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March 2021—Vol.44 No.3
BEATSON CLARK PROFILE SCHOTT ENVIRONMENTAL PLAN UK OVERVIEW I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
Glass International March 2021
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www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Assistant Editor: George Lewis Tel: +44 (0)1737 855154 Email: georgelewis@quartzltd.com Designer: Annie Baker
March 2021 Vol.44 No 3
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Managing Director Tony Crinion tonycrinion@quartzltd.com Chief Executive Officer: Steve Diprose Chairman: Paul Michael
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Editor’s Comment + International news
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Company profile: Beatson Clark Sustaining a positive future
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Company profile: Schott An energy plan to 2030
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UK overview: Glass Futures Accelerating global sustainability
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UK overview: British Glass Glass and its position in the new world order
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UK overview: Maps of the UK Glass sector
25
Ware handling: Sheppee A brief guide to ware handling
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Company profile: Socabelec The swabbing robot specialist
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Recycling: Recresco MRF glass can deliver on quality
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Furnaces: Fives Melting technologies to make change possible
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Furnaces: Stara Glass Designing a high efficiency melting system
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Refractories Measuring radar thickness in tank melters
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Refractories: Masso Brise, a bordless inspection service
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Decoration: Inkcups Introducing the Double Helix
56
Inspection: Heye International Advanced evolution of glass container inspection
58
UK overview: SGT SGT plots futre meetings
59
History
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International News
GREG MORRIS, EDITOR WWW.GLASS-INTERNATIONAL.COM
March 2021—Vol.44 No.3
BEATSON CLARK PROFILE SCHOTT ENVIRONMENTAL PLAN UK OVERVIEW I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
Be first with the news! For breaking, up to date news
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A big year for the climate Ahead of the UN Climate Change Conference in Glasgow, Scotland later this year expect to see a lot more focus on the environment. If, hopefully and as anticipated, the pandemic gradually fades during the course of 2021 it is likely that attention will revert to all of those pressing issues before the virus spread. Some of those big issues that affect all of us include the rise of globalisation, the increased focus on mental health, the Black Lives Matter movement, global trade across international boundaries and, most pertinently for the glass industry, the environment and climate change. We, as a sector know the benefits of glass and its endless recyclability which thus prevents more CO2 emissions entering the atmosphere. In the last three years in particular, the sector has made rapid strides in its aims to reduce its environmental impact. FEVE’s Furnace for the Future project, the Close the Glass Loop campaign to collect more recycled glass and Glass Futures’ recent biofuels trial at Encirc are all impactful contributions which have the potential to dramatically change the way glass is manufactured. But despite this, is the glass industry moving quickly enough? While a 2030 deadline for the Paris agreement is looming, glass customers are already feeling pressure from end consumers to reduce emissions. The glass industry is moving in the right direction - but it may have to take more drastic action soon.
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Verallia invests €60 million in Brazil plant expansion
Verallia will more than double the glass packaging production capacity at its Jacutinga, Minas Gerais, Brazil plant with a €60 million investment in a plant expansion. The world’s third largest food and beverages glass packaging producer said the investment will include a second
furnace which will increase capacity from 1 million to 2.3 million bottles a day. The expansion is aimed to meet the increased demand in the beer and alcoholic segments with amber and green bottles. The production will primarily serve the domestic segment and is scheduled to
be completed in 2023. The factory will promote the generation of at least 90 direct jobs and another 50 indirect jobs, which will practically double the plant total number of employees. During the construction, the outsourced contingent should reach 1000 employees.
glasstec 2021 called off The organisers of the glasstec trade fair has announced the 2021 show has been called off due to the sustained pandemic and continued global lockdown measures as well as international travel restrictions. Erhard Wienkamp, Managing Director of Messe Düsseldorf, said that holding the event successfully on the planned dates in June could
still not be guaranteed under the given circumstances. He said: “As of 3rd March the German Federal-State Conference has decided to further extend the nationwide lockdown. “Based on this decision and due to the current level of infection rates and the associated international lockdown restrictions we cannot guar-
antee holding the event in the accustomed format and quality.” The next glasstec will be held on 20th – 23rd September 2022. Organisers are working on a hybrid trade fair experience with a view to also allowing digital participation in conferences and Special Shows such as glass technology live.
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International News
NEWS IN BRIEF
Ardagh reports 2% rise in glass shipments
Slovenian premium glass packaging manufacturer Steklarna Hrastnik has inaugurated its new oxy-fueled G furnace. The manufacturer hosted a digital event that was filmed and broadcast on YouTube. The G furnace is an oxygen-fueled oven with a ca-
pacity of 120 tonnes per day. Construction work started on it in August last year and took 88 days to build. A total of 300 people were involved in the project, which included 450 tonnes of steel structure and 610 tonnes of fireproof materials. The new furnace has tech-
nology which allows it to convert to hydrogen technology in future years. Peter Cas, Steklarna Hrastnik’s CEO, said the majority of last year’s investment of €22.7 million was on the new furnace. It was the largest investment cycle by the company in 15 years, he added.
Carlsberg trials low-carbon bottle Carlsberg Marston’s Brewing Company has partnered with UK glass manufacturer Encirc to trial a beer bottle that has the potential to cut the carbon impact of its bottles by up to 90%. The trial will include the use of 100% biofuel and increases recycled content of the bot-
tles to 100% while maintaining quality, the brewing giant said. Carlsberg said the trial had significant potential to support its target to cut emissions across its supply chain, with the possibility to transform the bottle from ‘the highest-carbon impact packaging
type to the lowest’. Mark Comline, senior category director group packaging materials, Carlsberg Group, said: “Across Carlsberg, we are inspired to work together towards a zero-carbon future. Trials like this in partnership with Encirc are a massive leap towards making it a reality.”
O-I’s Magma glass production line set to debut in March A full-scale generation 1 line of O-I’s MAGMA glass manufacturing technology is expected to be live within weeks. The line, located at its Holzminden, Germany facility, is expected to be in operation sometime in March. It said this will represent a major milestone and pave the
way for broader deployment starting next year. Andres Lopez, Chief Executive of O-I, the world’s largest container glass manufacturer, told a Q4 financial analysts call that plant personnel are being trained and that the line will be transferred to them over the next three months.
O-I said that the Modular Advanced Glass Manufacturing Asset (MAGMA) will re-imagine the container glass manufacturing process. It is a flexible, modular, standardised glass production line which ‘will enable rapid mobile capacity expansion in smaller increments’.
Sorg to rebuild Gerresheimer’s Lohr furnace
Glass engineering company Sorg has been appointed to rebuild pharmaceutical glassmaker Gerresheimer’s Furnace 2 at its plant in Lohr, Germany. The furnace was last reconstructed in 2009, and after 11 years, it had reached the end of its life cycle. The furnace building will be extended to fit new technology and the extended production equipment, while the furnace, regenerative chambers, feeders and the exhaust systems will all be renewed.
Piramal Glass receives approval for sale
The Competition Commission of India (CCI) has approved the $1 billion acquisition of Piramal Glass by the Blackstone private equity group. The acquisition is the largest ever transaction for a packaging company in India. “The Commission approves the acquisition of the manufacture and sale of glass packaging business of Piramal Glass and shareholding in its subsidiaries; Vivid Glass Trading and certain businesses of Ansapack Private Limited by PGP Glass (an affiliate of Blackstone Group),” the CCI said.
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Steklarna Hrastnik inaugurates oxy-fuel furnace
Ardagh Group reported a 2% increase in glass shipments in the second half of 2020 compared to the year before. In its Quarter 4 and Final Year 2020 financial results the group said its Glass Packaging Europe division performed strongly in the quarter, with packaging volume/mix increasing by 2% compared to the same period last year. Volume/mix in Glass Packaging in Europe increased in most categories, notably food, as lockdowns had a diminishing impact on consumption patterns compared with earlier in the year.
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Sunrise Glass to install 240tpd container furnace India’s container glass producer Sunrise Glass is adding a new furnace with an installed capacity of 240 tonnes per day. The company currently operates two furnaces with a combined installed of 380 TPD. Sunrise Glass’s Executive
Director, Gaurav Thakkar, said: “Sunrise Glass is part of the Astron Group and at present we have two furnaces with a capacity of 210 MT/day and 170 /day. “We are coming up with a third furnace of 240Mt/ day capacity. “The furnace will have
four lines with three AIS 10 triple gob (TG) Emhart Machines. “The container glass plant was expected to start in November 2020 but it got delayed due to Covid. “We will commence the commercial operations by April 2021.”
Stoelzle acquires Anchor Hocking US glass plant Stoelzle Glass Group has acquired the Anchor Hocking Glass Company facility at Monaca, Pennsylvania, USA. Austria’s Stoelzle Glass Group serves international customers from its four business units: Pharma, Perfumery & Cosmetics,
Spirits, and Consumer. This is its seventh glass plant and its first in the United States and the first outside Europe. Stoelzle said it planned to bundle its experts and specialists together with an investment and modernisation programme in the
next few years to secure sustainable growth. This will be paired with fulfilling the highest quality expectations to all customers in its aim to become a leading supplier for high quality glass containers in the United States and North America.
Visy Glass announces AUD $2 billion investment Visy Glass has announced a AUD $2 billion investment in Australian manufacturing over the next 10 years. The announcement was made during a visit by Australian Prime Minister Scott Morrison. Visy Executive Chairman Anthony Pratt bought O-I
Glass’ Australia and New Zealand (ANZ) business unit for AUD $947 million (US$ 658.9 million) in July 2020. He said: “We are pledging an additional $2 billion over the next 10 years in Australia, creating thousands of new green collar
jobs, manufacturing jobs, reducing landfill and increasing the recycled content of our packaging.” Visy’s activities span two of the Australian Government’s six National Manufacturing Priorities – ‘Food and Beverage’ and ‘Recycling and Clean Energy’.
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Orora increases recycled glass content
Australia’s Orora has increased the amount of recycled glass in its manufacturing process. The group, which operates a glass manufacturing facility in Gawler, South Australia, has secured all the glass cullet that is generated by the Western Australian government’s container deposit scheme. Orora CEO, Brian Lowe, told financial analysts during a half year report that over time this will increase recycled content from 25% to 40%.
Arc to recruit 225 permanent staff
French Tableware glass manufacturer Arc will recruit 225 permanent staff thanks to a long-term, part-time scheme. The glass group, based in Arques, in Pas-de-Calais, northern France, said the recruitment contracts for production staff were facilitated by a long-term partial activity agreement (APLD) negotiated with the state. General Manager of Arc France, Tristan Borne, said: “We agreed on the fact that we were going to anticipate future needs and take advantage of the smoothing of the activity provided by the long-term partial activity in order to be able to train employees, in particular young recruits.”
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Solvay to exit soda ash business?
Raw materials supplier Solvay may leave the soda ash business. The soda ash manufacturer said it had started to organise its business into a separate legal entity, a step companies usually undertake before selling a business. Solvay says the new legal structure will enable it to optimise the business’s cash flow generation and profit while increasing its ‘future strategic flexibility.’ It is the world’s largest producer of soda ash (sodium carbonate).
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Borosil Renewables plans 500t/day Indian float glass plant O-I’s Magma glass production line set to debut next month Verallia invests €60 million in Jacutinga, Brazil plant expansion Stoelzle acquires Anchor Hocking US glass plant A letter of endorsement for the ‘Furnace for the Future’ Cristalerias Toro ignites 300t/day Maipu furnace Glasstec suspends admissions for June 2021 show Carlsberg trials low-carbon glass bottle Sisecam secures $30 million loan to upgrade Egyptian glass facility Verallia starts €60 million Villa Poma furnace, Italy
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Verescence acquires South Korea’s Pacifiglas Perfumery and cosmetics glass manufacturer Verescence has acquired South Korean glass packager Pacifglas and secured a long-term partnership with Amorepacific. Verescence produces 500 million bottles per year in its three glass production sites and its four decoration sites in
Europe and North America. In 2019, the company employed 2,300 people worldwide and achieved sales revenue of €309 million euros. Thomas Riou, CEO of Verescence, said: “This is a major step in our Strategic Plan, Verescence 2022. Amorepacific will become a top customer
of Verescence group and with Pacificglas, Verescence will reinforce its leadership in highend perfumery and cosmetic glass packaging.” Amorepacific supplies more than 2000 types of glass bottles to nearly 110 cosmetics companies in and outside South Korea every year.
Cristalerias Toro ignites 300t/day Maipu facility furnace Chile’s Cristalerias Toro has ignited a 300t/day furnace at its Maipu plant. The container glass manufacturer said the entire startup process had been and will continue to be supported by technicians of the different suppliers from Germany, the United States, Colombia and
Mexico. Director General, Francisco Ruiz said: “It has been a tremendous challenge for us to meet the dates we set ourselves, since the travel restrictions imposed by the pandemic have demanded our utmost ability to coordinate the different specialties and have
everything ready to start the furnace operation.” It said the electrical energy the furnaces uses come from 100% renewable sources and will produce bottles with more than 60% glass recycling. Cristalerías Toro is a family business, with more than 60 years of experience.
