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PROFILE: STEKLARNA HRASTNIK ICG: PENG SHOU INTERVIEW QUALITY CONTROL
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Glass International April 2014
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Contents
April 2014
Vol. 37 No.4
2
Editor’s Comment
3
International News
PROFILE: STEKLARNA HRASTNIK ICG: PENG SHOU INTERVIEW QUALITY CONTROL
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Company profile: Steklarna Hrastnik Steklarna Hrastnik sees benefits of G furnace
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Society profile: ICG Prof Peng Shou outlines his plans for the ICG
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British Glass
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Nuclear energy Vitrification of radioactive wastes
22
Front cover image courtesy of Pennine Industrial www.pennine.org
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On the web: www.glass-international.com/ features Analysis & testing Glass Technology Services intoduces harmonising standards for pharmaceutical glass Quality Control Biebuyck discusses hot versus cold laser cutting for tableware
Plus find us on Linked-In and Twitter.
@Glass_Int
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Glass machinery Lattimer introduces clutch control Country focus: India Indian glass industry: A journey over six decades
31
Refractories A no-lime silica brick for oxy fuel technology
35
Glass recycling Turning food waste into glass
41 42
Quality control & inspection A plant management system Vision sidewall inspection solution for round engraved articles The best things come in small sizes Wet chemical analysis of redox state of glass
45 47
Architectural Glass functionality Architectural glass processing
49
Glassman review
50
Events world Furnace Solutions 9
51
Diary
37 39
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Float glass Can float glass cullet be used in the container glass industry?
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1 Glass International April 2014
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Editor’s comment
Greg Morris
www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Editorial Assistant: Sally Roberts Tel: +44 (0)1737 855154 Email: sallyroberts@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com
Fourth Brazilian exhibition attracts local support
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F
irstly a big thank you to all those who attended Glassman South America in São Paulo, Brazil last month – whether it be as a visitor or an exhibitor. As the event’s organiser and publisher of the show’s official magazines we were proud to welcome you all through the doors of the Fecomercio exhibition centre. It is the fourth time the event has been held in São Paulo and each event has been a great success. There were more than 80 exhibitors each showcasing their products, machines equipment and services to the glass industry. The accompanying two-day conference benefitted from the organisation of leading Brazilian glass trade industry association Abividro, supported by Glass International. Papers for the free-of-charge event were provided by glass manufacturers, suppliers, associations and consultants. It was standing room only throughout day one with the majority of the 120 seats all occupied as speakers discussed a variety of topics. Many of the speakers were from Brazil and it was clear to see how the glass industry is flourishing in this country. Hot on the heels of one exhibition is another with China Glass this month.
We are now in event season, with a number of conferences and exhibitions taking place in the next few months. The Glass International team aims to be at as many events as possible whether it be walking the halls of an exhibition or reporting from a conference. Speaking of China, this issue contains an interview with Prof. Peng Shou, who has been President of the International Commission on Glass (ICG) since June 2012. As well as talking about his achievements so far within the ICG, he discusses how important China’s glass industry has become. It accounts for 55% of total global flat glass production, meeting the demands from the real estate, automotive, solar, and electronic industries. We also feature Slovenian manufacturer Steklarna Hrastnik in this issue, which has transformed itself since being in financial difficulties in 2010 thanks to the leadership of Andrej Bozi. As ever it is a busy issue, so much so that we have published extra features on the website. Articles by Glass Technology Services and Biebuyck can be found at glass-international.com/features. Greg Morris Editor gregmorris@quartzltd.com
Directory 2013 Annual international reference source
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2 Glass International April 2014
Production Executive: Martin Lawrence
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april Glass news copy_00_GI_0909 4/2/14 12:19 PM Page 1
International news
NEWS IN BRIEF
Management change
G Clinton Shay named 44th recipient of Phoenix Award Mr. G. Clinton (Clint) Shay has been selected to be the 44th recipient of The Phoenix Award. Mr. Shay, now retired from Corning Inc, has been awarded the prize for his contribution to the industry in the field of glass forming. Clint, as he is known to the glass making fraternity, is responsible for inventing the revolutionary, ‘down draw’ or ‘fusion’ process. This process produced a pristine flat glass as an alternative to the well-established Pilkington’s float process.
He was also leader of the team that invented the chemical strengthened fusion glass which resulted in the name of Pyrex glass, as well as its use in ophthalmic glass and LCD products. However it was in the 1990’s when the technology really came in to its own, with the convergence of the LCD, TV market. The fusion process’s thin low warp hardglass fulfilled the needs of this breakthrough in visual communications. Since then the process has moved on to be incorporated
in to the hand held devices market, such as touch screen computers, tablets, mobile phones and many other electronic devices, utilising the protective touch screen glass carrying the brand name of Gorilla Glass. The Phoenix Award Committee said it was proud to be able to make this award to such a deserving person as Clint, and look forward to presenting him with The Phoenix Award at a presentation ceremony later in the year, at a venue to be announced.
