raw material, the foaming behaviour of the batch is reduced, illustrated in Fig 1. Results of an energy demand test on a simple ternary soda-lime silicate glass containing 10% of calcium oxide are shown in Fig 2. Two batches are heated up to 1200°C, one with classic limestone and the other with freshly burnt lime. The use
of a decarbonised calcium carrier led to a decrease in energy demand of 20%. Since the batch recipe is known its heat capacity can be calculated, as well as the quantity of emitted gases, the composition of the obtained glass and the heat capacity of the glass. The energy demand for the heating of the batch, gas and melt can be calculated. The batchto-melt conversion reactions require a significant amount of energy that must be considered in the calculation. The chemical energy demand coefficients of the raw materials are used to calculate this. These coefficients are obtained or derived from the literature [1, 2] and use detailed thermodynamic data. Results of the measurement and calculation are presented in Table 1. The glass obtained from both batches has the same composition, so the energy demand for heating the glass is the same. The batch with burnt lime emits less CO2, so the energy demand to heat the gases is lower. The batch-over-melt ratio is higher, so less batch is required to produce the same amount of melt and the energy required to heat the batch is lower. The total result of experiments and calculations agree within 5%, demonstrating the accuracy of the measurement set-up. The positive impact of burnt lime is well documented in the literature based on lab-scale trials but there is a lack of information at full scale. Lab-scale results such as the energy demand data presented in Table 1 and information about the foaming behaviour of the melt can be used in the Energy Balance Model (EBM) to model a full-scale furnace. An example of a U-flame, air-gas furnace with 0.7 MW of electrical boosting, running with 50% cullet, is presented in Fig 3. In this base case, the furnace produces 220 tons of glass per day. To achieve a throat temperature of 1340°C, 1040m3 of gas are burned with 9195m3 of air, leading to the total production of 288kg of Scope 1 CO2 per ton of produced glass. A few selected data are presented in Table 2. When the limestone is changed for burnt lime, the CO2 emission of the batch decreases by 40%, and the total CO2 emission of the furnace decreases by 12%. Then, several parameters can be modified: � Due to the decarbonised limestone, if the energy input and the glass output remain the same, the energy consumption of the furnace stays the same, but the throat temperature increases by 48°C. Continued>>
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Decarbonisation
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Decarbonisation
� The pull rate is increased to 245 tons of glass per day to bring the throat temperature back down to its initial value. This 11% increase in glass production leads to a 10% decrease in energy consumption and a 19% decrease in CO2 emissions from the furnace. � An alternative way to reduce the throat temperature down to its initial value, consist in decreasing the energy input without modifying the pull rate. This 8% decrease in energy consumption reduces CO2 emissions by 17%.
100
Relative energy demand (%)
80
40
20
Conclusion In a context where the glass industry is progressing towards decarbonisation, the use of well-assessed, alternative, decarbonised raw materials is a concrete way to reduce direct CO2 emissions. By combining an experimental and modelling approach, CelSian offers a unique procedure to assess raw materials. The batch-to-melt conversion behaviour, kinetics and energy can be observed and quantified on a laboratory scale. This data can then be used in the EBM tool to calculate the full-scale potential CO2, energy and financial savings. These savings can be weighed against the differences in the batch price to obtain a complete economic picture of the changes in raw materials and to guide the glass industry towards more sustainable production. �
60
0 Lime stone
Burnt lime
� Fig 1.Extract from an HTMOS video of a
� Fig 2. Relative energy demand of a ternary
glass wool batch at 900°C. On the right side,
soda-lime-silicate batch heated up to 1200°C.
standard raw materials are used. On the left
The use of burnt lime instead of limestone as
side, burnt dolomite was used. The height of the
a calcium carrier reduced the energy demand
camera vision is approximately 10 cm.
by 20%.
� Table 1. Components of an energy demand calculation. All values are expressed in kJ/kg glass. Calculation and measurement agree within 5%.
References [1] R. Conradt and P. Pimkhaokham. An easy-to-apply method to estimate the heat demand for melting technical silicate glasses. Glastech. Ber., 63K:134– 143, 1990. [2] R. Conradt, Fiberglass Batch-to-Melt Process in H. Li (ed.), Fiberglass Science and Technology, 323-381, 2021.
� Table 2. Results of an EBM simulation for a U-flame container furnace running with 50% cullet.
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Writers 1. Glass Scientist and Academy Manager 2. R&D Project Manager and Consultant 3. Consultant and CFD Specialist 4.Operations and Software Developer CelSian, Eindhoven, Netherlands, https://www.celsian.nl/
� Fig 3. EBM user interface showing the base case parameters.
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Vacuum technology
Modernising Vacuum and Pressure in Hollow Glass Production Daniel Hilfiker* discusses the evolution of vacuum technology and how the use of digital and industry 4.0 elements ensure they continue to remain an integral part of a glass manufacturing facility.
I
n glassworks, uncertainty prevails for most people when it comes to the use of vacuum, this intangible and elusive state of energy. Not so for Pneumofore, which has been active for three generations in the global glass community. The familyowned company has nearly a century of experience in supplying dedicated pneumatic solutions for vacuum and compressed air. The secret to its success? Flexibility. Built on the reliable and beneficial simplicity of the rotary vane principle, Pneumofore machines are easily adapted to evolving moulding technologies and the latest supervisory control systems. This article presents real cases of Industry 4.0 networking, connectivity, and security of Pneumofore installations, along with durability and efficiency highlights.
in energy-intense equipment like compressors and vacuum pumps, forwardthinking customers look beyond the purchase price: they also demand exact figures regarding power consumption, spare parts, and maintenance needs. Their analysis can easily look 10 years ahead, especially if they are subject to penalties for falling short of efficiency limits. Pneumofore solutions comfortably satisfy these parameters, as these pumps and compressors are built on rotary vane technology and engineered for long-term, continuous operation at high efficiency. Extended warranties can further guarantee performance, though in the case of compressors and vacuum pumps, the manufacturers are limited by the warranties of their own suppliers of critical components, such as electric
and electronic devices. That said, the key mechanical machine components manufactured in-house, like the pumping Air-End, are often covered by extended manufacturer warranties - up to seven years for Pneumofore Air-Ends. In addition to technical specifications and contractual conditions, customers should ask for references and collect feedback from the end user, preferably about older installations. Pneumofore still receives testimonials for the V100 pumps running since 1991 at the Verallia plant in Villa Poma, Italy, among many others. Within this modernised factory, which was the object of important investments when its furnaces were recently rebuilt, all the IS machines were upgraded, whereas the Continued>>
The Right Foundation for Performance
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Not that long ago, the approach to vacuum technology was so casual that screw compressors were often used as vacuum pumps by simply reversing inlet and outlet. The evacuating and the compressing version of the same machine differed only little. As vacuum leaks aren’t easily detected, such momentary inefficiency was initially tolerated. But when glasswork furnaces with an average lifespan of 12 years now set the timeframe for efficiency, auxiliary pneumatic equipment needs to perform reliably and economically over that duration. To that end, only volumetric machines with active sealing, such as piston or rotary vane technology, have prevailed as long-term solutions for the heavy duty, continuous operation in glass manufacturing plants.