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Schott reaches Covid-19 milestone
Pharmaceutical glass manufacturer Schott has delivered enough of its glass vials to provide more than one billion doses of Covid-19 vaccines around the world. The company says it remains well on track to deliver vials for more than two billion vaccine doses throughout 2021. The vials were delivered to projects around the world, with a focus on the US, Europe, and China. Approximately 90% of approved vaccines rely on Schott vials.
Pilkington IGP expands Ostroleka, Poland plant
Insulating glass manufacturer Pilkington IGP is expanding its plant in Ostroleka, Poland. The investment will not only increase the company’s production capacity but will also provide nearly 100 new jobs. The project includes, among other things, enlargement of the production hall and office space. The total area after the expansion will reach almost 10 thousand square meters, meaning the size of the plant will be more than doubled compared to the current situation.
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Kioo obtains $10 million loan
Tanzanian container glass manufacturer Kioo has obtained a $10 million loan from IFC to help the company weather Covid-19 related challenges and to invest in more energy-efficient machinery. IFC’s $10 million loan will provide Kioo with working capital due to falling demand because of Covid-19 and associated measures to contain its spread, including the closure of bars and restaurants. The loan to Kioo is part of IFC’s $8 billion fast-track financing package to support existing clients and preserve jobs and economic activity during the pandemic.
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Horn starts heat-up process of GCA’s 400 tpd furnace Horn Glass has started the furnace heat-up process at tableware manufacturer Gürallar Cam Ambalaj’s (GCA) new 400 tonnes per day end fired furnace in Turkey.
The entire start-up process had been and will continue to be supported by Horn Glass technicians. Horn explained that it was a special project as it was the
first time its GCS 301-advanced forehearth system has been used. The performance test is expected to begin in mid-March 2021.
Sisecam secures $30 million loan to upgrade Egyptian glass facility Turkish glass manufacturer Sisecam has secured a $30 million financial package to upgrade its Pasabahce Egypt manufacturing site. Sisecam said the money will be used to help the company boost exports, introduce cleaner production practices, and create jobs.
It secured the package from the International Finance Corporation (IFC), a member of the World Bank. IFC’s support will help Pasabahce Egypt upgrade its glassware production facility outside Cairo, and introduce efficiencies to cut its natural gas and electricity consump-
tion by more than half. The funding is also expected to allow Pasabahce Egypt to create about 330 new direct jobs in engineering, production, and quality control, and more than 1,500 indirect jobs. Pasabahce Egypt mainly serves markets in the Middle East, Turkey, and the USA.
Verallia starts €60 million Villa Poma furnace, Italy Verallia has inaugurated a €60 million furnace investment at its Villa Poma facility, Italy. The container glass manufacturer said the investment included cutting edge production equipment and environmental technologies. CEO Marco Ravasi said the investment exceeded €90 million if the modernisation of
the other furnace at the facility if taken into consideration, which took place in 2019. He said: “In the last five years, we have invested over €250 million in Italy, confirming that this is a central market in the group’s global strategy. The technologies will enable the glass packaging site to reduce its CO2 emissions by
10% and electricity consumption by 15%. A further investment in the Mantua area in the planting of some wooded areas, equal to about 20,000m2, which will allow absorption of CO2. The plant expansion has led to the hiring of 80 young people between 20 and 30 years old, including 34 women.
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Company profile: Beatson Clark
Sustaining a positive future for Beatson Clark In a year where companies have had to adapt their businesses, Beatson Clark was no different. George Lewis spoke to Charlotte Taylor* who explains what it has done to overcome the challenges posed by the Covid-19 pandemic and and how the company is becoming ever more sustainable.
“
It’s been an extremely busy and challenging last 12 months”, said Charlotte Taylor of UK container glass manufacturer Beatson Clark, based in Rotherham, South Yorkshire, UK. The Coronavirus pandemic has affected nearly every business in the world, and Beatson Clark was no different, with many obstacles having to be overcome since the start of 2020. “We’ve adapted the business and how we do things,” Miss Taylor said. Along with making the factory more ‘Covid-safe’, it has also invested in even better health & safety and personal protective equipment (PPE) in order to keep production going in a time when people in the UK have been at home, buying more alcohol and cooking more meaning more glass jars were needed. But it is flexibility that Beatson Clark has needed to show, especially with its customers and breweries. Miss Taylor said it has had to change the way they deal with customers with many things now done virtually. “It’s been increasingly difficult to work to a forecast since the start of the pandemic, and flexibility has been key to keeping up with the ever-changing demand,” she said.
removes matter from the waste gas streams in the furnace exhaust. This captured dust is then recycled in the furnace, replacing some virgin raw materials and reducing waste. Miss Taylor also explained that the electricity on site all comes from renewable sources. She said: “Right across in all areas of the plant, improvements are being made. “This is especially so over the last seven to eight years. As the technology advances, we look to implement them as soon as possible.” A new IS machine installation is scheduled for the fourth quarter of 2021, which will have servoelectro mechanisms installed. Installing these mechanisms in other machines on the site has already reduced compressed air consumption by 10%. Another way Beatson Clark is investigating to reduce emissions is to use more cullet.
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A focus on sustainability But while an ever-changing outlook for the country has seen Beatson Clark adapt the business, it has still maintained its need to be a glass manufacturer with a focus on sustainability. Miss Taylor said: “We are always looking at ways to reduce emissions and energy consumption.” Examples of this include Beatson Clark using regenerative furnaces, which has reduced energy consumption to heat the furnace by 15%. It also has electrical boosters in its amber furnace that reduces fossil fuels by 10%. Beatson Clark’s abatement plant
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� Beatson Clark has been able to meet the demand of its customers despite Covid-19 affecting all parts of the business.
� Beatson Clark also has a range of pharmaceutical glass used for such things as medicines and supplements.
Miss Taylor explained that ‘for every 10% of recycled content, it reduces CO2 emissions by 5% and energy consumption by 3%’. She added: “The main thing we can do as an industry is to use more recycled content when available.” Beatson Clark has increased its recycled content by 23% since 2016, with a third of the recycled content used coming from its own recycling plant, which processes kerbside pickups alongside collecting cullet from local bottle banks and hospitality venues. The company is about to invest £1m in upgrading its recycling plant, which will increase the proportion of cullet in Beatson Clark’s recycled content to 40%. She maintained that ‘if you’ve got good quality cullet it’s a good way to reduce energy usage as recycled glass burns at a lower temperature.’ Miss Taylor feels that Beatson Clark’s customers are becoming a lot more conscious with regards to the importance of sustainability because the end consumer wants it, and feels this has been especially so in the last couple of years. Continued>>
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Company profile: Beatson Clark
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but I think it’s the right time as consumers want to choose sustainable products.”
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A challenging 2020
Being a more sustainable manufacturer has seen Beatson Clark become part of various projects initiated by the European container glass association FEVE. It is a part of the ‘Furnace for the Future’ project that has brought together 19 European container glass manufacturers, including some of the biggest manufacturers in the world including Ardagh Group, Verallia and O-I. This project has been organised to construct the world’s first large-scale hybrid electric furnace to run on 80% green electricity. Ardagh Group will build the furnace and run it in Obernkirchen, Germany, while the other glass companies, including Beatson Clark, will cofinance the project. In return for help with co-financing the project, the other manufacturers will receive all the necessary information, such as training of operators and operating parameters to run similar plants in the future. This furnace is scheduled to be built in 2022, with first results seen in 2023. Beatson Clark is also part of one of FEVE’s more recent project launches, called the ‘Glass Hallmark’. FEVE hopes this hallmark will eventually be marked on bottles during the manufacturing process in order to highlight the environmental and health benefits of choosing products packaged in glass. Michel Giannuzzi, President of FEVE said at the time of the launch: “This symbol marks the first milestone on our journey to work together with customers and brands to provide packaging solutions that answer to a growing sustainability focus from consumers.” Beatson Clark has recently had a promotional bottle sampled, that will be used to promote to both consumers and brand owners to use this hallmark on either the bottle itself or on the label, to promote the benefits of using glass. Miss Taylor said: “We will be looking at incorporating this hallmark as part of our design process for future containers. “It might take some time (to see it on a bottle)
�It offers customers the ability to change to amber glass which protect the contents by up to 90% of UV rays.
Miss Taylor explained that the demand for container glass did increase in the UK at the start of the first lockdown in March 2020 as consumers stockpiled food and medicines and entertained themselves at home instead of going out. Demand for glass has continued to be high thanks to increased supermarket demand and more home deliveries by supermarkets and online retailers. Miss Taylor believes daily life ‘certainly won’t go back to normal straight away post Covid-19’ and believes that in the UK especially, there will be a lot of staycations, and more cooking from home which may last for a long time, which means glass production should remain strong. Miss Taylor felt that ‘having such a successful year in such challenging times speaks volumes for how hard our loyal staff worked’, and explained that a big reason for having a successful last 12 months has been because of its workforce. She said: “They’ve made us really proud. When we were clapping for the NHS we’ve also been clapping for our own keyworkers too .”
2021
“Working to a forecast has been increasingly difficult and flexibility has been key to keep up with the ever-changing
”
demand.
With the UK slowly coming out of lockdown in 2021, Miss Taylor believes demand for glass drinks bottles and food jars will remain strong. She predicts that another current trend will continue – the use of pharmaceutical glass bottles and jars for premium cosmetics products, candles and so on. She also believes that the demand for glass bottles for vitamins, minerals and health supplements will increase as people look to improve their health and fitness after a year when gyms and sports clubs were closed and many people were stuck indoors. And the last future trend Miss Taylor anticipates growing in the next 12 months is the demand for no- and low- alcohol beverages – another sign that the consumer will be focusing on health and fitness this year. Many of the items in highest demand are normally manufactured using white flint glass, and as demand rises there is sometimes a delay in production. Beatson Clark is keen to discuss with its customers whether their product could be switched to amber glass to reduce these delays. Miss Taylor says that switching to the darker amber glass also means that it can better protect the contents by blocking over 90% of UV rays. Beatson Clark remains positive that the demand for container glass will still be strong going into the rest of 2021, and it will continue to look at ways to be a more sustainable manufacturer in the years ahead. �
*Marketing Manager Beatson Clark, Rotherham, Yorkshire, UK. https://www.beatsonclark.co.uk/
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Company profile: Schott
Schott unveils energy plan to 2030 When did you set yourself the goal of ensuring all US locations’ electricity needs were renewable and when did you achieve this? Schott set itself the goal to become climate neutral by early 2030 last year as part of the company’s new group strategy. As one major measure, we decided to cover our worldwide electricity supply via green energy by 2021. In an initial step, we decided to concentrate on the countries where we operate melting furnaces, because this is where the energy demand is the highest. In the US, we have already transitioned 100% of our locations’ electricity to green energy. Was it a challenge to achieve this? Yes, because we are moving at a quick pace to switch our global electricity purchases entirely to green electricity while following very high standards. Overall, we are following a two-phase approach. In the first phase, we will switch to green power with a practicable short-term solution by purchasing Energy Attribute Certificates (EACS). When purchasing EACs, we ensure that they meet two criteria. First, the certificates - as far as possible - come from power generation plants in the countries where the company actually needs the electricity. The second criterion is the
“We rely on energy sources such as wind power, solar energy and
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biomass
quality of the certificates. There are different standards for the providers as well as for the green power certificates themselves. Schott pays close attention to ensuring that the certificates of origin it purchases guarantee a high standard of quality and make a sustainable contribution to the energy transition. In the second phase, we aim to use the instrument of power purchase agreements (PPAs). These are long-term power purchase agreements with operators of energy plants when purchasing green electricity. Here, too, our focus is on quality: by entering into PPAs, preferably with newly constructed plants, Schott aims to support the expansion of renewable energies and thus contribute to increasing the availability of green electricity. What renewable energies are used to cover your electricity needs? We rely on energy sources such as wind power, solar energy, and biomass. We attach great importance to the fact that green energy has a high-quality certification and thus makes a strong contribution to the energy transition.
Continued>>
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Anja Schlosser, Sustainability Manager at Schott discusses how the speciality glass manufacturer plans to become climate neutral by the year 2030.
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Company profile Schott.indd 1
16/03/2021 06:48:39
Company profile: Schott
In regards to electrical energy, we plan to rely on green electricity in the future. As mentioned above, we intend to cover 100% of our electricity needs with green energy sources by 2021. When it comes to compensating for technologically unavoidable emissions, we rely on our involvement in sustainable climate protection projects that are certified according to high standards Glass manufacturing requires a furnace to melt raw materials. Many furnaces in the industry use fossil fuels to power them. Will your furnaces be climate neutral by 2030? Do you work closely with your furnace suppliers on this topic? We are aiming for climate neutrality by 2030. It is a long way to go, and we are just at the beginning of this journey. We aim to lay the R&D foundations by the end of this decade. However, the path will also be determined by external factors that we can hardly influence ourselves. Availability and costs for green electricity and hydrogen are decisive influencing factors that will determine our final solution. As such, we are preparing for various scenarios. We think that the first plants should be converted to climate-neutral production in 2030. However, a rollout will take significantly longer simply because of the lifetime of the plants. We see the biggest hurdle in the global conversion of our production facilities in the stable and competitive green energy availability.
Were many other organisations involved in this project? Overall, not too many other organisations have been involved, as we have many experts in-house. However, we also rely on support from external independent experts who evaluate our projects.