Iris Inspection secures O-I Estonia order The Estonian glass container production arm of OwensIllinois (O-I) has placed an order for eight machines with Iris Inspection. Based at Jarvakandi, at the heart of the northern European Baltic State and in the glass capital of Estonia, O-I Estonia operates two furnaces and four production lines. The factory manufactures
white flint glass packaging, including vodka bottles, water bottles, soft drinks and beer bottles, as well as jars. Most output involves articles with complex shapes (conical, square, rectangular etc) and engravings, which are typical for the region’s vodka industry. Iris was commissioned to supply eight machines to replace existing automatic
inspection equipment. The order includes four Evolution 16 machines, each of which features 12 cameras to provide full coverage of bottles and jars, as well as four additional cameras for the detection of stress defects in the body. The equipment can inspect 100% of a container, even in engraved and decorated areas.
NSG board change George Olcott will retire from his position as External Director at NSG, to be succeeded by Günter Zorn. Mr. Olcott has been an External Director on the NSG Board since June 2008, and has completed the full sixyear term for External Directors. As stipulated by NSG’s internal rules, he will now be retiring, and the NSG Board has nominated Günter Zorn as his successor. Mr. Zorn is a German executive with vast international experience, who has lived and worked in Japan for more than 20 years.
AGR Glassman success Agr's participation in Glassman South America is complete. The company said the two-day show was a great opportunity to visit with current and future customers to discuss its latest capabiliitles and services for the glass container industry. This show provided a great opportunity for Agr staff to meet with key people, current and future customers from Brazil and other South American and Latin American countries.
VISIT: www.glass-international.com – For daily news updates and regular features
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Phoenix Award Committee Chairman, Mr. Wally Evens (left) and Phoenix Award Winner 2014, Mr. G. Clinton Shay (right).
Ardagh Group has appointed John Riordan as President of Ardagh Glass North America. David Matthews, formerly of DS Smith plc, has joined the company as Chief Financial Officer and will be proposed for membership of the Board of Directors of Ardagh Group at its next Annual General Meeting in May 2014. Mr Riordan’s appointment comes ahead of the anticipated enlargement of Ardagh’s North American Glass business, through the acquisition of Verallia North America, and reflects the importance of the market to the future growth of the company.
3 Glass International April 2014
april Glass news copy_00_GI_0909 4/2/14 12:19 PM Page 2
International news
NEWS IN BRIEF
GPS changes logo GPS, affiliate of Saint-Gobain Oberland, has launched a new logo and an extended range of IS machines. The extended range of IS machines and components are part of a company focused drive to improve the company’s customer service offering. To mark the change, the logo – steely grey with a flaming glass gob – represents the strength of GPS and the ‘made in Germany’ quality that GPS prides itself on.
Slovenian success Steklarna Hrastnik iimproved its business results in 2013. It generated €48.6 million of total revenue, earnings before interest and taxes (EBIT) was the highest in the last ten years and amounted to €3.87 million. Profit from continuing operations rose by 63%, to €2.8 million. “Last year’s operating results show that the strategic direction of Steklarna Hrastnik is the right one. We will continue to invest in the modernisation of production and training of employees. This ensures that we can produce technically demanding products, while maintaining the highest level of quality glass,” said General Manager Andrej Božic. New markets it accessed in 2013 included the UK, USA, Romania, Macedonia, India and Albania.
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Viridor to close UK site Recycling company Viridor plans to close its Sutton, St. Helens factory. The site at Lancots Lane was bought by the company in 2002, and recycles flat plate glass along with container glass. The company is confident staff redundancies can be avoided by relocating employees to other sites in the local area. A company spokeswoman said it had made every effort to secure the future of the business, including a restructure in 2012.
4 Glass International April 2014
Allied invests in 3D printing Glass packaging manufacturer Allied Glass Containers has invested in a new 3D printer and is now offering customers the opportunity to create a bottle from scratch in hours. Allied is the first glass packaging company in the UK to make available 3D printing as part of its design service. The technology gives the company’s designers the ability to go from a flat screen to an actual physical bottle, Steve Glover Product Design Engineer at Allied Glass said. He stated: “The acquisition of our new 3D printer allows our team to bring our design ideas to life, physical prototypes allowing
investigation and interaction with the product, so before a bottle is produced our customers can touch it, feel
it, turn it and look inside it. “In essence they can react emotionally to it and fully evaluate it.”
Ardagh Glass reheats Danish homes Ardagh’s glassworks in Holmegaard, Denmark, has helped warm more than 1000 homes in the area by capturing excess heat from its factory. Surplus heat from its glass production is piped from the plant to a tank which can store 100MWh – equivalent
to two days production – from where it is piped into the local district heating plant’s system and on to homes in Fensmark. Henrik Bonné, Plant Director at Ardagh Glass Holmegaard, said: “The district will receive a secure supply of cheaper energy
from one of its largest employers, a case of neighbour helping neighbours. It is good for the environment, as, against a traditional gas boiler heating process, it saves at least 3300 tonnes of CO2 a year, the equivalent of taking 400 cars off the road.”