Criteria for Choosing the Right Equipment When
considering
an
investment
� Fig 1. A520.4 VS400, W air compressor at Ardagh Glass, Drebkau, Germany.
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Vacuum technology
� Fig 2.Three UV50 VS90 W at Vetropack in Straza, Croatia. slow-rotating, water-cooled rotary vane pumps of Pneumofore remained in place and continue to perform to this day - the only equipment from the historical past that was kept in service.
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IT Solutions for Vacuum and Compression Control The integration of status information from vacuum pumps into the digital factory, as recommended by recent industry 4.0 criteria, is becoming a standard. In addition, vacuum pumps and air compressors must also offer a communication interface to interact with a supervisory central control. Several factories have standards for electrical components, e.g. the entire process is based on Modbus TCP, ProfiBus with Simatic by Siemens or Ethernet IP with AB Rockwell IT components. For optimal functionality, it appears that also the brand of the electrical motor, its protection and efficiency degree, as well as valves, variable speed drives, or VSD, and soft-starts are specified. Consequently, off-the-shelf vacuum pumps and air compressors cannot be installed. Since the wish-list of engineers can sometimes exceed the budget, initial specifications become adapted or reduced to match what standard equipment is offered on the market at a lower price. If the budget is available, however, and
the engineering specifications seek to match modern state-of-the-art criteria, it is recommended to use similar brand components for IT communication and LAN programming. Thus, a PLC and a VSD or another component are installed on-board of the vacuum pump or compressor in accordance with the latest technological standards. As a result, the electrical cabinet alone can double or triple in size and cost. Still, it is best not to ‘save now and spend later’, as the integration of industry 4.0 data transfer in a second step is possible but becomes more difficult and costly. Pneumofore’s flexible systems result in tailor-made machines which integrate industry 4.0 technology. They can easily be set up with most popular components and protocols to achieve smooth communication. The supervisory control room of the glass factory has immediate access to all information, such as machine on/off, alarm, vacuum level, electrical data for kW, Ampere and Hz, hour meter countdown for service, and, in some systems, flow.
Air Compressors Revisited Historically, industrial air compressors embraced electronic technology earlier than vacuum pumps. Variable speed drives and electronic controls appeared towards
the end of the last century. Compressors called for energetic improvements decades ago, as the amount of electrical energy consumed for compressed air is far greater than for vacuum. Today’s challenge is to match the communication protocol used by customers in their SCADA. Serially produced machines usually fail to do so, therefore customised solutions are required. Long gone is the era of installing an oversized turbocompressor and simply blowing off the excessive pneumatic energy or throttling the inlet to match the correct flow and pressure. Environmental awareness now demands that industry contributes to reducing power consumption and minimizing pollution. The optimal setup in compressor and vacuum rooms consists of running several machines about the same size with a back-up. These units are connected via an electronic box, a ‘machines management system’ that summarises all major information coming from the installed units. The most common protocols found in new plants are Modbus TCP, Profibus, Ethernet IP. For vacuum, Pneumofore has developed the VacMan, for up to eight connected pumps, which can be configured to run with all these protocols. For the low-pressure compressed air used in moulding, it is today standard practice to avoid pressure reducers, as the compression to higher pressures requires more energy. Best is the compression to the exact pressure required, e.g. 3.5 bar(g) and the option to vary the capacity by means of a variable speed drive, or VSD, in order to cover all production situations, including job changes. To manage several compressors, a popular device is the AirLeader, which takes data from each machine and transmits it to the Supervision Control System. This is the case of the A520.4 VS400 W air compressor running since 2019 at 3.5 bar(g) and serving the low-pressure pipeline loop at Ardagh Glass in Drebkau, Germany. This compressor with a nominal 400 kW of power is water-cooled and is equipped with VSD to continuously adapt the machine’s rotation speed to the production requirements, maintaining the line pressure constant. Not all units require a VSD. One frequency converter unit is usually Continued>>
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PSR SYSTEM 500 FOREHEARTH
Achieves the best glass thermal homogeneity and energy efficiency.
www.parkinson-spencer.co.uk
Vacuum technology
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� Fig 3. Three UV50 W VS90 at Ardagh Glass in Doncaster, UK. sufficient to cover the fluctuations of flow in m3/h by keeping the pressure constant. In locations with critical access conditions, the independence of the factory from the equipment suppliers is of particular importance, and therefore simpler solutions may be recommended. At Belstekloprom in Gomel, Belarus, next to one UV50 pump, four A260 compressors totaling more than 6.000 m3/h capacity were installed in 2008 and still run 24/7 today. When compressing air, other important factors to consider are the air humidity as found near the sea and air density: compressors running at high altitude with ‘thin’ air will result in a reduced performance, unless appropriately sized. Pneumofore machines supplied in “.alt” version (for Altitude) also feature a larger electrical motor, such as the units running at 2.650 m elevation at the O-I plant in Zipaquira, Colombia.
A Closer Look at Vacuum Control: Installation in Croatia In some European countries, the modernisation of glass manufacturing plants has been supported by partial financing through national subsidies, particularly to meet the target of ‘green’ production as soon as possible - a rising
interest in every industry. What’s more, Industry 4.0 is understood as an update, as a new approach to modern productivity resulting in higher competitiveness with reduced costs. This makes it the object of public funding in some nations. A fortunate situation was the installation of five Pneumofore pumps model UV50 VS90 W at Vetropack in Straza, Croatia, in 2021. The plant could profit from the reduced power consumption and the total integration in the SCADA, based on Siemens ProfiBus. Every pump has the HMI touch panel and each electrical cabinet contains one Siemens PLC S7 1200 processor for the high-level supervision of the machines, with considerable data transmission for the graphical display in the remote supervisory control room.
UK installation The Ardagh Glass site in Doncaster, UK has three furnaces with 820 tons/day hollow glass production, split in two with East and West side, the total of about 100 sections on ten IS machines. Large plants such as this one benefit from the latest IT solutions in production: recently installed vacuum pumps that were successfully integrated in the SCADA system. Pneumofore supplied five units
of UV50 vacuum pumps, customised according to the plant specifications in terms of communication protocols and components. With AB Rockwell electronic components, including the Powerflex variable speed drive VSD and the Compactlogix PLC, the pictured three vacuum pumps are on the east side, whereas two units are installed west. Each vacuum pump room is equipped with the VacMan, which works as ‘sequencer’ for the even distribution of the working load; it represents the SCADA interface for remote monitoring. The five pumps were installed in 2020, the immediate result was a reduction of total power consumption, quantified as 24% by the customer at commissioning. The access limitations to the site, following the pandemic, caused a delay in completing the installations with the VacMan controls and the connection to the SCADA. Nevertheless, during these months the customer could also benefit from the reduced service requirements, as the intervals for ordinary maintenance were extended to 8000 hours of operation. From an IT perspective, which required precise custom programming and testing, the installation is finally complete now that all five pumps are visible on the monitor in the control room, displaying the operation status, working hours, vacuum level, temperature, Hz of the VSD and hours left until maintenance.