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Approximately how much electricity does Schott’s US operations use? In the US, our facilities use about 90 GWh of electricity annually. You have set yourself the goal of being climate neutral by 2030. How will you achieve this? To achieve this goal, we have set an action plan that consists of four main areas: Technological change, increasing energy efficiency, switching to green electricity, and compensating for technologically unavoidable emissions. In the long term, we want to avoid using fossil fuels by developing new technologies – as far as this is technologically feasible. Here we are pursuing two transformation paths in particular: electrification and hydrogen technology. However, this transformation process takes time and requires enormous development and investment costs. It will take many years before large-scale CO2-free solutions are available in specialty glass production. Schott has been working on improving its energy efficiency for decades. The introduction of oxy-fuel melting technology and the increasing use of electricity to heat the melting tanks since the 1990s have already helped the company reduce its specific energy consumption by over 30%. Our experts are continually working to identify and exploit further energy-saving potential within the proven energy management system.
“Ideally, we would completely eliminate CO2 emissions and substitute all fossil fules with green electricity, green hydrogen,
”
or bio-energy
How important is hydrogen as a substitute to fossil fuels in the future? Green hydrogen will play an essential role for the glass industry. We will need it to completely change our processes, and our scientists are researching this internally. However, we are also dependent on the external availability of hydrogen for implementation at our production plants. Today, green hydrogen is not available at any of our sites. In Germany’s case, the German government is working on expanding the H2 network with its hydrogen strategy. Internationally, we are not yet able to assess how this will affect our foreign sites. Tell us what your ideal glass manufacturing facility would look like from an environmental point of view? Ideally, we would completely eliminate CO2 emissions and substitute all fossil fuels with green electricity, green hydrogen, or bio-energy. We assume that solutions will depend on the regional availability of energy sources. If we had one wish, we would want both green electricity and green hydrogen available 24/7 globally and at competitive prices. These would be ideal conditions for combating climate change in the glass industry. �
Schott, Mainz, Germany www.schott.com
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Company profile Schott.indd 2
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UK overview: Glass Futures
Glass Futures: Accelerating Global Sustainability
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he past 12 months have been a testing time for many people and businesses in a multitude of ways, with all of us needing to adapt the way we do things and the way we approach our work. As such the success of the recent three- week long sustainable biofuel demonstration at Encirc’s Derrylin plant was a huge personal and organisational success for both me and the whole Glass Futures team. When venturing on the journey to identify potential plants for a major biofuel trial in June 2019, when this trial was first conceptualised and discussed as part of our early fuel switching studies, I never envisaged that a global pandemic was on the list of risks and potential barriers to consider for low carbon fuels in the glass sector. However, following a successfully funded application for £7.1m from the Department of Business, Energy and Industry Strategy (BEIS) in 2020, it quickly became a logistical nightmare, with restricted access to sites, delayed re-builds, reduced staff site numbers, no international travel for periods and general uncertainty. However the global glass industry has played a brilliant part in enabling Glass Futures’ trials to continue through these testing times with particular thanks to Encirc and our membership for the technical support to make this trial a success. As with many aspects of current life, regular teams calls, extensive
� Lara Edison (L) of Encirc and Aston Fuller (R) of Glass Futures have worked jointly with their teams to produce a bottle made from completely renewable fuel sources.
planning, patience and perseverance enabled this project to go ahead and prove the technical feasibility of a new biofuel group with some long term economic solutions possibly on the horizon, which is the next key step Glass Futures is investigating. This trial is part of a much wider look at the techno-economics of biofuels as well as hydrogen, all-electric and hybrid approaches to primary melting which Glass Futures is set to deliver to BEIS as part of an overall study into the viability of fuel switching within the UK glass sector (Industrial Fuel Switching Competition Phase 3). What has been clear throughout this work is that our adoption of low carbon technologies will likely be a transition as opposed to a switch, and
will be heavily influenced by regional and national factors including low carbon fuel availability and cost, with the industry unlikely to find a one-size-fits-all approach within the next 30 years. Clearly, in the face of adversity, the priority to prove new low carbon fuel sources has not dropped off the agenda for any global manufacturer, in fact I would go so far as to say it has accelerated the need for a global solution to low carbon glass manufacture. The interest generated by the trial and what it could offer in the future is a clear sign that this growing trend is starting to pull in more interest than just that of the manufacturers, but also the equipment suppliers, the brands and most importantly, consumers around the world.
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UK overview Glass futures.indd 1
16/03/2021 06:52:56
UK overview: Glass Futures
aims to play a key role in supporting in the coming years.
Glass Futures Aston Fuller* and Encirc’s Lara Edison** discuss the recent groundbreaking biofuel trial at Encirc’s Derrylin plant which resulted in the production of glass bottles made from a renewable and sustainable fuel source.
With the global trend towards challenging the status quo in mind, I am proud to say that Glass Futures will be accelerating global sustainability over the coming years. With an even bigger and more explorative chance to demonstrate technology such as this at the Global Centre of Excellence, 30 tonnes per day Pilot Plant we’re building in St Helens, UK as a collaboration across the global glass sector. This facility will really allow Glass Futures and its members from across the glass supply chain to demonstrate the newest developments in low carbon fuels and new raw materials, as well as the control mechanisms that drive these processes. Projects such as Glass Futures’ Pilot Plant and the FEVE Furnace for the Future show a clear pathway for a global industry to trial new technology, demonstrate at pilot scale, and commercialise at a large scale with a new set of assets that represent a paradigm shift in global glass manufacturing mentality. I never imagined when joining what is seen as a very traditionally heavy industry, that I would be so close to seeing the change in attitude that often precedes a change in business models and approaches. I am an avid Glass person through-andthrough, after a relatively short 11 years in the Glass Industry (barely an apprentice compared to many, I know!) I strongly believe the rate of change which the industry must adopt to tackle the carbon question is an unparalleled challenge. I’m
inspired however by the willingness for technical collaboration within this space and have seen the warm welcome that the people throughout the industry share, including our love for manufacturing, high temperature processes, automation and glass as a material. These passions bond the glassmakers of the world and the future of glass as a common place material relies on the hard work to be carried out over the coming years of this small, highly capable and dedicated industry, of which Glass Futures
Ground-breaking trials like this push the boundaries of what’s possible in production, and we’re proud of the pioneering role Encirc plays in creating a more responsible glass sector. The results we’re seeing from this ambitious project could truly make a difference in the fight to address the climate emergency, and position glass as the packaging material of the future. At Encirc, our ultimate goal is to create a glass bottle which has absolutely no carbon impact throughout its entire lifecycle. The ultra-low-CO2 containers we’re making using biofuel and 100% recycled cullet are a big step forward towards this goal. But more needs to be done across other areas of the supply chain and our products’ route to market, which is why we’re working to promote more responsible bulk shipping methods, as well as reducing the carbon impact of our production lines and filling operations through innovative Industry 4.0 technology. Working with Glass Futures has allowed us to share our knowledge and expertise with the wider industry. The glass sector must work together to ensure the ageold material we work with is always involved at the forefront of cutting-edge developments and schemes like this one. Going forward, we’ll continue to look further into the development and potential of alternative fuel sources like biofuel and hydrogen, while also helping green up our customers’ supply chains. No matter what changes in our operations, one thing remains the same – the fact that glass is infinitely recyclable. For this reason, encouraging and promoting better glass recycling levels throughout the communities we operate will always be a key focus for us. An industry-wide reduction in carbon emissions is on the way, and with everything that’s been happening in the world around us for the last year, this certainly gives us something positive to work towards and to look forward to. �
*General Manager at Glass Futures, Chapeltown, Sheffield, UK www.glass-futures.org/ **Batch & Furnace Supervisor, Encirc, Elton, UK www.encirc360.com/
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Lara Edison, Encirc’s Batch & Furnace Supervisor:
19 Glass International March 2021
UK overview Glass futures.indd 2
16/03/2021 06:53:02
Glass and its position in the new world order While the world has rightly focused on Covid, the glass industry has been doing fantastic things behind the scenes to ensure it leads the manufacturing world by example when the pandemic ends, writes Dave Dalton*.
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s we hunker down in our enforced confinement contemplating what life will be like once Covid has been at least ‘tamed’ if not beaten, we take a little time to consider the opportunities amidst the devastation. True, the economy will have taken a beating. High Street names will have gone forever, and life will be conducted in a different way – it’s certainly going to be a fascinating period for future historians to reflect upon, and potentially one of the most opportunistic periods for scientists, engineers, researchers and forward-thinking business managers and entrepreneurs, vying to establish their position in the brave new world order. It’s also going an interesting time to be a player in the environment and materials sectors which need to be alive to the opportunity – as I believe the Glass community is. Long before Covid, glass manufacture here in the UK at least had begun to reflect on its own situation and started a new dialogue about change and future positioning. At the heart of this was the Decarbonisation Roadmap through which a pathway towards a cleaner, greener, more productive future was discussed, designed, committed to and embarked upon. Glass moved first amongst competing
materials and moved more meaningfully, setting a very positive message to challenge others to follow. Now glass remains ahead of the game and well positioned to continue leading in the exciting times. Whilst other major materials looked to Carbon Capture (Utilisation) and Storage (CCUS) and to buy time, glass pioneered forward-looking more critically at carbonfree manufacture, new fuel sources, different manufacturing techniques and process efficiency improvement. Similarly, glass has looked at carbon impact from a post-consumer perspective and worked relentlessly on recycled glass (cullet) capture to further enhance performance to practically, rather than figuratively, tick the box. With every tonne of carbonate containing raw material, a tonne of pure clean cullet will save around 580kg of carbon dioxide being released throughout the supply chain, so it’s an obvious win for the sector to get this right. The UK container glass sector has recognised this issue in relation to the proposed Deposit Return Scheme and is working closely with Westminster officials to demonstrate why more consideration to how glass is treated in this impending legislation is critical to future environmental and economic performance.
Even though the UK has finally and officially left the EU, practically many ties remain. Large manufacturing sectors still collaborate through European agencies and glass is no exception, collaborating closely still with GAE, FEVE, GFE and others to ensure good initiatives are still supported. Close the Glass Loop, led by the European container glass sector, with the aim to achieve a 90% minimum recovery rate for post-consumer container glass right across Europe is one such approach that we here in the UK remain closely allied to. Whether we like or loathe Brexit, the reality is that we are now outside the control of a federal Europe and free to trade and operate as best we can negotiate on a global platform. Though this presents difficulties it also presents opportunities and in true British style we will have to get on and endeavour to make best of what we have. It is inevitable that given the framework agreement struck with Brussels in late December there will have to be many similarities with EU rules, and these will significantly assist with ongoing trading with our nearest neighbours. Equally though, there will be differences where new latitudes will be afforded to challenge previous constraints. The future will be shaped by many new necessities including circular economy.