Lattimer launches training academy The UK’s Lattimer group aims to uncover the next generation of leading precision machinists after launching a specialist training academy. The precision engineering company has a twin facility in Vineland, New Jersey, USA, and a maintenance and repair division in Birmingham, UK. The Lattimer Training Academy has been set up in
the firm’s Southport, UK office in a bid to deliver high level training to apprentices. Lattimer managing director Mark Hailwood said the academy will up skill the local workforce, future proof the firm and help drive further international growth. “We are thrilled to be launching the Lattimer Training academy, which has already seen a strong uptake of recruits,” said Mr
Hailwood “We have found it hugely beneficial to carry out focused and intense in-house training, where longstanding machinists have converted to full-time training and mentor roles. This enables the recruits to receive guidance from our most experienced team members who have worked with us for decades,” added Mr Hailwood.
Be first with the news! Visit www.glass-international.com for daily news updates
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april Glass news copy_00_GI_0909 4/2/14 12:19 PM Page 4
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International news
German inspection company moves location
Regenerators Air-Fuel Burners Waste Gas Exit
Checkerwork Chimney Damper
Oxy-Fuel Burners
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German company Optische Prüfsysteme Günther has moved. The company, founded in 1995, has operated in its own rooms since 1999, which were extended in 2000, 2003 and 2009. Now, it has built a new factory hall connected to an office building on former grassland in the middle of a business park
in Meerane, Germany. The new factory hall has a floor area of 2000m2, the office building a surface of 600m2. The factory hall benefits from the extension by being divided into several departments: mechanical manufacture, electrical goods department, final
assembly, test area and a department for training and performance. Its products include the inspection of clear and coloured glass containers of all kinds. Its new address is Optische Prüfsysteme Dr. Günther, Lauenhainer Weg 3, D – 08393, Meerane, Germany.
futronic modernises Ukrainian glasswork’s control system Ukrainian container glass manufacturer ConsumerSklo-Zorya is to retire its futronic MP-ST Control System. By order of the Veralliaowned company, futronic
technicians have replaced the MP-ST System for 8 sections with a FMT24S. As part of the modernisation, a second control system is planned to be exchanged in the
near future. The MP-ST control system was introduced to the glass industry 35 years ago and still operates in some glassworks today.
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6
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Pyrotek buys Infinity Machine Pyrotek has bought the assets of Infinity Machine, a Tulsa, Okla.based company that manufactures individual section (IS) machine components and other equipment for the global container glass manufacturing industry. The addition of Infinity’s product line provides an opportunity for Pyrotek to increase its Glass International April 2014
range of consumable products and level of support to glass customers around the globe. “Because Infinity and Pyrotek had been serving the same customers (including Saint-Gobain, Ardagh and OwensIllinois), this expanded business line will allow Pyrotek sales engineers to broaden the scope of
products and services offered to container glass manufacturers,” stated Tim March, Pyrotek’s Global Glass Industry Business Unit Manager. Infinity employs 20 people. All will remain with Pyrotek. The Tulsa operation manufactures precision machined parts and assemblies critical to an IS machine’s operation.
april Glass news copy_00_GI_0909 4/2/14 12:19 PM Page 5
International News
NEWS IN BRIEF
NEG launches smartphone glass Nippon Electric Glass (NEG) has launched Dinorex, a new brand of glass for chemical strengthening for the cover glass of smartphones and tablets. NEG released the new cover glass products into the market last year and started sales on a full-scale. The company decided to launch Dinorex integrating all the current T2X series cover glass in order to build awareness of its products among touch panel manufacturers and end users.
Magma opens Vietnamese site Magma Ceramics & Catalysts has commissioned its ceramic manufacturing facility in Vietnam. The new 6000m2 facility is located between Hanoi and North Vietnam’s main international sea port, Haiphong and will strengthen the company’s capabilities in the manufacture of refractory ceramic products used in the glass industry.
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Glass Technology Services appear on TV The UK’s Glass Technology Service featured on the BBC’s ‘Watchdog Test House’ television programme. The episode focused on toughened safety glass construction products used in architecture and glazing. The focus was on the rigorous safety and performance requirements that must be met before the product can be CE marked and made available on the European market. Philip Marsh, Business Development Manager at GTS said: “The programme makers contacted us to provide independent insight into the relevant product standards, and to film the physical tests and assessments needed to meet stringent safety and performance requirements for glass.”
8 Glass International April 2014
Steklarna Hrastnik in €8 million furnace investment Slovenian manufacturer Steklarna Hrastnik is to invest €8 million in the reconstruction of its Bfurnace on its Special production line for bottles. The installation of the new B-furnace is scheduled for August and September. Installation will last 48 days and be implemented by 250 people, 24 hours a day. The new B-furnace will increase the capacity and quality of
production of bottles, with current production of 120 tonnes in the current quality glass rising to up to 140 tonnes per day at twice better quality glass. Janez Tomažin, adviser to the General Manager, said: “The new furnace will bring us greater production efficiency, which for Steklarna Hrastnik means a higher return per unit of product. At the same time
this will be more environmentally friendly investment, since the new furnace will be much more technologically advanced than the existing one. “According to our calculations, we will have 15% lower power consumption, and NOx emissions will be reduced by 30%.” (See Page 10, this isue, for a full feature on the company).