Upgrading Aged Equipment Ardagh has more Pneumofore vacuum pumps and air compressors within its constellation. Eight UV30 vacuum pumps have been installed since 1998 in Valdemorillo, Spain. They continue to run after 24 years of 24/7 operation, namely 200,000 hours with total customer satisfaction at the extreme reliability, high efficiency and low maintenance. Typically, industry units of this age would be written off, yet in practical terms there is no reason to replace them. If required, these aged pumps could have the electronic board VIM installed, to connect them to the VacMan. However, over-digitalisation is a danger to the practical functionality of machines. The priority is to match the lifespan of the furnace with adequate means of control rather than deploying the latest control technology for its own sake. �
*President, Pneumofore, Rivoli, Italy www.pneumofore.com
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LEHRn°
GLASS MACHINERY
Decarbonisation
Renewable Glass Conference 2021 Industry experts discussed options of how the glass manufacturing sector can decarbonise at the recent Renewable Glass Manufacturing conference. Topics included hydrogen, electrical and biofuel glass production. Jess Mills reviews the event. Topics such as decarbonisation, carbon neutrality, sustainability and alternative fuels were highlighted at the recent Renewable Glass Manufacturing conference, hosted by Glass International. Speakers at the online event included glass manufacturers such as the NSG Group, Wiegand-Glas and Encirc, customers such as Coca-
Cola Europacific Partners as well as technology suppliers such as FIC UK, Sorg and Horn Glass. Encirc discussed the challenges of using biofuel instead of fossil fuel combustion in glassmaking, while Wiegand-Glas spoke of its Eco2Bottle brand, which uses biomethane for product lines – partly supplied by bmp-greengas.
Glass companies in attendance included O-I, Bangkok Glass, Nihon Yamamura Glass, Saint-Gobain, Sisecam, Bormioli Luigi, Guardian industries, Vetropack, Saverglass, Grupo Vical and CristalChile. Attendees were from a variety of countries such as Indonesia, South Korea, Thailand, Italy, Turkey, Mexico and the USA.
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DECARBONISATION – COCA-COLA EUROPACIFIC PARTNERS Charles Richardson, Procurement Director of Metal, Glass and Other Primary Packaging at Coca-Cola Europacific Partners (CCEP)1, spoke on how CCEP aims to reduce its carbon impact. Mr Richardson discussed how CCEP’s sustainability framework ‘This is Forward’ and its ‘Action on Climate’ programme will lead the company towards net zero carbon emissions by 2040. CCEP, the largest Coca-Cola bottler in the world by revenue, has reduced its total carbon footprint by over 30%. It plans to cut these emissions by a further 30% across its entire value chain by 2030, before reaching net zero by 2040. (Fig 1)
� Fig 1. CCEP’s carbon reduction pathway. To do this, the company will focus on reducing its Scope 3 emissions. Scope 3 emissions are from CCEP’s suppliers and have increased to 93% of the company’s total emissions since 2010. This is due to the reduction of emissions from CCEP’S own direct operations and
facilities (Scope 1) and emissions from the production of energy required to run CCEP’s business (Scope 2). Emissions in these areas have decreased by 22% in Scope 1 (now 6% overall) and in Scope 2 by 98% (now less than 1% overall) over the last 11 years. (Fig 2)
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Decarbonisation
� Fig 2. CCEP’s emissions breakdown by scope, 2019 Mr Richardson stated that packaging was critical to achieving net zero, as it is responsible for 43% of the company’s
Scope 3 emissions. Therefore, he believed that glass could grow in the company’s portfolio, due to its usability and
sustainability. CCEP plans to ensure that all its packaging is reusable, refillable or recyclable. Thus, Mr Richardson believes glass could dominate the ‘on the go’ market, provided it is made to be lightweight, resealable and robust. Consequently, Coca-Cola’s most recent global campaign ‘Real Magic’ features glass bottles – the iconic packaging for coke. Mr Richardson also outlined his hopes for the FEVE-led ‘furnace of the future’, which would be a breakthrough for reducing the carbon emissions of glass packaging production. However, Mr Richardson questioned whether the technology could be implemented in enough areas by 2030 for it to have a significant effect on emissions. He believed it would require approx. 50% of the industry to use these new furnaces within the next 10 years to achieve decarbonisation.
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Continued>>
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Decarbonisation
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NSG PILKINGTON HYDROGEN TRIALS Andrew Keeley, Principal Technologist at NSG Pilkington2, discussed the outcome of the hydrogen firing trials undertaken at Pilkington’s Greengate furnace in St Helens, UK. (Fig 3) Mr Keeley spoke on how the trials were working towards NSG’s decarbonisation strategy. He said that hydrogen was ‘very attractive’ to the company due to its potential to reduce CO2 emissions substantially, without the need to drastically change furnace designs. Firing 100% of hydrogen instead of natural gas at NSG’s Greengate float glass manufacturing site on its cross fired furnace would reduce CO2 emissions by approx. 80%, whilst the remaining CO2 would be from the decomposition of carbonates. In August 2021, the company ran two separate programmes to test whether the furnace could run on hydrogen in any capacity. The first trial was for port one of its furnace, where a series of six-hour tests were conducted under the manual control of an R&D team. In these tests, the hydrogen percentage was gradually increased to 100%. This was to identify the maximum percentage that could be used on the port whilst maintaining an effective operation. The second programme was a fiveday continuous trial where 15% of hydrogen was used on all H2 ports. During this trial, the furnace was in full automatic control. Before NSG undertook this trial, it did extensive CFD (computational fluid dynamics) modelling to understand the impact on the furnace operation and structure from firing hydrogen. Mr Keeley outlined the concerns the company had prior to the trials: “Hydrogen burns with an invisible flame, so there is a big drop in the emissivity of the flame as you go to higher percentages of hydrogen. “Another factor related to hydrogen is its low calorific value, so the volumes of fuel that you need to fire increase substantially. You have to fire three times the volume of fuel on a given port to get the same amount of energy into the furnace, on a firm per firm basis.”
Hazard and operability report Mr Keeley also outlined several risks from the company’s HAZOP report (a hazard and operability study). One of the main issues was that if a hydrogen control valve failed during reversal, the backpressure produced would cut off the entire site’s gas supply. Therefore, NSG set appropriate measures in place to ensure this issue couldn’t arise. Hydrogen also has the potential to leak through any small orifice, so a gas detector system was installed for the current pipes at Greengate - although fully welded pipes would be used for a permanent installation. Additionally, concerns over invisible flames outside of the furnace were addressed with thermal imaging cameras, and cullet bays were converted into hydrogen delivery stations to solve layout and transportation issues.