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UK overview British glass.indd 1
15/03/2021 10:33:11
UK Overview
Glass should be the material choice of future society being infinitely recyclable, easily produced from carbon-free fuel sources (renewable electricity, biofuel or hydrogen) leading to no carbon footprint. It already provides materials for highefficiency glazing units, solar panels and wind-turbine blades which collectively offset at least 10x more carbon in their lifetime of use than the whole carbon generated in glass manufacture. Glass is looking to continue its investment in technology and many initiatives pay testament to this. The already mentioned FEVE Close the Glass Loop project aspires to collect and utilise every piece of glass placed on the market, and rolled out to national level. Similarly, the Furnace for the Future project aims to build and demonstrate a full-scale glass production furnace capable of working at the highest efficiencies with the lowest carbon emissions of any such plant in the world; again a truly inspirational ambition of the glass sector. In the UK, working closely with BEIS and Innovate UK, the glass sector has brought together other fundamental
UK overview British glass.indd 2
manufacturing sectors including steel, ceramics, cement, chemicals, and paper (known as the foundation industries) as providers of over 75% of all industrial materials to society to collaborate collectively. Having established this visible position, over £65m of UK government funding has already been allocated to the foundation industries and £15m invested direct in glass from the start. Clear evidence of the leadership set by glass and the rewards that can be achieved by an industry revitalised to set the standards for the future. Glass Futures, an initiative born out of British Glass, is already demonstrating the path to future glass furnace fuels in its ground-breaking Industrial Fuel Switching project looking at biofuels, green electricity, and hydrogen as potential future fuel sources. The activities already mentioned are creating a great profile for glass in both government and society and bodes well for the position of glass as the material of choice for the future. To ensure this British Glass, as the trade body for the industry, is greatly increasing its connectivity within
UK Government on developing policy, particularly within BEIS and the Industrial Strategy element. British Glass now sits on many advisory groups and task forces helping shape government thinking, providing technical date and evidence through support from Glass Technology Services; being ideally positioned to develop technical arguments from a detailed understanding of the sectors at a scientific and operational level. So, despite the fact that the world has been rightly preoccupied with Covid and both the immediate effect and the post pandemic concerns for the past year, glass has been doing fantastic things behind the scenes to ensure that once the new world order is established and we all tentatively emerge into the light, our sector is visible leading the world of manufacturing by example. Glass would appear to have an extremely bright and opportunity ladened future! �
*CEO, British Glass, Chapeltown, Sheffield, UK https://www.britglass.org.uk/
15/03/2021 10:33:14
UK SUPPLIERS
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1. A.E Chapman, Clapham, London 2. AEGG Creative Packaging, Andover, Hampshire 3. AFT UK, Retford, Nottighamshire 4. Ashton Industrial, Harlow, Essex 5. Ametek Land, Dronfield, Derbyshire 6. Calumite, Scunthorpe, Lincolnshire 7. Croxsons, Morden, Greater London 8. Dismatec, Sheffield, Yorkshire 9. DSF Refractories, Buxton, Derbyshire 10. Electroglass, Benfleet, Essex 11. Eurotherm by Schnieder Electric, Worthing, West Sussex 12. Ferro (GB), Stoke-on-Trent 13. FIC UK, Penzance, Cornwall 14. Fife Silica Sands, Alloa, Falkirk, Scotland 15. Fives Stein, Didcot, Oxfordshire 16. Fuchs Lubricants, Stoke-on-Trent 17. Forehearth Services, Swinton, South Yorkshire 18. Glassworks Hounsell, Halesowen, Dudley, West Midlands 19. Global Combustion Systems, Livingston, Scotland 20. Glassworks Services, Doncaster, South Yorkshire 21. Graphoidal, Chesterfield, Derbyshire 22. Hunprenco, Hunmanby, North Yorkshire 37 23. Johnson Matthey, Farringdon, London 24. Krysteline Technologies, Southampton, Hampshire 25. Lattimer, Southport, Merseyside 26. MKD32, Chester, Cheshire 27. Newport Industries, Richmond-upon-Thames, Surrey 28. Omya, North Ferriby, Yorkshire 29. Pattesons Glass, Grimsby, Lincolnshire 30. Parkinson-Spencer Refractories, Halifax, West Yorkshire 22 31. Pennine Industrial Equipment, Huddersfield, Yorkshire 33 34 30 31 32. Pro-Sight Vision, Barnsley, Yorkshire 25 39 17 6 28 33. Rondot Graphoidal Britain, 20 32 29 Elvington, York, Yorkshire 40 3 8 34. Sheppee (part of Rondot), 36 Elvington, York, Yorkshire 5 38 35. Sibelco, Sandbach, 21 Cheshire 26 35 9 36. Siemens Process 12 Instruments Manchester, Lancashire 16 37. Simpson Combustion and 18 Energy, Ayton, Berwickshire, Scotland 38. Tata Chemicals Europe 4 Northwich, Cheshire 10 23 39. Tecoglas, Sheffield, 15 Yorkshire 27 1 40. Vitritech, Sheffield, 7 2 Yorkshire 11 24 41. Wall Colmonoy UK, Swansea, Wales
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UK overview.indd 1
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UK GLASS MANUFACTURERS 1. Allied Glass (2 sites) – 1. Leeds and 2. Knottingley Ardagh Group (4): 3. Barnsley 4. Doncaster 5. Knottingley 6. Irvine (Scotland) 7. Beatson Clark (1)- Rotherham, Yorkshire Encirc (2): 8. Derrylin (Northern Ireland) 9. Elton 10. Guardian Glass (1) – Goole (Yorkshire) O-I Glass (2): 11. Harlow 12. Alloa
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13. NSG Pilkington (1) – St Helens 14. Saint-Gobain (1)- Eggborough
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15.Stoelzle Flaconnage (1)- Knottingley 16. Nippon Electric Glass (1) - Wigan
8 16 13
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1 14 10 15 2 5 3 4 7
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23 Glass International March 2021
UK overview.indd 2
15/03/2021 10:38:08
FIC SGT advert 2020 AW_FIC-Society advert 2019 27/01/2020 16:29 Page 1
Society of Glass Technology Join the worldwide network of interests centred on making glass great The Society of Glass Technology exists to serve people who are interested in the production, properties or uses of glasses, whether from a commercial, aesthetic, academic or technical viewpoint. It is a non-profit making organisation serving a worldwide membership publishing journals and text books, organising meetings and conferences on glass related topics. You can now join the SGT by going to www.sgt.org and selecting your journal choice and appropriate package. You will also be able to see the comprehensive history and activities of the society.
Serving the Glass Community for more than a century
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9 Churchill Way, Chapeltown, Sheffield, S35 2PY, UK
Ware handling
A brief guide to ware handling Every aspect of hot end warehandling is equally important – no element can individually cure sub-par ware handling performance, reports Andy Ross*.
� Fig 1.stacking alignment is crucial for lehr efficiency and cold end spraying
� Fig 2. Pocket appropriate to container shape.
� Fig 3.
Continued>>
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he culminating point of hot end handling is the lehr belt and for containers to arrive on it in the optimum condition. To achieve this, a number of factors at points throughout the containers’ hot end journey must be respected and adhered to. Here are the main points, working back from the lehr. For a whole range of reasons, a pushbar must be straight. It has a positive (or negative) effect on pocket and article spacing, lehr efficiency and cold end coating effectiveness. Pocket shape should suit the article being produced and size appropriate for the diameter or major axis (Fig. 2). Consideration should also be given to container height so that the pushbar pocket provides the container with appropriate support. Stable and well aligned bottles are also reliant upon the cross conveyor unit delivering and presenting the bottles for loading. The area of transition from delivery to cross conveyor belt (Fig. 3) and from cross conveyor to lehr belt (Fig. 4) must be as level and as smooth as possible. A stacker is only as good as the pushbar it is pushing. Nevertheless, control of the movement of the pushbar is also key, whether at a high cross conveyor speed, typically for beer bottle production, or with unstable, small cosmetic pieces (Fig. 5). The transfer selection should be contingent not only on the number and size of fingers the unit is configured with but also for the spacing of the fingers as the containers arrive in to the mechanism. Throughout the curve of the 90 degrees, or across the conveyors in parallel line formats, container spacing should ideally be reduced when transitioning from delivery to cross conveyor (Fig. 6). Consider a specialist unit designed and engineered for the container type to be produced. One single transfer unit cannot truly handle all container types.
25 Glass International March 2021
warehandling sheppee.indd 1
16/03/2021 09:19:11
Ware handling
� Fig 5.
� Fig 6.
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� Fig 4.
Spacing of all containers types and the orientation of non-rounds is crucial to ensure effective transfer performance and reliable spacing and alignment at the exit point on the cross conveyor (Fig. 7). Conveyor belt will stretch over time and if not compensated for mechanically, or electronically, in the hot end machinery drive system, it can prove to disrupt container-to-transfer-finger, or containerto-pushbar-pocket synchronisation. It may even be necessary to physically measure the actual distance (a) travelled after one full machine cycle and adjust the settings accordingly (Fig. 8). Good warehandling starts from the delivery of the bottles on to the I.S. Machine delivery conveyor and must be maintained through each step of the hot end production process right up to the point of release on the lehr belt. �
*Regional Sales Director, Sheppee, Elvington, UK www.sheppee.com
� Fig 7.
� Fig 8.
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warehandling sheppee.indd 2
16/03/2021 09:19:15
Company overview: Socabelec
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ocabelec has very much been a part of Marco’s Veri’s career. Since joining the company as a project engineer fresh from university in 1987 he progressed up the ranks and is now its CEO. He has seen many changes at the company in that time. In 1997 he bought the organisation in a management buyout. Then almost as significantly, the company transitioned from supplying robots to the automotive glass industry to its current role today: as a supplier of automated swabbing robots for IS machines in the container glass sector. The company decided to shift from the automotive sector when it saw a gap in the container glass market in 2011. After an initial installation of its new swabbing robot it decided to focus all its efforts on this new innovation. Mr Veri said: “I said to the board that if we are not the number one in one market then we are no one. “We felt there was a need on our side to focus on
� Socabelec CEO, Marco Veri.
the product, to develop it and that it wasn’t just a side project. “We wanted to be a global leader with this but you cannot be a global leader by only making a few installations a year, because you will never be up to date with the requests from the demands of the market.”
Return on investment Socabelec is based in Belgium, a country where labour costs and parts are high, meaning the swabbing machines are costly. On top of that approximately 90% of the company’s products are made to export. It devised a strategy where customers would receive a better return on investment than anyone else. Socabelec knew that if it didn’t provide a top class service then customers could easily turn to other companies located in geographic regions where manufacturing costs were cheaper.
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company overview Socabelec.indd 1
15/03/2021 10:41:52
Company overview: Socabelec
Socabelec’s on-the-fly swabbing robots have helped increase productivity and improved the environment within container glass manufacturing factories. Greg Morris spoke to owner Marco Veri about the company’s evolution.
“We know automation and robotics can end some jobs for operators but at the same time it creates “Everyone has their own strategy, so considering the parameter of where we are located and so on, the only way to survive and develop the company is to offer a better service than the other, better product than the other, the price will not be cheaper than another one but whoever buys a Socabelec robot knows they are buying the best equipment which gives back the maximum return on investment.”
Automated process Socabelec joined the container glass sector in 2011 after an invitation from Ardagh Group’s Moerdijk plant, The Netherlands, to manufacture an automated swabbing robot. Swabbing at this time was often done manually, which was hazardous and caused pollution. Manufacturers felt the process could be automated and wanted to swab on-the-fly to prevent the machinery having to be stopped and
new jobs because automation and robotics is the future. The robots do the repetitive jobs.
”
Advantages During his subsequent conversations with glass manufacturers Mr Veri would highlight the benefits of a swabbing robot. Alongside productivity gains, the robots reduce the chance of accidents because operators no longer have to swab manually. Automatic swabbing is also more environmentally friendly because there are less fumes from the process for operators to breathe. It also increases productivity because the machine is not stopped during swabbing. Mr Veri points out that the robot is more appropriate for a manufacturer with a pack to melt rate of 87-90%, particularly if they have to stop the section to swab or if they reject a lot of articles after swabbing to avoid contamination. A glassmaker with a pack to melt of 94% and above should not require a swabbing robot, he adds. Mr Veri is convinced robots will enhance people’s roles rather than take jobs away. “We know automation and robotics can end some jobs for operators but at the same time it creates new jobs because automation and robotics is the future. The robots do the repetitive jobs. “Where there are roles which require social contact then I recommend to put a human there. But with repetitive jobs then replace them with a machine.” After the successful installation at Moerdijk, Socabelec secured an OM agreement with Ardagh’s technical partner Heye International. Then in Continued>>
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The swabbing robot specialist
to also reduce the number of rejected bottles. An automated process would also mean more control over the amount of lubricant that needed to be sprayed onto the bottles. When sprayed manually, it was possible that each bottle would have a varied amount of lubricant sprayed onto it. At the time of the approach from Ardagh, Socabelec had been working as a robot manufacturer for the handling of flat glass and would often produce equipment on demand. Ardagh had already approached several companies in the container sector but all felt they were unable to help. However, one of those organisations recommended Socabelec for the job. At the time Socabelec soon realised that this was not just another job demand but was something that was as yet untapped by the market. Mr Veri said: “We realised that what we did in Moerdijk was the first in the world. No one had been able to swab equipment on the fly with a robot before. We checked the market and saw that what we did was like a revolution in the container glass industry. It was a big moment for us. “As a robot maker, when we saw the result in Moerdijk we were so proud about the robot’s efficiency. It can increase pack to melt by 2-4%, which can be a huge amount depending on the process.”
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company overview Socabelec.indd 2
15/03/2021 10:41:53
Company overview: Socabelec
* latest swabbing-robot installed in July 2017 in Germany
*
company overview Socabelec.indd 3
2015 it collaborated with oil lubricant supplier VDV Lubricants to tap into its global network of agents and contacts. At the same time it increased its visibility at glass exhibitions and as a result, began to have more meaningful conversations with customers. Since then business has rapidly increased, particularly in the last three years. More than 55 robots have been installed around the world, in places such as South Korea, Germany and the UK, at recognised glass manufacturers such as Encirc in the UK and SGD Pharma. The group will continue to serve the container glass sector and continue with the evolution of its swabbing robots. Its latest version, Version Six, is described as more intuitive and easy to use for operators and has a range of new features. In 2019 the group won a British Glass Focus award alongside its customer Encirc for its health and safety contribution to the glass manufacturing industry. It was proudest moment of Mr Veri’s nine years in the container sector. “I have won awards in the past but this one was the most important because it confirmed that we offer a product that helps people. We got this for health and safety action which means we are making a difference to operators’ lives.” �
Socabelec, Ham-sur-Sambre, Belgium www.socabelec.com Glass International March 2021
15/03/2021 10:42:15
www.growth-group.com
Don’t just look at it, look into it.
Tiama Xlab – the revolutionary 3D sampling solution Turn virtual reality into reality with the new Tiama Xlab. This highly flexible laboratory module can be installed at the hot end, the cold end or in the laboratory. It loads the container automatically and makes a 3D scan, generating an image composed of millions of facets. The 3D image can be rotated and “dissected” on all sides. Virtual volume, capacity, and vacuity can be measured as well as glass distribution fully mapped. You can also analyse engraving, embossing and much more. Practically all container types and shapes can be inspected and it’s non-destructive because the image (and not the container itself) is “cut” virtually. For an online presentation of the Tiama Xlab please contact us at marketing@tiama.com.