O-I appoints Country Executive Owens-Illinois (O-I) has appointed Rens de Haan to the new role of Country Group Executive for the Netherlands and UK. Rens will be responsible for the overall operational and commercial functions of O-I
in the Netherlands and the UK, comprising five plants and 1500 employees. He will take the lead in strengthening O-I’s capabilities and competitiveness in these countries to support the
developing needs of customers for more sustainable and healthy glass packaging solutions. He joins from food processing company, Cargill, where he was a marketing director.
Ardagh re-interprets whiskey bottle Ardagh Group’s application of glass embossing is shown with a limited edition interpretation of the 1L bottle for Jameson Irish whiskey. The new design for Jameson Irish whiskey is distinguished by three different depths of embossing incorporated in the label panel. The detailed triple layered embossing gives a more premium as well as tactile feel to the bottle by highlighting the depth and detail of the artwork. Recent research has shown that tactility communicates
powerful messages on a product or item directly to the brain. These messages can be more important for consumers than the look of that product. A study carried out recently for Ardagh concluded that key sensory receptors such as the hands, ‘offer a great opportunity for brands to influence consumer interaction and enjoyment.’ The product design team at Ardagh succeeded in replicating the 1L bottle’s existing paper label detail in glass. As some of the original graphics were too thin or
small to form in glass, they ‘opened out’ some of the detail, increasing the size without altering the overall design to ensure a high quality of definition. The de-bossed seal feature on the bottle was developed to house an insert made from metal provided by steel company Signet Marking Devices. The effect conveys a seamless transition from glass to the installed insert, making it look like an integral part of the glass container. The de-bossed seal was developed to sit just above and to be in line with the lower eyebrow feature.
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slovenia profile_00_GI_0909 4/2/14 12:36 PM Page 1
Company profile: Steklarna Hrastnik Working end with feeders.
Steklarna Hrastnik sees immediate benefits of G furnace Andrej Božic, General Manager of Slovenian tableware manufacturer Steklarna Hrastnik, outlines how a new G furnace was installed within the company last year and explains some of the benefits it has brought.
I
The fundamental reasons for deciding on oxyfuel technology were: The availability of existing premises for building a furnace and setting up polishing machines and annealers; Environment: A drastic decrease of NOx emissions; The quality of glass; Specific use of energy per mass of molten glass; The method of management and control of operations – combustion; Planned service life; Operational safety.
demolition of two furnaces, the displacements of machines and devices, and in the purchase and installation of certain peripheral (yet important) machines and devices, was €7.5 million. The engineering related to the furnace and to some devices used for the reconstruction of the new G furnace was performed by the main supplier, Sorg, under our continuous cooperation and approval. The increased capacity of a single furnace enables a different distribution of machines. Of the six machines installed prior to the investment, only four of the best machines for sales and productions are now installed on the new G furnace. This state of affairs improves the efficiency of production planning. All four machines with pertaining equipment were thoroughly overhauled in cooperation with Slovenian subcontractors, and almost exclusively under the surveillance of our maintenance officers. Furthermore, during the overhaul, the compressed air production system (now
The value of the total investment in the reconstruction of the existing B furnace, the
continued »
n 2013, Steklarna Hrastnik invested in a new G furnace and a thorough overhaul of all existing machines where tableware was produced. Instead of two regenerative furnaces with a total capacity of 100 tonnes per day, one oxy-fuel furnace with a nominal capacity of 80 tonnes per day and an actual capacity of approximately 90 tonnes per day is now in operation.
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Oxy-fuel technlogy
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Glass International April 2014
slovenia profile_00_GI_0909 4/2/14 12:37 PM Page 2
outsourcing) was replaced, the overhauled soft water system was upgraded with further softening technology using osmosis (use of graphite tools), and stage 1 to automate the cullet return line was carried out. The result is an excellent production facility that allows us to achieve an average efficiency of 85 to 90%, sometimes even higher, despite the fact that production is flexible and programmes changes are frequently made. The quality of our products after the implementation of this investment has been enhanced, meaning that Steklarna Hrastnik is now one of the leading manufacturers of tableware products in the world. Our programme, completely new products and approaches, as well as certain patents, have generated much better financial results than before the reconstruction. The priority of the investment was to establish a safe and employee-friendly working environment, and 70 of our employees and 295 outsourced employees were included in the investment process. In this field, we took all known safety measure checks and carried them out on a daily basis, the result of which was one relatively minor injury of a worker employed by an outsourcer. G furnace benefits: The investment was finished sooner than if a regenerative furnace had been built: 53 days and 9 hours from blob to blob; Improved quality of glass, as expected, right after the investment. Merchantable quality was already achieved on the first day of production; Savings in the mixture formula as a result of improved glass quality (after a few months of operations and an optimisation carried out exclusively by our experts); A displacement of main cooling fans for furnaces to a location where air is now drawn in from outdoors. By doing this, the vacuum under the furnace was decreased, thus producing more amiable working conditions, an improved energy condition and better effects on the efficiency of machines and the production building. Excellent results of environmental measurements. Decrease in noise: Two furnaces were replaced with one new furnace. Oxy-fuel technology provides lower noise emissions, as there is no air injection, which is a major source of noise in existing furnaces. Furthermore, the new fan area has been made with noise protection panels. The termination of two old production lines also helped decrease the existing load. As a result, lower noise levels were achieved than before the change. Decrease of waste glass: Because of improved quality of glass and waste glass treatment processes, we decreased waste by 30%. Decrease of water consumption: Within the
“
New technology also means a major step ahead with respect to the efficient use of energy.