Port one trials The three-week long trial started on 10th August 2021. There were six hours of trials per day, with the percentage increased manually by 10% (starting from 20%) every three hours. This increased until the 18th, where the percentage remained at 100% for the rest of the trial. At full flow, a tanker of hydrogen was used every 40 minutes. The trials progressed as expected, with the equipment performing well and the production unaffected by the trials. Mr Keeley said that the batch melted effectively underneath hydrogen flames, with no changes in furnace conditions downstream. However, even with thermal imaging cameras, the flames were often still invisible – making it one of the main challenges moving forward with
hydrogen. Despite this, 100% of hydrogen was successfully fired on port one. The company also did not see a significant increase in NOX emissions, despite this being one of the potential risks of firing hydrogen. Mr Keeley said: “[The emissions] were well within the scope of our existing pollution control plant. Based on that, we would be comfortable in terms of firing hydrogen, at least on the upstream part of the furnace at the moment.”
Full furnace trials From 13th September 2021, the entire furnace operated on 15% hydrogen for 4.5 days. NSG had planned to run 20% on all ports, but could only run 15% due to supply issues. Mr Keeley said the trial was largely ‘unnoticed’ by the furnace operator due to the furnace functioning as usual. Glass quality also remained consistent throughout the trial, with good yields and no deterioration in product quality. Unlike the port one trials, the full-furnace trials were operated automatically via a modified gas chromatograph. The chromatograph could analyse the composition of the fuel and assess the percentage of hydrogen. The signal was then fed into the control systems to adjust the fuel being fired on each of the ports within the furnace. Overall, the full furnace trial proved that the plant could cope successfully with a hydrogen/natural gas blend. Mr Keeley said that the trials ‘gave confidence’ that NSG could convert its furnace to fire hydrogen when it becomes available in large quantities.
� Fig 3. NSG discussed the outcome of hydrogen firing trials at Pilkington’s Greengate furnace in St Helens, UK.
Continued>>
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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 • Integrated high efficiency oxygen supply system This burner is the latest innovation in the long line of industry-leading Cleanfire® burners for the glass industry, which are now able to utilize hydrogen as a fuel, for a lower carbon footprint. To learn more or to schedule a demonstration in our state-of-the-art lab, call 800-654-4567 (code 10868) or visit airproducts.com/HRx.
© Air Products and Chemicals, Inc., 2021
tell me more airproducts.com/HRx
Automatic Chutes
SCRAPER CONVEYORS
CULLET CRUSHERS vidromecanica@vidromecanica.com
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Decarbonisation
FINANCING SUSTAINABILITY - IFC Li Tu, Senior Investment Officer, and Marek Stec, Senior Industry Advisor, from the International Finance Corporation (IFC)3 highlighted the company’s approach to financing sustainability in the glass industry. Ms Tu and Mr Stec discussed IFC’s Climate Change Action Plan, implemented in April 2021, and its sustainability objectives for the glass industry. They also highlighted IFC’s mission to reduce poverty by supporting development in emerging areas. IFC is a member of the World Bank Group (WBG), with offices in nearly 100 countries around the globe. Ms Tu described the company as an institution that provides advisory services and technical support as well as financial aid; IFC has invested more than $321 billion since the company’s founding in 1956. The company largely focuses on developing countries, maximising the amount of finance available in the areas that need it the most, as well as creating new markets and expanding weaker ones. IFC also offers equity, trade and commodity finance, donors and loans; its 3.8 credit rating provides competitive loan rates within the market. The company’s manufacturing portfolio is categorised into three main areas: chemicals and fertilisers, construction material and energy efficient machinery. Glass falls into the second largest category of construction material. Mr Stec said that IFC was aware of the growth within the glass industry, and emphasised the increasing demand for glass products in several sectors including flat glass, beverages and electronic goods.
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Sustainability One of IFC’s main goals is sustainability. The company focuses on development impact and climate change as well as promoting environmental, social and corporate governance standards. This includes advice on how to improve issues such as energy efficiency. The WBG plans to invest $200 billion over the next five years in climate related financing. Ms Tu said that, for
IFC, this would be reflected in two commitments. The first being that, by July 1st 2023, 85% of IFC’s operations will align with the objectives of the Paris Agreement, such as limiting global warming to 1.5°C. This number will increase to 100% by July 1st 2025. The second commitment is that at least 35% of WBG’s financing will have climate co-benefits over the next five years. In manufacturing, IFC will support proven abatement measures and innovative new technologies. To achieve these objectives, IFC has collaboratively developed a strategy to assess the Paris Agreement alignment, which is currently being tested and refined. According to the methodology, projects must pass both a mitigation assessment and an adaptation and climate resilience assessment. Mr Stec defined mitigation as the influence of industry towards the climate, and adaptation as the influence of climate towards the industry. He said both of these forces could be balanced and assessed.
Green loan IFC’s ‘Green Loan’ is specifically for projects that are climate-related (migration or adaptation). The Green Loan Principles have four core components: 1. Use of proceeds must be destined exclusively for eligible green projects. 2. Must undergo a strict process for project evaluation and selection. 3. Processes must be managed to ensure that they will be allocated to eligible green projects. 4. Processes and the impact of eligible green projects must be reported. Ms Tu said that companies eligible for the Green Loan can use the IFC and WGB name to promote their image in the market, and will have access to a ‘green channel’ within the IFC, resulting in a quicker processing time. Ms Tu also outlined a set of criteria for eligibility, and said that if a glass company addressed any of the sustainable practices listed, then it could apply for a Green Loan. Practices included: having a heat recovery
system, exploring carbon capture and storage, having good energy efficiency and using renewable energy. After applying, in-house industry specialists and experts from IFC’s climate team join other assessors to decide whether the company can grant the loan.
Glass objectives Over the years, the glass industry has implemented a variety of methods to reduce its carbon impact, such as developing carbon capture technology and increasing the percentage of cullet usage. However, Mr Stec said that it was still difficult to find a method that was ‘economically feasible’ on a large scale, and that a solution for decarbonisation would require some time. The company has the following sustainability objectives for glass: � Ensure efficient energy consumption in the production processes (supporting clients in glass recycling). � Reduce the amount of GHG emissions � Increase the cullet usage in production � Have innovation in products that contribute towards sustainability IFC has worked with two major glass manufacturers, Kioo and NSG. Kioo is the largest glass container manufacturer in East Africa, and the only such producer in Tanzania, whilst NSG has operations in over 20 countries. IFC increased the production capacity of Kioo by approx. 35% and implemented several sustainable practices, such as energy-efficient retrofits and increased cullet use. Similarly, at NSG, the company enhanced productivity through new R&D investments. Clean technologies and ‘green’ glass products (triple glazed glass) were also introduced. Additionally, IFC has recently released a report entitled ‘Strengthening Sustainability in the Glass Industry’. Ms Tu said this report outlined the company’s view on the industry and its approach to support sustainable development within it. Continued>>
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For humans, it’s obvious. For NEO too.