Data – the deciding factor
Recycling
With the right investment, MRF glass delivers on quality and quantity To do a difficult job well with outstanding results is very rewarding says Recresco director, Tim Gent.
collections provide reprocessors with clean material ideal for remelt into cullet with end use in the container industry and other high-end products. The average wine bottle in the UK contains on average 68% recycled material demonstrating how well the circular nature of glass works however, it’s important to remember that ‘clean’ glass is not the only option available. When it comes to the issue of quality, MRF glass is often disregarded by reprocessors for being unsuitable and too contaminated for remelt but as new technology and sorting systems emerge, this no longer needs to be the case. Glass from comingled collections is
mixed with a variety of other materials, compacted, crushed, broken and delivered to the MRF. The process causes heavy contamination with paper, cardboard, metal, heat resistant glass, plastics, toys, ceramics, porcelain just some of the items regularly identified. At the MRF everything that drops through the trommel (typically 40-50ml mesh) is considered ‘glass’ although it is often difficult for the naked eye to see any glass in the material at all. Historically this glass would have been rejected by reprocessors ultimately leading it to landfill or aggregate but today not only is Continued>>
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T
he effects of climate change and the environmental impact of human activity is now well known and this increased awareness has caused us to consider our behaviour as consumers; waste less, reuse more and recycle. We are all too aware that the items and products we use, the packaging they come in and the way in which we dispose of them directly affects the environment. When it comes to packaging, glass is the ultimate material; it is incredibly sustainable being 100% recyclable and capable of being re-melted endlessly without any loss of quality. The UK boasts an impressive glass recycling rate at 68.8% and the glass industry is fully committed to pushing this further by increasing the target to 90% by 2030. Recycling is positive; it’s good for the environment and encourages sustainability but as rates increase so too does demand for good quality cullet for the manufacture of new glass bottles, jars and fibre glass. When glass is recycled into new glass products, it saves around 246 kg of carbon dioxide emissions for every tonne re-melted while reducing energy consumption and the need for virgin raw materials. The glass industry agrees that driving glass into remelt is essential and this is a priority in the Glass industry decarbonisation action plan. For recycling purposes, hand separated
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it possible to use this material for remelt; it is possible to reprocess it to a standard comparable to that expected from clean, separated collections. Innovative sorting and cleaning technology makes what was once an impossible task, possible. Ground breaking machinery can produce the same yield from comingled collections as separated, making the 90% recycling target easily achievable. The ability to reprocess MRF glass to this standard is beneficial for both the industry and
34 0
the environment. It drives more glass into remelt over aggregate, resulting in less waste, fewer carbon emissions and reduced energy consumption. It also solves any issues of material availability for the industry. The glass industry agrees that re-melt must be prioritised and welcomed the increase in re-melt over aggregate targets for 2021-22 to 72%. By investing in the technology and systems that make it possible for MRF glass to be included in the remelt market, the industry can easily
meet and even exceed this target. The evolution of sorting technology makes it possible for glass recycling to enjoy both quality and quantity of material while meeting increased targets and exacting industry standards. Only by considering co-mingled material and investing in the technology to reprocess it effectively in a closed loop system, can glass be considered truly circular. �
Director, Recresco, UK www. recresco.com/
Ware Handling. Custom Design. Sweepout Assemblies. Innovation. Ware Transfer. Research Dura Temp Corporation and Development. Fingers and Pads. Expertise. Takeouts. Quality Materials. Quick-Change Hot Ware Handling Sweepouts. Mold Top Plates. Technical Support. Ware Handling. Custom Design. Sweepout Specialists Assemblies. Innovation. Ware Transfer. Research and Development. Fingers and Pads. Expertise. Customer Service. Takeouts. Quality Materials. Quick-Change Sweepouts. Mold Top Plates. Technical Support. Ware Handling. Custom Design. Sweepout Assemblies. Innovation. Ware Transfer. Research and Development. Fingers and Pads. Expertise. Customer Service. Takeouts. Quality Materials. Quick-Change Sweepouts. Mold Top Plates. Technical Support. IN 2021 Ware Handling. Custom Design. Sweepout Assemblies. Innovation. Ware Transfer. Research and Development. Fingers and Pads. Expertise. Customer Service. Takeouts. Quality Materials. Quick-Change Sweepouts. Mold Top Plates. Technical Support. Ware Handling. Custom Design. Sweepout Assemblies. Innovation. Ware Transfer. Research and Development. Fingers and Pads. Expertise. Customer Service. Takeouts. Quality Materials. Quick-Change Sweepouts. Mold Top Plates. Technical Support. Ware Handling. Custom Design. Sweepout Assemblies. Innovation. Ware Transfer. Research and Development. Fingers and Pads. Expertise. Customer Service. Takeouts. Quality Materials. Quick-Change Sweepouts. Mold Top Plates. Technical Support. Ware Handling. Custom Design. Sweepout Assemblies. Innovation. Ware Transfer. 949 S. McCord Road Research and Development. Fingers and Pads. Expertise. Customer Service. Takeouts. Holland, OH 43528 Quality USA +1-419-866-4348 Materials. TopOPlates. Ware Handling. W WQuick-Change W . D U RSweepouts. A T E MMold P.C M Technical Support.sales@duratemp.com Custom Design
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UK focus: Fives
Melting technologies to make change possible Andy Reynolds* explains why now is the perfect time to look at different glass melting solutions.
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I
t is generally accepted today that the world faces big challenges of which perhaps the most impending and significant is the threat of global warming. The manufacturing industry has a particular duty to clean-up it’s operations, and any supplier of process plant must strive to develop technologies that make such change possible. Extra impetus is provided today through growing public demand for more sustainable products. Glass manufacturing is energy intensive and so we must recognise our responsibilities. As a major supplier of glass melting technology, Fives is collaborating with end-users in many different glass sectors working on innovative solutions to meet the challenge.
A need for change Glass is a recyclable and potentially sustainable material whether used in packaging (containers), engineering (automotive/fibreglass), architecture, medical (vaccine vials), or electronic applications; yet today the primary
heat input to most melting furnaces still comes from burning fossil fuels. In terms of technical advancement, our industry could justifiably be labelled as conservative, perhaps understandable when extended furnace campaigns necessitate long-term commitment to a single melting technology. Ten to fifteen-year furnace campaigns favour risk mitigation by incremental change; when the relatively infrequent opportunities for advances do arise at rebuilds, departure from proven solutions have, to date, been difficult to rationalise. It could be argued that this evolutionary process has led us up ‘dead-ends’ in respect to the design of modern-day melting furnaces, dead-ends from which escape will require a ‘step-change’ in technology and perhaps also in our attitude to other factors such as campaign durations and in how we manage risk. As the rate of change of financial drivers is accelerating, the incentive to change our approach becomes ever more apparent. Relative cost of electricity and gas will alter, carbon taxation will increase
– perhaps multiple-fold. Incumbent technologies are at the risk of becoming obsolete or at least uneconomic within their next campaign.
Getting greener Fives is committed to a greener industry by developing more energy efficient technologies and environmentally sustainable processes. Its approach is underpinned by a strong commitment to innovation, developing tailored solutions rather than off-the-shelf proprietary systems. Within the field of glass manufacturing, it is focused on selected fields, including: � Improving combustive heating efficiency (furnaces and glass conditioning) � Advancing applications of electric boosting (including increasing energy inputs on float furnaces) � Up-scaling of all-electric melting technologies (principally for container applications) � Hybrid technologies (gas/electric)
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UK focus: Fives
� Fives BH-F Radiant Electric Forehearth.
� Prium Eco-Flex concept - 500 tonnes per day (CFD model of boost heat input).
Strategic partnerships with both endusers and other technology providers allow the right balance of theory and practical application. Fives’ objective is to provide flexible solutions which meet expectations of high-efficiency and low emissions. When developing new technologies, mitigation if risk is critical; Fives’ methodology is always to create proven building blocks from which larger significantly advanced systems can be assembled.
Advanced melting technologies The essence of our approach is characterised by the Prium Eco-Flex, a gas-electric hybrid furnace, capable of adaptation to a broad range of fuel input ratios up to 80% electric. Utilising its Heat Recovery Area (H.R.A.) technology where the crown and flue profile are modified to recover heat from waste gas and incorporating multi-zone super-boosting technology well established in the fibre industries, a revolutionary design is realised. Implementation risk is minimal
because each part of the design is proven, in addition, final securely can provided by relatively low-cost fall-back options. Fives works to extend the potential envelop of applications particularly into large container and float furnaces. All-electric melting is already well established within many glass sectors. Already proven as a highly energy efficiency, low polluting (zero combustive emissions), and relatively flexible option for melting of cosmetic, pharmaceutical, borosilicate and tableware glasses, the challenge now is to show that it can be cost effective for larger capacity container applications. Furnaces of 350 tonnes per day are entirely possible. The reluctance to move to electric melting is partly and justifiably due to questions relating to compositional flexibility (especially for reduced glasses), however such issues are completely solvable. The risk adverse nature of decision makers is perhaps more difficult to overcome; electric melting is still perceived as a high-risk option. And, a 350 tonnes per day tank is not such a big step from where we are today, indeed we believe it is well within the ‘design envelope’ current validated by the largest furnaces already in operation. The choice between all-electric and
hybrid furnaces, such as Prium Eco-Flex, may ultimately be determined by the required operational and compositional flexibilities. Hybrid designs provide greater flexibility in all aspects however, if the production regime offers a stable load with limited compositional variation, then there is nothing that will beat the energy efficiency and low emissions delivered by all-electric systems. Once melted, glass needs to be thermally conditioned and Fives is also engaged in developing improved all-electric and combined fuel/electric heating systems for working ends and forehearths; although in many applications the heat input in the forehearths is relatively low compared to that of the furnace, manufacturers are already realising there are potential benefits to applying new technology here too.
What’s next? The industry is looking for alternative combustive sources, such as biofuel or hydrogen, and Fives recognises that such fuels will certainly play a part in the future of glass melting. Electric melting will certainly play a major part too in both allelectric and hybrid solutions. Different batch formulations will also Continued>>
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in float and container sectors � Electrically heated glass conditioning systems (working ends and forehearths)
37 Glass International March 2021
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T hi si snotas ol arecl i ps e
Wi r eEdgedet ect i on
wi t hz er ocompr omi seby
UK focus: Fives
� Fives all-electric Cold-Top Vertical Melter (CTVM) under construction.
come in which reduce or eliminate CO2 liberated by the melting process itself. What is for sure is that glass melting in the future, based on a broad range of technologies, will achieved dramatic reductions in emissions from the levels of today. It is the time to act now and the responsibility for cleaner technologies falls on us all. Fives believe that industry can and will rise to meet today’s challenges; this belief, and our resolve to support change by delivering innovative world-leading solutions, not only for glass manufacturer but for many other industrial sectors, is symbolised in Fives’ motto ‘Industry Can Do It’. �
MOULDS
ANNEALING
PRE-HEATING
LEHRS
KILNS
HOT-END vidromecanica@vidromecanica.com www.vidromecanica.com
COATING
COLD-END
COATING
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* Business Development Director – Glass, Fives Stein Ltd., Didcot, Oxfordshire, UK https://www.fivesgroup.com/
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We print your world
Uniting inks and substrates to create a uniqueness, which is incomparable.
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Furnaces
Designing and implementing a high efficiency furnace system Cravero C., W. Battaglia, Mola A., Rollini M, and Spinelli L and E Cattaneo explain the criteria to apply a high efficiency air staging (HEAS) system on a furnace.
� Fig 1. HEAS system layout.
features a wider angle between the port axis and the duct (approximately 5° higher). It is worth pointing out that the experimental data acquired during the operational test campaigns on the Sagittario furnace showed a slight
underestimation of flow rates by the CFD simulations. This is likely due to the fact that in the initial CFD simulations “ideal” geometries were used, with sharp connections Continued>>
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A
hybrid melting furnace called Sagittario has been installed in the Vetrerie Meridionali (Ve.Me) plant in Castellana Grotte, Italy. Sagittario represents an evolution of the Centauro solution, developed by Stara Glass to separate the heat recovery system in two sections, a hightemperature ceramic regenerative and a low-temperature metal recuperative one. The hybrid (ceramic/metallic) furnace was specifically designed to limit polluting emissions (NOx). This is achieved through the integration of primary and secondary abatement technologies, which exploit the specific hybrid nature of the system. In particular, the furnace has been equipped with a system connecting combustion air and waste gas ports to create combustion staging (HEAS). In addition, a urea injection system has been installed at the base of the chambers, where the temperature is suitable for the Selective Non-Catalytic Reduction of nitrogen oxides (SNCR). This article will specifically analyse the set-up of the HEAS system and its performance under various operating conditions. The system is depicted in Fig.1 and designed using CFD techniques. The results of these simulations suggest that: The effectiveness of preheated air extraction by the compressed air ejectors is increased when the ejectors are located closer to the duct centre. The final air and waste gases mixing is more effective when the ejector is located closer to the port. Thus, a geometric compromise solution must be found to optimise overall performance. Compared to previous installations of the system, the Castellana Grotte system
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Furnaces
� Fig 2. Parametric analysis - Ejectors position.