”
scope of the investment and works after the investment, we carefully examined the condition of process water and its consumption. Electric circuits were closed in all areas where it was possible to do so without affecting the technological process. Hence, the consumption of urban water was decreased by 50% compared to the consumption of the last service life of the furnace. Decrease of air pollution: The new furnace, which uses oxygen-fuelled melting, is of vital improvement in substance emissions. The natural gas (methane) combustion furnace uses oxygen. The percentage of oxygen purity depends on whether liquid oxygen is used or supplied by the so-called on site devices, which in fact separate oxygen from the nitrogen in the air by absorption. In this case, the presence of nitrogen is minimal. In light of the technology, we expected to decrease the amount of waste gas by around two thirds (primarily through lower emissions of nitrogen oxides). Measurements revealed that the company achieved the emission level of NOx <0.4kg/t of molten glass, which is much less than the limit value of 1kg/t of molten glass. Furthermore, they showed that the measures taken resulted in decreased emissions of all pollutants due to new technology, i.e. of total dust by 35%, of metals by 10% and, mostly, of nitrogen oxides by more than 75%. Decrease of energy consumption: New technology also means a major step ahead with respect to the efficient use of energy. Oxygen combustion means that combusted air is replaced with oxygen (of more than 90% purity). By extracting most of the nitrogen from the combustion atmosphere, we reduce the volume of waste gas by around two thirds. This saves energy as there is no need for heating atmospheric nitrogen to flame temperature. Considering the operations recorded so far, it was found that the company achieved a drop of specific energy consumption by a third and, consequently, lower greenhouse gas emissions. Despite the fact that oxy-fuel technology produces five times lower quantity (volume) of hot exhaust gases, it is difficult to make use of the thermal energy produced, according to information provided by numerous specialists. However, we succeeded in doing this by applying a fabric filter (today, three glassworks furnaces are connected to it), installed two years ago, with ‘exhaust gas-air’ heat exchangers and by installing additional ‘exhaust gas-water’ exchangers, which were installed based on our own know-how and the assistance of a Slovenian subcontractor. The heat obtained from exhaust gases is used for vapourising and heating liquid oxygen (365 days a year), for heating greywater and certain other users.
*General Manager, Steklarna Hrastnik, Slovenia. www.steklarna-hrastnik.si/en/ Glass International April 2014
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Company profile: Steklarna Hrastnik
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slovenia profile_00_GI_0909 4/2/14 12:38 PM Page 3
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I am very satisfied with the results that we have achieved with the new G furnace and renewed machinery on the tableware production line.
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Andrej Božic spoke to Greg Morris about the new furnace and Steklarna Hrastnik Congratulations on the new G furnace at Steklarna Hrastnik. How pleased are you with the furnace and what benefits will it bring to the company?
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I am very satisfied with the results that we are achieved with the new G furnace and renewed machinery on the tableware production line. Our average production efficiency is from 85 to 90%, sometimes even higher, despite the fact that production is very flexible and programme changes are made frequently. From the first day of the production of the furnace we produced top quality glass and also increased quality of the glass. Targets regarding energy consumption on 1 tonne of the produced glass and environment were also met.
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Can you tell us a little bit about Steklarna Hrastnik such as, its total daily output, products made and the regions that you serve – are you domestic based or do you export abroad? We sell 97% of our turnover to 50 different markets around the world. The most demanding clients from the spirit market are buying products from our container line. On this segment we produce 120 tonnes of glass daily. We also produce high quality tableware products, among which is promotional glass for Glass International April 2014
very demanding clients. Daily production of this line amounts to 90 tonnes. In our lighting line we produce glass for designer lights. In this line we also employ 50 glass-blowers who are making very demanding handmade items. Among other things they produced 2 metre tall bottle and a light. The lights that we developed together with our clients and produced, received five Red Dot awards. We produce 15 tonnes per day on this line.
You have rehabilitated the company since you took over in 2010. There was a global financial crisis in 2010. Did this ever impact on your decisions when you took over the plant in 2010? When I took over the management of Steklarna Hrastnik, the company was in a very bad financial situation, mainly because it was using the wrong business model for its size. At that time it was strongly focused on the commodity market. So, in the last four years because of the company’s long tradition, technical capabilities and excellent quality of the glass, a high percentage of sales were redirected to the niche and high quality markets. This is my fourth case of turnover. I saw at that time a lot of potential in Steklarna Hrastnik. This turnover was focused around potential employees and in this process motivation and team work played an important role.
peng shou 2_00_GI_0909 3/31/14 12:05 PM Page 1
Society profile: ICG
We need to vigorously “develop new glass products, further expand the application of glass products in the areas of electronic information display, solar energy photovoltaic, and photo-thermal and architecture
”
energy saving etc.