NEO Artificial Intelligence for defect recognition
Decarbonisation
CARBON NEUTRALITY - STEKLARNA HRASTNIK Tilen Sever, Research Scientist at Steklarna Hrastnik4, spoke about the company’s four-phased project for carbon neutral glass production. Mr Sever discussed how hydrogen could significantly reduce the company’s scope emissions and enable it to reach carbon neutrality. Steklarna Hrastnik has 160 years of experience developing and manufacturing engineered glass products in partnership with other brands. The company produces approx. 280 tons of glass daily, has nearly 600 employees and exports its products to around 55 countries worldwide. The company’s range of products includes premium and ‘super-premium’ glass containers, primarily dedicated to the spirits, perfumery and cosmetics market. Its main focus for glass making is innovative and sustainable solutions. Mr Sever said: “Reaching climate neutrality by 2050 is one of the biggest challenges for the industry today. Meaning that the glass industry will have to decarbonise completely over the next 30 years.” Steklarna Hrastnik focuses on sustainability challenges such as renewable energy sources, improving energy efficiency, renewable fuels, electrification and green investments
and innovations.
Pilot project In 2017, Steklarna Hrastnik started a project for an innovative, hydrogenbased solution for glass melting, which would use pure, low-carbon hydrogen gas to reduce carbon emissions per unit of glass produced. This resulted in the OPERH2 Pilot System (Fig 4 and 5), which introduced a number of new technologies for production. These included: renewable energy sources, the use of solar cells, the production and storage of green hydrogen and the partial addition of hydrogen to natural gas. The production of renewable energy from solar cells is used to power the system. The electric current then splits water into oxygen and hydrogen, and is later stored in hydrogen vessels. Consequently, the only emission produced in the glass melting process is water rather than CO2. After investing €1.5 million in development and building the industrial pilot, the system was successfully commissioned in 2020. For small-scale demonstrations, key components of the system included: a photovoltaic (PV) power plant, an electrolyser, hydrogen
storage and a glass furnace of 200 kg/day capacity. One of the main goals was to balance the capacity of the electrolyser with the solar power generation, which was achieved through software. Mr Sever described the energy management system, which was installed through control units at individual production sources: “The software solution combines, aggravates, predicts and optimises allincluded production sources and flexible loads automatically, or on the request of the user. The solution provides benefits, savings and a lower ecological footprint.” Messer also helped Steklarna Hrastnik produce a customised burner with hydroflexibility. The system used hydrogen from 0% to 100% with air and oxygen combustion options, and informed the company of the technological limits of using hydrogen for melting. Mr Sever said: “By implementing the pilot system, we can confirm that a PV plant with an electrolyser and glass furnace is possible, and hydrogen can be used with up to 100% of higher efficiency. The hydrogen is also suitable for oxyfuel as well as regenerative furnace technology.”
Fig 4. OPERH2 Pilot system, an innovative and hydrogen-based
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solution for glass melting.
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Decarbonisation
Fig 5. Outline of Steklarna Hrastnik’s OPERH2 project.
Steklarna Hrastnik demonstrated an almost carbon neutral glass production by using the OPERH2 pilot system, due to a reduction of scope emissions. Mr Sever outlined the company’s scope emissions as follows: Scope 1 emissions are made up of process emissions, fuel emissions and other direct emissions. Scope 2 emissions are purely from electricity, whilst Scope 3 emissions are value chain emissions from the supply of raw materials. The first measure to reduce CO2 was to use 100% of external cullet. This resulted in the complete reduction of process emissions, and a reduction of fuel emissions by 25%. By using external cullet (collected from waste recycled glass) as the only raw material, the Scope 3 emissions were reduced by 84%. The second measure was to use hydrogen. By using 100% of hydrogen fuel, Steklarna Hrastnik reduced fuel emissions entirely, but Scope 2 emissions increased by 950%. However, by using renewable energy only, the company’s
Scope 2 emissions were reduced by 98%. The last measure was to implement electrification (annealing) as well. With this measure, the company additionally reduced its direct emissions by 70%. Mr Server concluded: “Altogether, we reduced the Scope 1, 2 and 3 emissions by 92%. Which means we almost completely reduced all emissions. However, to go to 100% additional carbon offsets are needed.” He suggested that planting 0.4 trees per tonne of glass could enable the company to reach carbon neutrality.
Phase two Now the pilot phase is finished, Steklarna Hrastnik is working towards its three phases for large-scale demonstrations, which are: achieving an industrial qualification for the use of hydrogen in glass furnaces (2022), designing and constructing the system (2022-2023) and operating the system (2024-2028). The large-scale system design is composed from a PEM water electrolyser, which will be used to produce
hydrogen from clean electricity. The electrolyser will be included in a mix of grid services to reduce the price of hydrogen production. Mr Sever said that the creation of hydrogen would be compensated with large-scale industrial hydrogen storage with a short, stable carbon-free supply of fuel. After the hydrogen is produced, it would then be applied to the existing oxyfuel firms, to avoid any damage to the furnace whilst melting, at a capacity of 120 tonnes per day. Mr Sever said that, on average, hydrogen fuel would replace 50% of primary fuel, resulting in approximately 20-25% lower carbon emissions from fuel. This would save more than 3000 tonnes of CO2 per year. Steklarna Hrastnik is ambitious to replace a third of its fossil fuel consumption by 2025 using green energy. The company plans to increase its energy efficiency by 10% and decrease its carbon footprint by over 25% - which will decrease by a further 15% (approx.) by 2030.
1. CCEP: https://www.cocacolaep.com/
3. IFC: https://www.ifc.org/
2. NSG Pilkington: https://www.nsg.com/
4. Steklarna Hrastnik: https://hrastnik1860.com/
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Scope emissions
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FIC SGT advert 2020 AW_FIC-Society advert 2019 25/11/2021 10:06 Page 1
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Refractories
An update on fused cast AZS exudation Dr Roland Heidrich* discusses how, under standard furnace working conditions, gas forming mechanisms are the main reason for the exudation of the fused cast AZS glassy phase.