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� Fig 3. Abatement yield and NOx trends.
between the surfaces. In real cases, the joints are smoothed and the resulting flow structure is less affected by reduced flow separations and re-circulations. See “Numerical prediction of the flow structure inside components of industrial glass furnace systems”, by C. Cravero et al. (WSEAS Transactions on Fluid Mechanics, Vol. 15, 2020, DOI: 10.37394/232013.2020.15.11) Experimental data and observations: Monitoring of flue gas composition and measurement methods The “Multipoint Continuous Monitoring (MCM)” method was used. With such approach the gaseous streams’ composition is continuously and simultaneously measured at different points of the heat recovery system. For this first monitoring campaign on the HEAS system, the most representative monitoring points were identified in the middle of the port neck and at the centre of the top regenerator chamber, just above
� Fig 4. state of the lance after removal.
the checkerworks. The exploited measurement principles were the following: � O2 concentration: paramagnetism � NOx concentration: chemiluminescence/non-dispersive infrared (NDIR) � CO concentration: non-dispersive infrared (NDIR)
First HEAS test campaign The “zero point” was initially measured in conditions of inactivity of the HEAS (with the duct between the ports closed by a refractory septum). Such operating condition was used as a reference for the estimate of the obtainable NOx abatement level. In addition, in the “zero point” conditions the composition of the flue gases in the top of the regenerator was also mapped. The resulting “measurement grid” showed a good homogeneity.
The acquired data show an increase of NOx concentrations moving from the port to the regenerator top, even with the HEAS offline. This is due to the fact that when the CO level is high, some slight “post-combustion” can take place at the expense of cold physiological air infiltrations. Measured NOx trends are in line with expectations, with values in the top regenerator chambers approximately 5-10% higher than those measured at the port. Once the situation had been characterised both with flames located on the left and on the right side, for simplicity the following measurements were carried out focusing exclusively on the right side of the furnace.
Continued>>
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2 wind turbines helped us improve our green credentials. With a potential 50% energy saving a System 500 forehearth conversion could improve yours.
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Furnaces
� Fig 5. Top regenerator - Single-hole “Lower” lance.
Pull [t/g]
NG flow rate [Sm³/h]
Electrical Boosting
kW cullet %
212 940
580
50
�T able 1.The main average process parameters during the experimental campaign on the HEAS system. condition
Right flue gas
HEAS
Left flames
Port-neck
Retro-camera
Zero point O2 %
1,11
1,12
CO Ppm
1900
132
NOx mg/Nm3rif
967 1038
Open duct O2 %
0,92
1,32
CO Ppm
3330
296
NOx mg/Nm3rif
768 828
50/20 O2 %
0,75
1,44
CO Ppm
3200
160
NOx mg/Nm3rif
829 800
100/20 O2 %
0,97
1,87
CO Ppm
3800
130
NOx mg/Nm3rif
695 730
150/20 O2 %
0,64
1,92
CO Ppm
5000
90
NOx mg/Nm3rif
630 705
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�Table 2. Summary of the measurements carried out under the different operating conditions. In addition to the zero point, the following four operational configurations of the HEAS system were tested: � Open duct: in this condition the refractory septum sealing the by-pass duct between the ports was removed, but the air ejection lances were not active; � 50/20: in this condition, the “driving” lance ejector flow rate was set at 50 m3/h, while the lance acting opposite the bypass flow (braking) was set at the minimum flow for cooling of the ejection nozzle, i.e. 20 m3/h; � 100/20: “driving” ejector lance set at 100 m3/h, “braking” lance at minimum
(20 m3/h); � 150/20: “driving” ejector lance set at 150 m3/h, “braking” lance at minimum (20 m3/h); Table 1 shows the main average process parameters during the days of experimental campaigns on the HEAS system. Table 2 summarises the measurements carried out under the different operating conditions. Fig 3 illustrates the abatement performance in the different configurations reported in Table 2:
the orange curve indicates the NOx concentrations; the green curve represents the abatement percentages referred to the zero point. The double abatement figures reported on the plot refer to two different reference values: zero-point NOx average and zero-point NOx central value. Fig. 3 shows how the opening of the bypass duct alone allows sufficient recirculation to obtain a reduction of about 15-20%. The other three tested conditions describe situations of mild (50/20), intermediate (100/20) and heavy (150/20) HEAS use, respectively. At 150/20 a NOx concentration of 705 mg/Nm3 @ 8% O2 was reached in the top chamber, which corresponds to a reduction of around 30%. Table 2 shows that the starting CO concentration in the port increases with the degree of use of the HEAS system. In fact, increasing the flow rate of compressed air ejected into the duct (50, 100, 150 m3/h) raises the quantity of preheated air bypassed directly into the final part of the flue gases port; therefore, increasing compressed air flow rates also decreases the oxygen excess in the combustion chamber, with a consequent reduction in the value of NOx in the port and greater production of CO, reaching up to 3200, 3800 and 5000 ppm in the three tested configurations, yet assuring limited CO values on the regenerator top.
Second HEAS testing campaign A further week of onsite testing took place in September 2020. The significant time interval was due to restrictions caused by the first wave of the COVID-19 pandemic. In addition to performance testing, this campaign was focused on assessing the Continued>>
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W12 12
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Furnaces
CONDITION HEAS
Higher Single hole lance
Left flue gas
Right flue gas
Port-neck
Port-neck
RC
RC
O2 %
0.33 1.37 0.21 1.23
CO Ppm
5375
NOx mg/Nm3rif
729 775 699 765
O2 %
0.29 1.42 0.20 1.66
CO Ppm
5300
NOx mg/Nm3rif
733 772 592 626
O2 %
0.37 1.17 0.27 1.47
CO Ppm
4682
NOx mg/Nm3rif
788 776 577 664
O2 %
0.34 1.26 0.32 1.71
CO ppm
4994
NOx mg/Nm3rif
709 713 624 689
O2 %
0.31 1.16 0.30 1.60
CO ppm
5117
NOx mg/Nm3rif
652 666 649 709
80 – 20
120 – 20
80 – 20
Lower Single hole lance
120 – 20
160 - 20
615
322
576
239
120
5989
6229
6246
5893
6000
840
397
660
258
145
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�Table 3. Overview of monitoring data. effect of different air lances geometries. On this occasion, the previously installed lances, which had been working continuously for more than eight months, were inspected. Fig 4 displays a lance just removed from the duct: the condition of the lance was satisfactory and no particular damage is observed. In regular lances (Fig. 4) the jet is placed in a symmetrical fashion inside the duct. In this campaign, we tested new lances of smaller dimensions and having more inclined jets, which were expected to propel more efficiently the preheated air present in the duct. CFD simulations of the two solutions predicted slightly overall better performances with the new “lower” and less “symmetrical” ejectors. A possible additional advantage expected from this arrangement is that it offers less exposure to combustion air. Consequently, a longer service life and less maintenance is expected. The results of the new tests carried out on site are shown in Table 3. It should be remembered that in this case, without a real “zero point” (i.e. sealed bypass duct) available, the driving/braking lances
configuration 80/20 m3/h was assumed as the reference condition to which the new results were compared. Two operating conditions (20-80 and 20-120) were analysed. Also, a more extreme 20-160 configuration was also tested for the “low” lance. This further configuration, while showing a significant reduction in CO levels in the top chamber, produced an impact on furnace and top regenerator temperatures that was deemed undesirable, and therefore was abandoned. Owing to the better overall results, it was jointly decided to keep the new “lowasymmetric” lances installed for the time being, and operate them between the 20/80 and 20/120 m3/h configurations, which provided the best compromise between environmental and energy performances. The two graphs below show the trends in the concentrations of O2, CO and NOx detected in the combustion gases respectively in the port and at the centre of regenerator top chamber during the experiments with the new “lowasymmetric” lances. The graphs cover six inversion cycles,
three with right and three with left flames. The first two cycles were carried out in configuration 20-80 m3/h, while the second two used configuration 20120 m3/h. The last two cycles featured 20 -160 m3/h configuration. The effect of increasing the driving jet flow rates is clearly evident not only on NOx reduction, but particularly on CO abatement. This is achieved through an increase in the bypass flow and also, as mentioned, through an increase in the mixing between the primary flue gases and bypass post-combustion air streams.
Conclusions Overall, the results of the experimental campaigns confirm that the HEAS combustion staging technique allows achieving a relevant reduction in NOx production through primary measures, without posing any sizeable harm to the chamber refractories. CFD simulation techniques, finetuned thanks to the feedback gathered from measurements, have proven to be an important asset for the design of the HEAS system and for its operational control. A satisfactory agreement has been found between model predictions and measured data. Further test campaigns are planned, in particular concerning other new modified lance geometries, and will be carried out as soon as the COVID emergency will allow. �
*Battaglia W., Stazione Sperimentale del Vetro scpa, Cravero C., Università degli Studi di Genova, Mola A., SGRpro, Rollini M., O-I Manufacturing, Spinelli L., Vetrerie Meridionali, Cattaneo, E., Stara Glass. https://www.spevetro.it/ https://unige.it/it/ www.o-i.com https://www.staraglass.it/ - Genova, Italy
ABOUT VETRERIE MERIDIONALI Vetrerie Meridionali has been active for for more than 50 years in the production of glass containers for food and beverages; in particular in the segments of the production of bottles for wine, oil, tomato puree, fruit juices, aperitifs, mineral waters and soft drinks. The plant covers an area of approximately 89,000m2 of which approximately 41,000m2 are covered. The glass manufacturer is 50% owned by Finista Holding and 50% owned by O-I.
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Refractories
Measuring radar thickness in tank melters Fernando Salvino* explains how the use of a tool like Refractories Thickness Measurements is useful during the monitoring of the lifetime of the furnace.
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W
e know that in a glass furnace, the most worn part during a campaign is the flux-line (or metal line). This is a critical point, the bottleneck of the furnace, in relation to the lifetime. Other critical point is the throat (used in furnaces for bottles or fibres, for example). Crowns, breastwalls and frontwalls can last multiple campaigns, but the flux-line does not last long. A widely used resource to reach a few more years at this zone is the overcoating. And for overcoating, the later it is, the better the use of them. It is currently possible to make up to four overcoatings in the same region thus extending several years of campaign. The limitation is due to the lack of space between the soldier block and the steel structure of the breastwall. Another possibility is to install three overcoatings and a water jacket, if you want to extend the life of the furnace even longer (attention to increased energy consumption due to cooling caused by the water jacket). But what are the ways to detect wear points, with the furnace in operation and exposed to high temperatures, and to be able to act before a major evolution occurs and an accident such as leakage of the
furnace, or collapse? A good way to know when an overcoating or a hot repair must be done is using refractories measurements. We can classify in four types of measurements: � Red points: in a tank melter (sidewalls – or soldiers blocks) for example, as soon as a red spot is noticed, ventilation must be increased, and when the increase in ventilation does not work, we can accomplish an overcoating. The guidance by red points is not very predictable and accurate. � Soldier block thickness measurement with tools: we open a region determined in the tuck line blocks (through sealing blocks), and is measured with adapted tools, the remaining thickness of the soldier block on the flux-line. It is a very aggressive method to operators, because it requires opening refractories, strain to heat, and the most complicated as it can generate moments of pollution in the glass, because some particles of refractories fall into the bath, and can cause defects. The opening of these points is not so easy, and we open only a few areas. In this case it is not possible to have a
measurement of the entire tank melter, but only of the opened points during the measurement. � Thermography: by measuring temperatures (with thermography cameras) one can have a more accurate view of the wear of the analysed region (tank melter, walls, crowns). But it is an indirect method and may undergo changes due to cooling interference or even due to temperature differences due to weather. � Radar thickness measurement: direct measurement by radar waves, without the need for opening in the refractories, i.e., without risk of pollution in the glass, and without any interference from other items, such as interference by the cooling. Through this technology, one can measure various parts of furnaces, such as flux-line, throat, bottom, crowns and walls (for crowns this system still in development). Another advantage of this type of measurement is not to be destructive. It is not necessary to make any opening in the refractories, or a dangerous drilling with diamond drills. The measurement is faster than in other methods, and you can
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Refractories
measure several points in the same day. � Fig 1 Radar Thickness Measurement on the flux line.
� Bottom wear thickness measurements: before this radar measurements technology, the only way to perform a measurement of the thickness of a bottom, was by drilling (carrotage), where through a drill with diamond drill type saw. In this case a hole is made until it reaches the glass, and collects all layers of insulation and refractories that accumulate inside the drill, during drilling. This allows you to measure a point, and determine the remaining thickness of refractory and insulation remaining at this point. To have a more comprehensive measurement, additional points are required, which makes a difficult and dangerous operation – with a risk of glass leakage, or personal accident. Comparing the four methods described above, it is apparent that the Radar Continued>>
� Fig 3. Another shot of radar thickness measurement using tomography.
� Fig 2. Radar Thickness
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Measurement - RTS Sensor.
� Fig 5. Data presentation of the XSight Furnace Health Platform Software.
� Fig 4. Bottom measurement, directly onto metallic grids.
49 Glass International March 2021
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Refractories
� Fig 6. Imaging of affected areas using the XSight Furnace Health Platform software.
is advisable mainly in float furnaces – due to the large dimensions of a crown of a furnace of this type. Through endoscopy you can identify the critical points, and at this point the thickness measurements are made, thus detecting some point that requires special treatment, such as removal of the insulation, cooling installation, or the ceramic welding – all to prevent a progression of the affected area and consequently an opening of the worn point.