Prof Peng Shou outlines his plans for the ICG
1. You were appointed President of the International Commission of Glass in June 2012. How honoured were you to be appointed President? I feel quite honoured to be appointed as President of the International Commission on Glass. I would like to extend sincere thanks for the trust and support that all fellow colleagues of the International Commission on Glass have given to me. This honour does not only belong to me, but also to the whole Chinese glass industry. Since entering the 21st century, the technologies and production capacity of the Chinese glass industry have obtained rapid
development, attracting the attention of world glass industry. All this is attributed to China’s reform and ‘opening-up’ policy that has been performed for more than 30 years.
2. How have you found the role so far? Any achievements or challenges? It’s now more than one year since I was appointed as President of the International Commission on Glass in June, 2012. I have gradually adapted to this role. It is one of the most important roles that I have assumed. As for the achievements, I would prefer to answer this question from the perspective of the work that I have done.
During the past year, the work of the International Commission on Glass has been conducted in an orderly way. I encouraged and recommended excellent glass experts and scholars to vigorously participate in the activities of ICG, further expanding the influence of ICG in the academic circle of glass. In the aspect of industry, I made efforts to invite more glass enterprises and organisations to join ICG, further expanding the membership team. Up to now five new glass enterprises and one glass organisation have already submitted their application for
continued » Glass International April 2014
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In an exclusive interview with Glass International, Prof Peng Shou, President of the International Commission on Glass (ICG), discusses the honour he felt in being appointed President, his achievements so far and the importance of China to the glass industry.
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Society profile: ICG
membership. There are also glass organisations and enterprises from South Korea, Indonesia and Vietnam contacting me, in the hope of joining this world-renowned group. I believe the figure that I just said would be constantly updated. Apart from expanding the membership team, I also paid close attention to the organisation and quality of ICG activities. I raised more than €45,000 sponsorship fee for the 2013 Prague International Congress on Glass, and $10,000 sponsorship fee for the Asia-Pacific Meeting of Glass and Allied Industries and ICG Steering Committee Meeting. I believe we could better organise our activities and meetings with sufficient funds. For the challenges for my work in ICG, I think the most important one is to further enhance the international publicity, visibility and influence of ICG.
3. How important is the ICG to the glass industry? What role does it play in promoting the benefits of glass? Most ICG members come from world renowned glass enterprises, universities and research institutes. Therefore, ICG could lead and promote the academic discussions, technical exchanges, information communication and coordinated development of the world glass industry.
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4. You are the first Chinese President of the ICG. How important is the Chinese glass industry at the present time?
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China’s flat glass production has ranked first place for 24 consecutive years, accounting for 55% of the total global production, and has met the rapid development demands of the related industries of domestic real estate, automobile, solar energy and electronic information. What’s more, China’s float glass technologies are also widely recognised in the world.
5. What are the current ‘talking points’ within the Chinese industry at the present time, such as energy efficiency, safety, innovation etc? At present, the most popular ‘talking points’ within the Chinese glass industry are energy saving and environment protection, and overcapacity. Chinese glass industry is making efforts to realise energy saving, Glass International April 2014
emission reduction, transformation and upgrading through scientific and technological innovations.
6. What are the main opportunities for the Chinese glass industry? The main opportunities for the Chinese glass industry are the state policies of architecture energy saving and construction of new urbanisation, which are being vigorously implemented, the rapid development of automobile industry, and the wide application of glass in electronic information and solar energy industries.
7. What are the challenges it is facing?
main
The main challenges that Chinese glass industry is facing now are the overcapacity of the industry and the pressure of energy saving and environment protection.
8. What can the rest of the world learn from the Chinese glass industry? Making great efforts to adapt to market demands, and improving the level of technical equipment in the glass industry through integrated innovation, are the points that I think the rest of the world could learn from the Chinese glass industry.
9. China will host the 2016 ICG event in Shanghai. How will this help the development of the Chinese glass industry? The 2016 International Congress on Glass will be held in Shanghai, which will further promote the technical advances, and transformation development of Chinese glass industry. We could take advantage of this international platform to strengthen our communication and exchanges with the international glass industry, enhance the technical level of special glass, and boost the energy saving and environment protection of glass industry. China is now at the moment of industrial upgrading. A large number of enterprises need to improve their capacity for independent innovation and technical level. Holding this highlevel International Congress on Glass in China is conducive to spreading and industrialising the achievements of new technologies, and promoting the development of the glass industry. In addition, 2016 is the centenary of
Society of Glass Technology. We would like to take this opportunity to organise a joint event with Society of Glass Technology as a part of series of celebrations. We also plan to co-organise an event with American Ceramic Society during the Congress to further strengthen and promote the communication and cooperation between the two countries. I believe all these activities would not only open the door for cooperation with Europe and North America, but also provide active stimulus for the development of the Chinese glass industry.
10. Is there any advice you can give the glass industry to improve its position compared to other materials? The rapid development of the glass industry has raised higher technical requirements for the related industries of refractory heat insulating materials, metal materials and equipment manufacturing etc. We need to vigorously develop new glass products, further expand the application of glass products in the areas of electronic information display, solar energy photovoltaic, and photo-thermal and architecture energy saving etc.