� Fig 1. Fused cast AZS refractory samples after exudation testing. The three samples show each 1.2%, 2.4%, and 5% (volume percent) glass phase exudation (from
F
used cast alumina-zirconia-silica (AZS) continues to be the most popular choice of refractory material for glass melting furnaces. However, AZS refractories exhibit a phenomenon called ‘exudation’, which is the migration of the in-situ glassy phase onto the refractory surface (Fig 1). All fused cast AZS refractories exhibit this exudation phenomenon, the intensity of which depends on various factors in both the AZS’ quality and the parameters of the subsequent glass melting process. Exudation can either be a natural and temporary behaviour during the initial heating-up of the furnace, or it can be a long-lasting and pathologic property related to furnace conditions. Exudation can be a source of concern for the glass manufacturer because the expelled viscous phase is capable of rundown over the tuckstones, eventually making its way into the glass melt, potentially causing glassy inhomogeneity – resulting in striae, cords, or knots. This is because the chemistry of the exudate is different to the chemistry of the glass being melted in the furnace.
Intrinsic causes of exudation Zirconia transformation
Upon heating, a reversible phase transition from monoclinic to tetragonal zirconia takes place between 900°C and 1200°C. For fused cast AZS with 33 weight percent zirconia, this will result in a volume shrinkage of approximately 1.3%. Upon subsequent cooling, this transition between crystalline structures results in a thermal induced expansion hysteresis loop. Due to this repeated expansion and shrinkage a pumping action occurs, expelling the glassy phase from the AZS. Chemical composition of the glassy phase The chemical composition of the aluminosilicate glassy phase contributes significantly to its viscosity and to the exudation it causes. To suppress the formation of mullite, the dosage of sodium oxide is crucial. However, the viscosity depends strictly on the network modifier content. Therefore, accurate and real-time control of the chemical composition is essential to ensure strict compliance with the raw material recipes. With a careful balanced alkali content, exudation only starts occurring at over 1500°C and with only minor glassy phase rundown.
Oxidation of reduced species Fused cast refractories are molten in an electric arc furnace, working with graphite electrodes. The chemical effect of the carbon monoxide produced in the electric arc generates a reducing atmosphere during the fusion process. During its first heat-up, the glass furnace is exposed to ambient atmosphere, resulting in changes of oxidation state of reduced species inside the fused cast AZS. This reaction is responsible for pushing the melt phase out of the AZS. The amount and type of reduced species present in the glassy phase are crucial for the consequent exudation behaviour. The oxidation of suboxide, nitride and carbide contamination is responsible for a single exudation event. Meanwhile, the presence of polyvalent oxides – typical raw material impurities like iron and titanium – can create a multiple exudation events. There is also a second effect here: under reducing conditions, Al3+ and Fe3+ are partly present in sixfold coordination, thus decreasing the viscosity and causing the segregation of the melt phase to also become easier. In an oxidised glassy phase, both ions usually occur in tetrahedral Continued>>
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left to right). Sample height 30mm.
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Refractories
Reactant
}
AZS test specimen as crucible lid
Reaction area with exudate
Crucible Unaffected test specimen
� Fig 2. After vapour test according to ASTM C987, the test crucible with phosphate containing alumina-chromia refractory as reactant (left) and exuded AZS test specimen with chrome discoloration. The difference between the reaction area and the unaffected, ‘dry’ AZS surface is remarkable. Crucible diameter is 35mm.
coordination. Therefore, the intensity of exudation is correlated to the oxidation level of the fused cast AZS. Insufficiently oxidized low cost fused cast AZS show a substantially higher exudation level in comparison to western style – well oxidised – AZS. Consequently, effective qualityenhancing measures include the use of selected raw materials with the lowest possible impurities and the implementation of controlled, stoichiometric oxidation with an oxygen lance during AZS manufacture.
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Extrinsic reasons Batch area The exudation phenomenon is often influenced by batch carry-over. In the batch area, running down glassy phase is significantly present, which is dictated by the interaction with alkali. Batch dust and alkali, present in large quantities, are absorbed by the fused cast AZS. This alkali enrichment results in a decrease of the glassy phase’s viscosity and in higher exudation. Molten glass volatile components Changes of the AZS glassy phase composition occur due to the absorption of volatile components in the furnace atmosphere, evaporated – directly or by reaction – with combustion gases such as carbon monoxide (CO) and water (H2O). As a result, sodium oxide (Na2O) and sodium hydroxide (NaOH) are formed during melting in fossil-fuel fired soda-
lime-silica glass furnaces. Following alkali diffusion into the AZS, the glassy phase viscosity decreases. Oxy-fuel fired furnaces For combustion with high water vapour pressures and low gas volume flows, a high concentration of NaOH vapour will be obtained in soda-lime-silica glass furnaces. Observations in oxygen fired furnaces have shown that the NaOH vapour pressures in these furnaces can be up to 3-4 times higher compared to air fired glass furnaces. This results in higher alkali diffusion, coupled with all the aforementioned consequences of AZS glassy phase deterioration. Phosphate binder The aforementioned factors are well studied and covered by literature. However, various other refractories can have an influence on exudation or, more precisely, their combination with one another. Upon investigation, the occasional combination of phosphate bonded refractories with glass defects has emerged. Based on this observation, vapour tests according to ASTM C987 were carried out, with phosphate bonded refractories as the reactant. The test results showed reactions with the sample AZS surface, such as forced glassy phase exudation (Fig 2). Based on this, it can be concluded that at high temperatures the phosphate bond tends to lose phosphorus through volatilisation. The reactivity of phosphate
with AZS glassy phase results in an additional portion of exudation in the glass furnace. Inorganic bonding agents such as aluminium phosphates and phosphoric acid offer high strength at quite low temperatures and can be used to bridge the area between chemical bonding and ceramic sintering. Therefore, these as additives are often favoured in refractory formulations for alumina-chromia bricks and ramming mixes for superstructurecrown sealing which have to be suitable for high temperatures. However, as described above, the combination of evaporated phosphates with fused cast AZS refractories can apparently lead to unexpected reactions in the furnace. In the future, this new finding should be taken into account when analysing glass defects and when choosing refractories during the planning of a new glass furnace.
Summary The exudation from fused cast AZS refractory is correlated to a multitude of parameters. One factor in the occurrence and extent of exudation may be the conditions during the manufacture of AZS. All other influencing factors are related to the service conditions of the glass melting furnace. The key finding is that, inside the refractory, under standard furnace working conditions, gas forming mechanisms are the main reason for the exudation of the fused cast AZS glassy phase. This natural exudation is an intrinsic behaviour and lasts only a limited amount of time. After the temperature and furnace working conditions have stabilised, the quantity of exuded glassy phase becomes stagnant and behaves normally. The other kind of fused cast AZS glassy phase exudation has extrinsic reasons, which are related to furnace conditions, such as the maximum temperature the blocks are exposed to, airborne particles of batch, and a furnace atmosphere ripe with corrosive vapours, such as phosphorus. The minimisation of the exudation phenomenon requires both the selection of high quality AZS refractory material and well-controlled day-to-day furnace operation. �
*Research and Development, Refel, San Vito al Tagliamento (PN), Italy www.refel.com
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Refractories
Thinking outside the box – refractory linings by ZCR Oliver Claußnitzer* and Michael Kampmann** discuss why both steel and refractory trades should be organised from a single source and under the leadership of an experienced project manager.