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XSight Furnace Health Platform: results and analysis of inspection data
Thickness Measurement Method is the most efficient and most reliable, so we will detail it further now.
Other areas this sensor is used on include overcoats, bubbler and electrode blocks as well as AZS throats.
SmartMelter
2) Furnace Tomography Sensor (FTS): through computer tomography, the sensor indicates the remaining insulation thickness, and some infiltration or wear may be noted in the insulation (see Fig 3 above). These two systems are not interfered with by other elements, so nothing needs to be turned off during measurements such as cooling air, cooling water, electric-boosting or bubblers. Of course, for safety reasons, the electrodes should be switched off if the technicians are going to access the area directly adjacent to the electrodes, and of course, if the point to be measured is an electrode block. As there is also no generation of debris in the glass, measurements can be performed during normal production, without the need to wait for the periods of colour transition. RTS and FTS sensors are resistant to high furnace temperatures, adapted for on-site measurements, and can survive surfaces up to 1000oC (1832oF). Best results are achieved if the surface being measured is below 500oC even if only temporarily. Both RTS and FTS sensors are as secure as using a cell phone, and their radio power is much lower than a cell phone. Another advantage of this system is that measurements can be made directly on some metallic grids - there is no need to remove them. The software can detect the different layers, including the metal infiltration. For a crown inspection, an endoscopy
It is safe to say that the method of measuring thickness by radar is a recent development in the glass industry. Some glass companies have developed this technology internally, and keep it as a precious secret. But there is already a technology developed and accessible to the world, through SmartMelter developed by PaneraTech. SmartMelter uses radar technology, and computer tomography, in order to be able to measure the complete thickness of a furnace, or certain areas of it. For a measurement of the tank, for example, it is possible to obtain all the measurements of thickness of a sidewall, at various levels, not only at the flux-line, but also to measure thicknesses below the metal line up to the glass contact material, even covered by layers of insulation. Looking for glass infiltration, or wear that has passed through the tank and will lead to a leak. Thicknesses of various critical parts of the furnaces can be measured, not only of the sidewalls, but also of the throat, bottom and other high wear areas. There are two types of radar measurement by SmartMelter: 1) Refractory Thickness Sensor (RTS): the sensor performs the measurement of the remaining thickness, directly measuring the remaining refractory of high wear areas such as the flux line (or flotation line) – i.e. the most critical point, or the most critical zone of a glass furnace (see Fig 2 above).
After the data is collected during the inspection with the sensors - RTS or FTS and uploaded to PaneraTech - the data are processed and examined by radar experts with PhDs. The results and recommendations are presented through the SmartMelter XSight Furnace Health Platform software. The Smartmelter package presents results with images, facilitating decisionmaking, such as increased air-cooling, overcoating, or a hot repair, as ceramic welding or a hot bottom repair.
Conclusion Thickness measurement is widely used in glass factories, but by very destructive, hard and even dangerous methods, such as bottom drilling for sampling the remaining thickness. With the advent of new radar technology, better results are obtained, faster, safer and less painful, both for technicians, as for the furnace and its production. The use of a tool like Refractories Thickness Measurements, measurement and data processing, is very useful during the monitoring of the lifetime of the furnace, following maintenance planning, and even deciding when to schedule the reconstruction of furnace, as well what parts will be repaired or replaced during the cold repair. More information can be found by visiting: www.smartmelter.com �
*Engineering and Technical Support for Glass Furnaces fernando.salvino@hotmail.com Full bio at: www.linkedin.com/in/ fernando-salvino-b338ab27/
All images courtesy of PaneraTech.
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Refractories
BRISE: A borderless refractory inspection service Jérôme Canaguier* discusses a borderless inspection service which couples patience and experience and can help reduce glass defects generated by fused-cast AZS.
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he Covid-19 pandemic has drastically reduced the ability to inspect blocks on site, and as Chinese suppliers are not really sensitive to deliver defect-free sets of blocks, we have established our base camp in Hunan for the whole year 2021. That enables us to inspect, any time, any Chinese fused-cast AZS supplier, to detect on average 300-500 defects for each set of 200 tonnes, according to our recent inspections and to accompany them to eliminate all those defects. Each remaining defect, a joint out of specification, a step between blocks, cracks, porosity, broken corners or edges will accelerate turbulence in the atmosphere and glass infiltration for glass contact parts, which will create a hot spot in your melting tank, reducing by one year or sometimes more the troublefree life of your production tool, which strongly affect your Capex and Opex. In the worst case, it will create a leakage in your glass melting tank, resulting in the stop of your production tool, which has happened several times in the past four years in France alone.
the real blocks to fit with their drawings and specification. How do we eliminate all remaining defects on simple fused-cast AZS target wall? Eyes and more than 200 inspections are our main tools. Fig. 1 shows the defects’ inventory found after three days on-site.
Identificaton of defects in a set of fused-cast AZS blocks
When the Masso team has arrived on site, we have checked each block one by one. Checking dimensions of assembled target walls, evaluation of broken corners and edges, porosities, cracks, graphite and iron zones, joints and steps between blocks. Blocks presents four types of faces: the hot face, the side faces, the top faces and the cold faces. Here are our comments about side face porosities. Block A9 should be accepted this time, otherwise 20% of the side faces have to be rejected. It shows a porosity of 7mm long, but not deep, in a place not close to hot face. It shows several bubbles, less than 3 mm, the area close to the hot face is homogeneous enough to resist the
Broken corners, broken edge, cracks, porosities, graphite and iron traces, steps, joints are the main defects for a set of fusedcast AZS blocks. We also inspect Silica, Chrome, Magnesia, Sillimanite, Alumina according to your own specification. Glass producers place orders for a set of fused-cast AZS blocks. They have followed our suggested 3SQC - presented in the February issue of Glass International and reduce the glass defects generated by fused-cast AZS defective blocks, from a chemical point of view. Now, glass producers need to eliminate all aspect defects to have a safe furnace, without rat holes, without leakage points. They need
52 0 Glass International March 2021
� Fig.1 Defects’ inventory on fused-cast AZS blocks.
erosion against the flue gases. We divided porosities found into two categories: those that Masso considers critical, and the other category, less critical those that are function of your experience and the discussion with the AZS supplier. If more than two porosities > 4mm are near to the hot face (2cm) of a visible face, we consider this defect as critical. The network of small bubble just below the AZS skin is not considered critical. Here are our comments about cold face porosities. Defects are judged critical if at least 10mm visible shrinkage cavity is measured with metallic rod. Defects are judged non-critical if less than 10mm visible shrinkage cavity is measured. The identification and localisation of defects for the target wall N°1 is presented in table 1. Dimensions are not presented here, for confidentiality. A25 is within the spec. but right in the middle of the wall, facing the highest combustion gases/dust flow, especially port N°1, rich in batch dust. So, we reject it. Our general remarks to the producer: 1. No fat belly effect on the bottom target walls, grind the face in contact with barrier wall, cover-joints, electrodes holes, do not grind glass contact faces. 2. GPRS scan shall be used for all glass contact faces at the bottom and at the top of tank blocks. Blocks with remaining porosities should be either replaced or put in the coldest part of the tank. 3. Maximum joint’s opening allowed between paving blocks should fit: 80% < 0,6 mm, 100% < 0,9 mm. 4. Maximum joint’s opening allowed between side wall blocks should fit: 80% < 0,5 mm, 100% < 0,7 mm. 5. No graphite-grey-black areas allowed, reject all blocks that may show it (we have not checked mating faces). 6. Dimensions according to Excel file, wait for The AZS supplier/Jerome feedback
Refractories
HOT FACE
COLD FACE
SIDE & TOP FACES
TOP & BOTTOM Broken corner
A133: b30 x a20 x c15
A80: a22 x c16
A21: b90 x a30 x c5
A25: a18 x c18 x b22
Broken edge
A139: d10 x z30
A19: d8 x z60 (photo 5)
A3: d20 x z50
Porosities, critical
A7 (photo 7),
A20 (photo 15),
A41 (photo 16),
A119
A32 (photo 8)
A96
Porosities, less critical
A139, A9 (photo 6),
A133, A140 (photo 11),
A55, A84, A105, A9,
A83, A138
A1, A20
Joints 0,75mm
A21-22, A9-10, A6-7,
A32-33
A89-90, A134-A133,
A55-56
A126-127, A100-101
Joints 1mm
A55-56
A82-83
A139-140 A135-136
A129-138 A131-132 A96-104 Joints 1,5mm
A134-135
A131-139 A139-140
A134-135
A96-104
Elimination of each individual defect
A115-116 Steps
A60-61, A19-20 A8-18,
A57-58 3mm
A1-9 1,5mm
A116-124, A118-119
A33-39 3mm
A135-136, 1,5mm
A103-104, A60-72: 4mm
A115-116 3mm
A132-140, 2,5mm
A119-120 A95-103 5mm
A103-104 5mm
Cracks
A129
� Table 1. Identification and localisation of defects. TARGET WALL N°1 Broken corner
HOT FACE
COLD FACE
SIDE & TOP FACES
A133 R A80 R A21 R A25 R
Broken edge Porosities, critical
A139 R A3 W
A19 R
A7 R A41 R A32 R
A20 R A119 R
A96 R
A139 W
A133 W A140 W
A55 W A3 W
A83 W A138 W
A1 W A20 W
Porosities, less critical blocks 462 mm long
Joints 0,75mm
A21-22S A9-10 G A6-7
A32-33 G
A89-90 G A134-A133 G
A55-56 G
A126-127 G A100-101 G A55-56 G A139-140 G
A82-83 G
A129-138 G A131-132 G
A135-136 G
A96-104 G
Joints 1,5mm
A134-135 G
A134-135 G
A131-139 G
A139-140 G
A96-104 G
A115-116 G
Steps
A60-61 G 9-20 G 8-18 G
A57-58 G
A1-9 G
116-124 G 118-119 G
A33-39 G
A135-136 G
103-104 G 60-72 G
A115-116 G
A132-140 G
119-120 G 95-103 G
A103-104 G
Cracks
Only by staying on site and careful guidance, can you adjust all blocks, or ask their reproduction, or grind them. This checking service requires four to five weeks. Each defect previously detected will be identified and eliminated with careful checking because sometimes, the same block will be presented, in the hope that you don’t see the defect. Sometimes, that is acceptable, in the case of joint’s adjustment, but often it is not acceptable. Patience and experience are key (Table 2). On the target wall N°1, 61 actions have been decided after Masso inspection >> 52 defects have been removed, either by reproduction or by grinding + 9 blocks to be weighed, so that we could validate the absence of casting cavities in their microstructure.
3. Conclusion:
Joints 1mm
7. All joints under 0,75 mm except below D43-D49, 1 mm maximum. 8. Broken edge d=width, z=length, d<10mm, z<50mm 9. Broken corner a=height, b=width, c=depth, a&c < 20mm a+b+c < 80mm on hot faces 10.If hot face is fully grinded, we reject block, this peep hole block is not rejected as only small areas have been grinded. 11. Small grinding max 2mm wide allowed to decrease offsets (steps) between blocks. Max 3mm hot face, max 2mm cold face, max 1mm top and side faces 12. During the dismantling, send pictures of 6 faces for F75, F80, H49, C91, C89, C75 to qualify or reject them. 13. We could not check cold faces of blocks hidden by Polystyrene. The AZS supplier will send a checking list indicating, for each block, if it is free of crack, it has small dimension crack (length?) or it has a long crack (length?)
A129 R
� Table 2. Elimination of each defect with R (reproduction), G (grind) or W (weigh).
BRISE, the defects’killer, the nightmare of fused-cast AZS producers The plant manager of a fused-cast AZS producer is generally reluctant to eliminate those defects if no one push them to do, which is human. They will all tell you that in China, those defects would be accepted. Only our presence and guidance can help them to deliver good quality set of AZS blocks as per your wishes. Continued>>
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TARGET WALL N°1
53 Glass International March 2021
Refractories
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Our inspection team is now based in Hunan province, China so we are ready to check the quality of your blocks, reduce risks generated by fused-cast AZS before the casting of blocks, with a strict three step quality control procedure and then with the elimination of any remaining defects, until the very last defect. On 14
54 0 Glass International March 2021
target walls, we have recently eliminated more than 400 defects. Your Capex optimisation is priceless, one year less furnace life is a huge financial loss. Your Opex reduction is also very important, each defective blocks generating turbulence, hot spots
increasing your gas consumption. �
*Ceramic engineer ENSCI, Head of Refractory Solution department, Comercial Quimica Masso https://www.cqmasso.com/en/
Decoration
Inkcups introduces the Double Helix Global printing industry specialist Inkcups has released the latest addition to its Helix line of products: the Double Helix.