11. Can you tell us of any plans for the future you may have for the role? First, I want to further promote the communication and exchanges of glass industry among different countries, and also with other related industries, through adopting effective measures and holding various activities and meetings. Second, I want to construct platforms, paying close attention to the frontier science and technologies of glass and its related disciplines, and promote academic exchanges throughout the world’s glass industry and the combination of ‘industry-studyresearch-application’ of glass enterprises, universities and research institutes. Third, I hope we could better serve the industry and promote scientific and technological innovations by focusing on industrial transformation and upgrading, enhancing the coordination role of ICG in the development of world glass industry, and constantly expanding the international visibility and influence of the ICG.
International Commission on Glass (ICG), www.icglass.org
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British Glass
L-R: Vallishree Murthy; Jenni Staves; Andy Hartley
The team Glass Technology Services
A CO2 reduction roadmap to 2050
British Glass, with technical expertise from Glass Technology Services* considers how leaders in the glass sector can reduce energy use & CO2.
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I
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t is often asked: “What is the glass sector doing to reduce its CO2 emissions?” The answer is: everything is possible! For anyone in the glass sector, this line of inquiry can seem ridiculous but the question is a fair one, because there is little evidence or communication in the public domain about just how vital energy efficiency improvements are for glass sector operations. In reality, much that can be done to decarbonise has been done and there are very real barriers that exist within the glass sector to further reduce CO2 emissions. The answer lies in overcoming barriers to implementation, which often requires collaboration with external stakeholders such as to increase the recycling rates of glass. The EU Commission recently published its 2030 framework for climate change policy measures, which proposes a 40% reduction in CO2 in line with the longer term trajectory of 80% by 2050. The issue with these targets is that they are political and aspirational, and therefore top down. There is a real danger that these targets will be assigned to sectors without consideration of the economic impact or the practicality of what needs to be done on the ground to achieve them. The UK Government has committed to a thorough, bottom up assessment of the potential decarbonisation options within a number of industrial sectors, including glass, as part of the UK Heat Strategy. The aim of this work is to produce a long-term decarbonisation plan in collaboration with each sector that is based on evidence. British Glass looks forward to engaging on this project and has prepared, in consultation with members, a roadmap setting out possible options for decarbonisation, the barriers to implementation and recommendations for the future. Its aim was to find a way for the glass sector to lower CO2 emissions without reducing competitiveness.
Glass International April 2014
Options The roadmap explores the following decarbonisation options: Energy - fuel switching to lower carbon energy, increased electrification and electric melting. Use of recycled glass - increase closed-loop recycling of glass Raw materials - batch pelletisation, batch reformulation Glass making process - furnace improvements, oxygen-fuel combustion, energy efficiency Additional waste heat recovery, carbon capture, carbon offsetting Glass products - product design, use of energy-saving glass products Options are placed into three trajectories which achieve different levels of CO2 reduction and require different levels of action and collaboration to accomplish. The current trajectory includes options which are expected to be implemented under a ‘business as usual’ scenario and gives low carbon savings. The options on the second trajectory can be achieved only if barriers to implementation can be overcome, potentially through collaborative effort with stakeholders and policy makers. The third trajectory, which leads to high CO2 reductions, involves step change decarbonisation options which require significant R&D before implementation.
Barriers Each decarbonisation option was assessed for barriers to implementation. One of the key barriers is a lack of financial viability under
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British Glass
current circumstances. Unproven technologies, commercial risk, technical issues, site suitability, requirement for collaboration with stakeholders, lack of policy support, aesthetic and quality requirements and availability are also challenges to be overcome. Furthermore, in some cases it is unclear whether the net CO2 impact would be reduced if the option were to be implemented. For example, replacing fossil fuels combustion with hydrogen would reduce glass sector CO2 emissions; however the current process for hydrogen production is highly carbon intensive and would result in a net increase in CO2 emissions unless made with decarbonised electricity. The roadmap then looks at recommendations to overcome these barriers. There must be a strong, clear business incentive to make expensive, disruptive and risky decarbonisation changes: Government must support positive change with balanced, stable and practical policies. Encouraging progressive UK manufacturing sectors is the best way to generate large social and economic benefits, and lead the world in environmental best practice. Funding streams should support innovation, research and development in energy intensive sectors. Manufacturing sectors must be proactive leaders of change. Glass sector employees are the foremost experts on glass and are the best people to lead changes in the sector. Longterm sector R&D and technology adaptation strategies should be created. Delivery networks must be created to enable implementation of the strategies. R&D, skills, communication, funding and other needs required to deliver the strategy should be identified and addressed. A centre for glass research or a glass knowledge transfer network could be created to support further R&D. A successful example is â&#x20AC;&#x2DC;The advanced manufacturing research centreâ&#x20AC;&#x2122; which is used by aerospace companies to develop and test ideas. Research & Development must be carried out. Further studies, research, development and demonstration of decarbonisation technologies are required. The glass sector could explore the viability of setting up a large-scale demonstration facility to prove existing and new technologies and also to reduce risk and encourage uptake. Positive collaboration is required to find win-win solutions. Industry, policy makers, consultants, academics, the supply chain and other stakeholders need to work together to find solutions to complex environmental challenges. The glass sector should also strengthen dialogue with government and others and feed in practical ideas. Glass is a solution for a low-carbon economy. The glass sector should further promote the environmental, social and economic benefits of glass and glass products. Supporting and incentivising the use of energy saving products will unlock large CO2 reductions.