R
ecently, we were explaining our business to a young trainee at ZCR. It was always obvious that in theory all the work steps for refractory linings are clear and logical, but in practice things are different, especially when there are several interfaces. “Taking a holistic view of the process and looking beyond the confines of one’s own trade can reduce these problems” said Michael Kampmann, Branch Manager of ZCR Darmstadt. Traditionally the refractory installation or hot repair team arrives and does their job until the last block fits and the last mastic is casted. Setting AZS, proper lehring and feeling for the mastics are the classic lining challenges at site. Here you have to think outside the box as the trades do not stand on their own but are built on each other - like steel and refractory construction. Often steel and refractories need to be installed simultaneously. This means that on the one hand you can use synergies, but on the other hand you are more dependent on each other. If the flow of information is guaranteed and the interfaces are clearly defined, then there is little potential for conflict. However, the situation is often different.
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Thinking outside the box “In order to optimise this interaction between steel and refractory, both trades should be organised from a single source and under the leadership of an experienced project manager,” said Oliver Claußnitzer, Project Manager and specialist on glass at ZCR. Since we know the processes and working methods of steel and refractory construction, we should be involved in the planning of the construction site at an early stage. This is to ensure that optimisation potential does not go unrecognised and interface losses are
� Oliver Claußnitzer and (below) Michael Kampmann
minimised. In concrete terms, this means accompanying the customer from the moment the material orders are placed to the piping until the tempering. If everyone gets together at an early stage, a project can be set up safely and successfully. This creates security and provides the chance to monitor and control keep costs together with the client.
What the future holds We recognise two interesting trends in our environment. A lot of technical knowledge has been lost in recent years. Even to customers, those employees who know the firing process or all the quirks of the kiln are becoming less. On the other hand, we as ZCR are part of one of the largest construction groups in Europe. Everyone is talking about digitalisation and building information modelling (BIM) among our colleagues in building construction and infrastructures. “Digitalisation can no longer be stopped in the construction industry. At ZCR, we are currently testing the use of
data glasses. But that will only be the beginning,” said Mr Claußnitzer. BIM describes the model-based planning, realisation and operation of construction projects with the aim of optimising the transfer of knowledge, the quality of results and the efficiency of all participants. All relevant data is digitally recorded, combined and networked throughout the entire life cycle of the project. “This results in a comprehensible, transparent and resilient information network for all those involved,” said Mr Kampmann. He concluded: “I think it is only a matter of time before this method also becomes an issue in the glass industry. We, as a member of Strabag SE, one of Europe’s leading construction groups, will then be ready for it.” �
*Project Manager glass, oliver.claussnitzer@zueblin.de Branch Manager Darmstadt, Michael.kampmann@zueblin.de www.zueblin-cr.de
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Glass experts Furnace support Process optimization Training and R&D Celsian’s aim is to minimize the cost of making glass for end users and the environment. We have an agile team of glass experts using proven methods like furnace modelling, laboratory measurements and practical furnace health checks to optimize glass melting processes. We also train operators and glass technologists through our standard course, dedicated programs and various e-learning modules. We strive to be the best partner for optimization of glass production worldwide.
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Pharmaceutical glass
Type II-glass for the pharmaceutical industry Dirk Diederich* and Marina Puhrer** discuss the boom in demand for pharmaceutical glass as a result of Covid and how this has led to a need for cost-effective soda-lime glass with high hydrolytical resistance.
Continued>>
� Fig 1. Type III-bottles with corrosion visualized via methyl blue.
� Fig 2. SEM-image of the damaged surface of a
� Fig 3. Silicon-flakes in a SEM-image in a filter of
type II-bottle.
a type II-bottle.
� Fig 4. Type II-bottles treated with distinct media
� Fig 5. Microscopic image of a type II-bottles
with corrosion visualised by methyl blue.
treated with citrate and coloured with methyl blue.
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G
lass as a packaging material is the first choice due to its special properties. It is chemical inert, can be thermally treated without any problems and protects the medium stored inside from contamination. In general, glass containers are divided into type I, type II, and type III due to alkali release and, thus, hydrolytic resistance. Since medicines and vaccines are usually stored in type I, the international COVID19-pandemic has led to a substantial demand for type I glass vials. This has also increased the need for alternative and more cost-effective soda-lime glasses with high hydrolytical resistance in the pharmaceutical industry. This type II-glass is created using a socalled inner coating, which decreases the migration at the glass surface towards alkaline, acidic, and aqueous solutions. Therefore, these type II-glasses are the best choice for most parentals. Common corrosion tests of inner glass surfaces are carried out using water as medium and evaluated regarding the leaching of alkalines. It is particularly interesting for the pharmaceutical industry to learn how the media attacks the glasses they are stored in.
47 Glass International February 2022
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Pharmaceutical glass
However, the most stable results were obtained when the samples, which were filled with the most aggressive test medium, were not treated in the autoclave as described above in accordance with DIN ISO 4802, but stored warm for a defined period of time and at a defined temperature. In an analysis according to DIN ISO 4802, the silicon values can be compared to the sodium values in a ratio of 1:4, when using vessels with a filling volume of 10 ml to 100 ml. In summary, the investigations indicate, that the analyses may not be carried out with the concentrations given in USP 1660. Additionally, the used media, concentrations, temperatures, and times must be adapted to the bottles to be tested. Taking into account the glass products, media and analytical conditions, the IGR routinely offers now a practicable solution for the execution of USP 1660 in the lab for the glass producing and glass processing industry. �
*Director, **Team leader Chemical analyses, Institut für Glas- und Rohstofftechnologie (IGR), Gottingen, Germany www.igrgmbh.de
Glass International February 2022
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*
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Using alternative test media allows to test the homogeneity of the coatings of type II bottles and to prove whether the bottles belong to type II or type III. For this, different test media are used to prove the delamination of inner surfaces according to USP 1660. This allows among other things to evaluate the ablation rate at inner surfaces via silicon analysis in the range of ppm using ICP-OES. The aggressive effect of media can also be visualised by the use of methyl blue, which adheres to corroded surfaces (Fig. 1). Even the USP 1660 itself states that the media described there are too aggressive for delamination analysis and attack the glass significantly more than the filling material. Therefore, the IGR has developed a more practicable solution to carry out the USP 1660 in a lab, using further standards as DIN ISO 695 and ISO 7086 as well as various analyses of type II- and type III-bottles. The first tests were carried out by using demineralized water, a potassium chloride solution and a mixed solution of potassium chloride and citrate, whereby the applied solutions were brought into an alcaline pH range by addition of potassium hydroxide. The used bottles were treated in the autoclave according to DIN ISO 4802, then filtered and the solutions were analysed using ICP-OES. The filtration is done to detect silicon flakes, which might come out of the bottles during analysis. Significant damages at the glass surface as well as silicon-flakes in the mixed solution of potassium chloride and citrate were detected using SEM-EDX (Figs 2 and 3). The bottles, which were filled with demineralised water and potassium chloride, showed much less damaged surfaces, which was supported visually due to the methyl blue (Fig. 4). The corrosion could also be verified microscopically in the coloured bottles (Fig. 5). This shows, that the used media massively influence the results of the analysis depending on their aggressivity and concentration. The pH-value of the used test media also has a massive influence on the test results, so vary the analytical results noticeably, when the pH-value is set incorrectly.