T
steel tumblers, pint glasses, beer cans, wine and spirit bottles, sports bottles and much more. “We are really excited to launch the Double Helix to the drinkware and industrial markets, and expect that it will be a major success. Our Helix printer is an amazing product for digitally printing with full colour images but it’s speed does not satisfy all the needs in
the market. The Double Helix will help our customers generate more revenue by getting increasing throughput and opening up new profit opportunities for higher volume printing,” said Ben Adner, CEO of Inkcups. The Double Helix is compatible with Inkcups’ full line-up of UV digital ink. With a printable area of 8.6 inches, this machine can print on items up to 12 inches in length with a diameter of 2-5 inches using design techniques such as spot varnish, tip-to-tip printing, mirror print, contour print and more. Other highlights of this machine include the ability to add the new and patented Transparent Pin Curing (TPC) system for transparent drinkware items as well as integrating pre-treatment processes. Delivered as a turnkey package with Inkcups world-class InkcupCare warranty and service coverage, the Double Helix is engineered and manufactured in the US and available for order now. �
Inkcups, Danvers, MA, USA www.inkcups.com
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he Double Helix features two sideby-side print stations that are able to simultaneously print the same artwork on two of the same vessels. These print stations have the ability to print superior quality, full-colour (CMYKWW+V) images on straightwalled and tapered cylinders. With this high-speed printing system, customers can focus and target medium to highervolume print runs. Fast and flexible just like the flagship Helix, the Double Helix can print fullcolour seamless graphics at around 6 to 8 parts per minute depending on artwork size. This new machine is ideal for use with drinkware, barware, spirits, craft beer, candle holders, and many other industrial cylinder printing applications. In these fields, typical end products include high quality graphics on stainless
55 Glass International March 2021
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Inspection
Advanced evolution of glass container inspection Hans Renders* discusses how the SmartLine 2nd generation starwheel inspection successfully combines speed, reliability and flexibility to deliver accurate results. Customers award top marks for Heye’s SmartLine 2 with the camera based check inspection system Ranger 2.
S
martLine 2 is the latest generation of Heye’s starwheel inspection machine series. Developed and manufactured at Heye International’s dedicated Cold End Centre in Nienburg, Germany, SmartLine 2 glass container inspection equipment can be configured in several ways, with up to six inspection stations available. The Nienburg facility employs a team of experts and features a modern production layout. Importantly, the centre is close to the Ardagh Group’s Nienburg glassworks to undertake essential testing work.
� Ranger 2 (Roboter).
Camera check inspection by Ranger 2 Equipped with camera based check inspection system Ranger 2, customers all over the world have confirmed the SmartLine 2 robustness and reliability. Heye’s Ranger 2 detect more than 99.8% of all critical defects. Ranger 2 is now able to inspect pharmaceutical mini-ware. With this evolution the system can fulfill all customer requirements to container sizes and shapes.
Non round
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How Ranger 2 works Each system inspects independently and does not have to be synchronised with others. So there is no influence between the systems and there is no need to compromise one system in favour of another. This allows an individual optimisation of all settings, e.g. lighting, camera position etc., on the respective type of crack. If one system is not available or is not optimally adjusted, the others are still fully functional. Every container produced must be considered unique and every concept of a crack test must take this into account. Therefore, the Ranger 2 uses the concept
� SmartLine 2.
of Intelligent Cloud Masking concept, which makes any kind of ‘teaching’ superfluous after a job change. Assuming that each container is unique, the Ranger 2 inspects each container for itself and sets one mask for each single container. Therefore, each container is its own reference and has no negative influence on the following ones. So the zones are subject inspection of high dynamics and can immediately adapt to changes that occur during production.
Container shapes, which differ from the standard round container, are one of the most common tasks in the glass container inspection industry. Heye masters this ‘non-rounds’ with the known excellence. The range of inspectable container sizes and shapes is above the average, inspection is possible with almost all imaginable shapes, no matter if they are angular, oval or simply round. With this huge range of testable container sizes and forms, the SmartLine 2 matches the market approach to be a real universal check inspection machine.
Improved job change times The application of servo technology results in a high degree of flexibility. Fast and easy changes to an item’s indexing positions and optimal use of the servo torque for up to four rotation stations are possible. Optimised motion sequences allow faster reactions to changing process parameters. The equipment’s innovative design and its large and easy-to-open hood
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provide more working space between the inspection stations. Job changes become much easier. The maximum article height accommodated is up to 450mm, with angular, oval and round containers processed. Thanks to the servo-driven starwheel, indexing positions from six to 48 are possible.
User interface The new design of the graphical user interface of SmartLine 2 has been conceptualised in cooperation with a specialised engineering service provider. The main goal of the development was a practicable and fast operating interface. Orientation for the development amount is coming from our customers. The twoclick-management is only one of many advantages next to smart configuration and a great overview over all statistics an operator needs for easy-to-use handling. Job history is even customised for: � Quality requirements � Setups � Reproducibility data
Feedback generated from Heye International customers has confirmed the SmartLine equipment’s robustness and reliability. The mechanical design and drive system in particular are highlighted for their robust design, while the control system is praised for its reliable operation. �
*Head of Product Management, Heye International, Obernkirchen, Germany tel: +49 5724 26-0 email: marketing@heye-international.com web: www.heye-international.com
Rosario high speed screen printing machinery
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Inspection Heye.indd 2
Curvink is exclusive agent for the glass bottle manufacturing industry worldwide for
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Palletizing- and depalletizing equipment for decoration lines
GmbH
12-02-2021 12:39
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UK overview: SGT
SGT plots future glass meetings T he pandemic seems to have put a dampener on activities in 2021 after a dismal 2020 for face-to-face meetings. Teams and Zoom are the default routes to seeing the faces you would normally see in the flesh at gatherings, committees, seminars and conferences. The Society of Glass Technology made some tough decisions in early 2021 in the light of restrictions to travel. Vaccines may allow workplaces and venues to open but the timing means there is little leeway to plan and commit to booking conference spaces. Furnace Solutions is seeking a new home, the long term established host Lucideon is converting the meetings room, that has hosted the event since 2006, into more office space in order to make employees distanced and safe. There is suitable conference space a very short distance from Lucideon but this has not opened like many potential venues because of UK lockdown measures. Other solutions are being sought including
to meet the demand to report on activities and research progress. Other online content is in discussion for September. The Heritage and History committee led by Professor John Parker is to hold an afternoon presentation on recycling glass through the ages in June 2021. Glass has always been re-used, Colin Brain and two other speakers will look back at the ages when glass was recycled up to the present day and the availability of current glass resources for artists. Exact date to be confirmed soon. The Tenth International Conference on Borate Glasses, Crystals and Melts and Third International Conference on Phosphate Materials, Corning, USA has been rescheduled for 17–21 July 2023. The SGT has been an active supporter of this conference since hosting the Second Borates conference in 1996. �
relocating to a centre for glass making along the M62 corridor. Furnace Solutions will not go ahead in June as a face-to-face meeting, instead there will be some online presentations in the afternoon of 9 and 10 June.
Physics of Non-Crystalline Solids Conference The SGT is the host of the 16th edition of this conference series, the organising committee has decided to postpone the event and have negotiated new dates with the venue. The meeting will now be on 10–16 July 2022 at the University of Kent in Canterbury. The event now follows the International Congress on Glass held in Berlin the week before. The 2021 Society of Glass Technology Annual Meeting was going to be held in conjunction with the PNCS conference in Canterbury and the frequent Murray Edwards Cambridge venue has been booked for 2022. There will be a Heritage and History online meeting in September
Society of Glass Technology, Chapeltown, Sheffield,UK www.sgt.org
Tableware
Handling / Assembly
Container Glass Beverage Processing
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Bulk Materials We are your partner for innovative and customized solutions in automation technology.
futronic GmbH | Tolnauer Straße 3- 4 | 88069 Tettnang Tel. +49 7542 5307- 0 | info@futronic.de | www.futronic.de
automation in a new dimension
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History
Prof. John Parker
Feeling the heat M
y dictionary defines the prefix ‘infra’ as meaning ‘below’ or ‘beneath’. Specifically, the term infrared (IR), created in 1873, refers to radiation with a lower frequency than red light. Sir William Herschel, an astronomer, had in 1800 described these invisible waves capable of heating a thermometer and anyone relaxing by a bonfire on an autumnal evening will undoubtedly acknowledge their existence. Light and IR are now recognised as parts of a wider spectrum of electromagnetic waves; IR has wavelengths from 0.8μm to 1mm. As a youngster I learned that IR was linked to heat and believed that solids – even glass - were opaque. That puzzled me - my glass lens could certainly focus the sun’s rays and ignite combustible materials. Later, I realised that visible light and IR were a continuum - of frequency and behaviour. Light also caused heating while my lens transmitted some IR. The temperature of a heat source defines the wavelength distribution of energy it emits; understanding this relationship helped develop quantum physics. The sun’s surface is hot, around 6000°C, and the emitted radiation is most intense in the middle of the visible range (0.5μm). Even so, over half the sun’s energy reaching us is infrared. Because our body temperature is much lower (unless very seriously ill!) we emit IR at much longer wavelengths (peak at 10μm). Our glass windows transmit most of the sun’s radiated energy but absorb or reflect our long wavelength radiated body heat (causing the greenhouse effect). Windows are transparent at shorter wavelengths but completely opaque by 4.5μm when the corresponding frequencies match those of atomic vibrations. Double glazing often has a thin silver coating to reflect more of the shorter IR
wavelengths back into the room. CO2 absorbs at 2.7, 4.3 and 15μm, reducing heat loss from the earth’s surface and causing global warming by the same greenhouse effect. Water absorbs at 2.9μm and is another potent greenhouse gas; because its concentration depends on temperature it amplifies the heating effect of CO2. Water is also present at low concentrations in glass, identifiable by its signature IR absorption. Weaker absorptions at half this wavelength are linked to overtones – atomic vibrations at double the frequency, half the wavelength. Using a musical analogue, when a guitarist or violinist touches/stops a string at its centre it vibrates with half the wavelength and sound a note an octave higher. Optical communication fibres operate at 1.55μm, in a window bounded by OH vibrations on one side and structural vibrations on the other. Other impurities in glass also absorb IR. A particular issue is iron. Ferric iron (Fe3+) does not absorb strongly in the IR but Fe2+ does. Specifically, it blocks part of the sun’s radiation at key wavelengths (1μm) which activate silicon photovoltaic cells. So low iron sands are used for glass PV cover sheets – down to 60ppm, compared with 300ppm for high quality containers. Secondly the iron needs to be in its 3+ state. Interestingly communications optical fibres are made by a chemical vapour deposition process which is costly but achieves iron concentrations below <0.1 ppb! Because of its manufacturing route, vitreous silica is purer and more transparent than a conventional glass. It also needs a much higher working temperature. So, for lampworkers, IR radiation presents a serious burns risk, for example when waveguided along a rod. IR radiation is vital in combustion.
Small, incompletely oxidised carbon particles are efficient emitters of both visible and IR radiation, much better than gaseous combustion products. Glass makers traditionally preferred luminous flames and the change from oil to natural gas 50 years ago caused considerable angst because atomised oil droplets naturally led to higher flame luminosities than gaseous combustion. So burners were engineered to create gas eddies where soot particles formed. A fascinating connection exists between dusty interstellar space and glass furnaces. The mathematics for the former has explained thermal energy transport in the later. In a glass furnace the near IR absorption of ferrous ion overlaps the peak energy of radiation emitted by flames at their operating temperatures and so energy is absorbed, re-emitted and absorbed again; this impacts on heat transport and the vertical temperature gradient in the bath. Consequently, control of total iron content in the batch along with its redox is critical in the flat glass industry which relies on undisturbed convection flows for mixing. Inevitably over time my childhood glass lens mentioned in the introduction has been re-imagined. A project in Granada, Spain uses curved mirrors for focussing. The mirrors, 620 000 in total, can track the sun and are strategically placed in a huge, landscaped basin. The focal point is a collector at the top of a tall tower where temperatures can reach 3000°C. A steam turbine creates electrical energy for half a million people and a bath holding 1000s of tons of salt acts as a heat sink to extend use beyond sunset or when conditions are overcast.�
*Curator of the Turner Museum of Glass, The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk.
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Prof John Parker discuss properties of infrared radiation and its role in heat transfer.
59 Glass International March 2021
History.indd 1
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for bottom / side / top
Transformers
Bock Energietechnik GmbH Gösen 15 92685 Floss Germany
Tel: 0049 9603/1295 Fax: 0049 9603/2995 info@bock-energietec.de www.bock-energietec.de
INSPECTION
RAW MATERIALS
Rio Tinto Minerals 2 Eastbourne Terrace London W2 6LG, UK TIAMA ZA des Plattes, 1 Chemin des Plattes, 69390 Vourles, France Tel +33 (0) 4 37 20 15 00, Fax +33 (0) 4 78 07 94 50 Email: marketing@tiama.com Website:www.tiama.com
Tel +44 (0) 207 781 1450 Fax +44 (0) 207 781 1851 Email: simon.cook@riotinto.com Web: www.riotintominerals.com
Contact Esme Horn T+44 (0) 1737 855136
SCREEN PRINTING
to book your space KAMMANN GmbH
DIGITAL SCREEN PRINTING HOT STAMPING FULLY AUTOMATIC UNIVERSAL DECORATING MACHINES
Bergkirchener Straße 228, 32549 Bad Oeynhausen, Germany kammann.de
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53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce, 6 Tel +39 0577 304730 ifv@fonderievaldelsane.com
www.fonderievaldelsane.com
Laser welded 2 pin Conveyor Chain