15/02/2022 15:11:59
O-I Design Awards
O-I awards showcase sustainable printing technology Students from around the world designed premium bottles with themes of sustainability for the recent O-I Expression Design Awards competition. Jess Mills was in attendance.
� Fig 1. Left to right: Josh Brooks (Easyfairs), Elaine Logan (O-I), winner Rebecca Edwards and Adam Ryan (Pentawards).
E
ntrants were instructed to create designs that could be directly printed onto glass bottles using O-I Expressions technology. The digital technique prints sculpted decorations onto bottles to create a 3D effect. The bottle used was a 75cl premium standard bottle, which will become commercially available in May as part of O-I’s new Contemporary Spirits Collection. The collection, which contains 33% recycled content, features three bottle shapes; the Lux design was selected for the competition. An expert panel of internationally renowned judges selected five finalists at the initial stage of judging. Each of the finalists had their entries printed onto a Lux bottle, which were all displayed at the Packaging Innovations Show.
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The winners Rebecca Edwards was the overall winner with her entry inspired by Old Norse legends. Her design and brand name Ormr (Old Norse for snake) derives from the story of Jörmungandr, a giant serpent who encircles the world. (Fig 1) Ms Edwards, who works for Hunter Luxury Packaging, said the Old Norse influence came from a familial link to Orkney and Shetland, which both have an extensive Viking history. She further commented that the combination of old mythology paired with modern innovations for manufacturing was ‘an interesting concept to explore’. Melianthe Leeman, O-I’s Global
Category Director of Wine and Spirits, said: “The judges were entranced by the creativity of Rebecca’s design, in which the 360° depiction of the serpent captured the essence of the circular economy, in which glass plays such a vital role.” The judges were impressed by the high standard of entries from students and young designers across the globe, although they weren’t the only critics. The People’s Choice award received hundreds of votes with only a few points between second and first place. However, João Vieira’s ‘Bright Future’ design came out on top.
O-I Expressions O-I and Dekron, a subsidiary of Krones, have worked together over the past eight years to develop O-I Expressions. The digital printing technology enables customisable packaging, with a range of colour and design possibilities, as well as affordable rates and industrial speeds; depending on bottle size, the Dekron printing machine can decorate 100 to 500 bottles per minute. The Dekron machine uses CMYK colours, which covers 80% of the pantone spectrum, and can print tactile effects, such as embossing, by layering ink in tiers. The technique also uses organic ink to ensure that the glass can be recycled and has lower inventories to reduce waste, making the process more sustainable. The Dekron machine is equipped with four double printing modules (eight in total) that work in batches. The printing
TITLE: ORMR DESIGN BY: REBECCA EDWARDS POSITION: WINNER (JURY’S AWARD) The inspiration behind the design comes from Old Norse mythology, where the giant serpent Jörmungandr grows so large that it encircles the world. The brand name is also inspired by the legend, with Ormr being the Old Norse word for snake. The design explores the tactile potential of OI Expressions, utilising detailed relief printing to produce a snakeskin-like texture. The distinctive design also facilitates 360° branding, allowing the consumer to recognise the brand regardless of how the bottle is oriented on shelf. Additionally, there is use of blank space, which would be difficult to achieve through traditional labelling techniques. The colour choice is also minimalistic to make the embossed sections stand out.
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O-I Design Awards
� Fig 2. The white basecoat, layered in tiers, gives the embossed effect on the majority of designs.
Contemporary Spirits Collection O-I has launched a new collection of standard glass bottles for its European spirits customers, which features three bottle shapes: Lux, Attenua and Noble. The designs were inspired by some of the most popular spirits shapes from around the world and will be produced in the UK. The collection has been designed based on research into European markets, particularly the UK, as well as being optimised to reduce filling times and ensure smooth transits. Features include: a core 700ml capacity with a 760g base, a high fill point, label protection, similar diameters between bottle types to reduce change parts and a push up bottom (even with a thick base). Each design is available in both a thick base and lightweight version (reducing the weight by 20%), and has two finishes – cork mouth and screw cap. The range will be expanded with the introduction of further designs, new sizes from 50ml up to 1l, and a variety of colour options. The entire range is produced in regular flint, which offers a 28% higher recycled content at 33% than the extra or cosmetic flint glass commonly used for premium spirits, which is approx. 5%. Other colour options, offering an even higher recycled content, are planned for the future Continued>>
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� The bottle designed by overall winner Rebecca Edwards.
module consists of two printing levels, firstly white (used as a base coat) and CMYK on the upper level. The white basecoat gives opacity to the ink, although it can also be made to appear transparent, which gives the embossed effect on the majority of designs. (Fig 2) The second level (CMYK) completes the colouring. After applying varnish, the bottles are cured using UV lamps. This finalises the polymerisation of the inks and ensures the hardness of the bottles. The bottles are then sprayed in a cold-end coating before being transported to customers. The bottles also undergo a pre-treatment process before printing to ensure the ink adheres successfully.
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FINALISTS The design focuses on the 100% sustainable production of O-I expressions. The window illustration reveals the vibrant future consumers would contribute to by purchasing the sustainable bottle. TITLE: BRIGHT FUTURE
The design represents the consequences of not being sustainable, such as waste and pollution, as well as contrasting themes of luxury and rubbish. The ornate illustration represents the luxuriousness of the brand, whilst the name ‘waste spectrum’ signifies the threat of pollution. The faded colour scheme also symbolises the decaying planet, and textures were added to give richness to the drawing.
DESIGN BY: JOÃO VIEIRA
TITLE: WASTE SPECTRUM
POSITION: PEOPLE’S CHOICE WINNER
DESIGN BY: DIANA MOREIRA POSITION: FINALIST
TITLE: GENIUS OF LONDON DESIGN BY: RITA PIRES POSITION: FINALIST
The design represents the threat rising seawater levels pose to the UK, and suggests the flooded London depicted could become a reality in several years. The addition of mythological marine animals is to give the sense of sinking over multiple years, as the animals lurking in the depths could come to surface if given time.
The tropical design is to reflect the bottles contents, i.e. rum or another cocktail component, and features endangered plants. The latter is to remind consumers of the beautiful world which could be lost if urgent action is not taken.
TITLE: CHERISH DESIGN BY: RODRIGO VILLALBA POSITION: FINALIST
52 0
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