*The British Glass Environmental team involved in creating and delivering the Decarbonisation Roadmap comprises of Jenni Staves, Environmental Manager and Vallishree Murthy, Environmental Policy Adviser, with technical expertise and support by Glass Technology Services (GTS) technical team. Glass International April 2014
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nuclear energy_00_GI_0909 4/3/14 8:52 AM Page 1
Nuclear energy
Vitrification of Radioactive Wastes Nuclear energy continues to receive considerable attention as a potential solution to issues such as global warming. However, the management of radioactive nuclear waste remains an obstacle to a true ‘Nuclear Renaissance.’ James C. Marra* and Michael I. Ojovan** discuss.
Glassy materials Glassy materials, in the form of both relatively homogeneous glass and glass matrices which incorporate crystalline dispersed phases, are currently the most reliable hosts for the constituents in nuclear wastes. Glass is a solid state material, which has a topologically-disordered internal structure made up of a 3-D network of interconnected structural blocks: Because of the disordered arrangement of the structural blocks, glass allows for the accommodation of the elements present in the wastes to be bound within its structure. Glass is typically formed via the rapid cooling of melted materials, and so little crystallisation occurs as little time is allowed for the ordering process of the structural blocks. Whether a crystalline or amorphous solid is formed on cooling also depends on the ease with which a random atomic
structure in the liquid can transform into an ordered state, and is directly related to the glass composition and cooling history of the glass. In industrial nuclear waste vitrification processes, glass is poured into containers to allow for handling and storage of the waste glass (Fig 1). The glass cooling profile varies with regards to the location in the canister, with the slowest cooling occurring at the centreline of the canister. The relatively slow cooling within the canister can promote crystallisation within the glass. Crystalline phases present in the glass, such as spinels and noble metals, do not lead to degradation in the aqueous corrosion behaviour. However, crystalline species such as nepheline that deplete the matrix of glass forming elements (namely silicon and aluminium) can decrease glass corrosion performance. Therefore, glass compositions must be carefully formulated to preclude the formation of deleterious crystalline phases. Additionally, the glass must be formulated to satisfy melter processing
Fig 1. Glass is poured into containers in industrial nuclear waste processes
constraints associated with viscosity, liquidus temperature, electrical conductivity and thermal conductivity.
Stability Glass is a metastable material, and its relaxation to crystalline structures is kinetically impeded so that practically no phase changes, such as crystallisation, can occur over extremely long periods – which for glass exceeds the lifetime of the universe ( 1.4·1010 years). The high chemical resistance of glass allows it to remain stable in corrosive environments for thousands or even millions of years1. Several types of glass are found organically in nature, such as obsidians (volcanic glasses), fulgarites (formed by lightning strikes), tektites (found on land in Australasia) and associated micro-tektites (from the bottom of the Indian Ocean), moldavites (from central Europe), and Libyan Desert glass (from western Egypt). Some of this glass has been in the natural environment for about 300 million years with low alteration rates of less than a millimetre per million years.
Nuclear waste vitrification Radioactive waste storage and processing varies from country to country, depending on their current policies. Most nuclear nations have generated waste from nuclear weapons programmes and/or commercial nuclear power generation, and store high-level radioactive waste from fuel reprocessing. The waste is stored either as neutralised nitric acid streams (US and Russia) or acid streams directly stored in stainless steel tanks (France, UK and
continued » Glass International April 2014
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G
lass is the overwhelming worldwide choice for the immobilisation of high-level radioactive waste resulting from nuclear fuel reprocessing. This is due to glass’s tolerance for the myriad of chemical elements found in the waste, as well as its inherent stability and durability. Vitrification is a mature technology and has been used for high-level nuclear waste immobilisation for more than 50 years. Borosilicate glass is the formulation of choice in most applications; however, phosphate glasses are used to immobilise high-level wastes in Russia. Glass has also proven to be a suitable matrix for intermediate and low-level radioactive wastes and is currently used to treat nuclear power plant waste in Russia and South Korea.
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Nuclear energy
Fig 2. Schematic diagram of a hot-walled Glass induction melter for high level radioactive waste vitrification.
Thermowell Off-gas Stainless steel shell
Calcine
1150°C
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Japan). The highly radioactive liquid waste is extracted from the storage tanks for subsequent vitrification1-4. Various pretreatment processes are employed on the liquid streams to prepare the feeds for vitrification including evaporation, filtration, and chemical addition to adjust the rheological properties. Off-gas systems are employed in the vitrification process to remove particulate carryover from the melter and to treat gaseous species prior to discharge of the off-gas from the plant. There are two primary approaches to vitrifying the liquid, high-level waste feeds: A two-step process involving calcination followed by vitrification of the calcined feed; and direct feeding and vitrification of the liquid feed. Both processes operate in a continuous feeding mode.
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Drain nozzle
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34”
Schematic 8’ 1/2” diagram of a Joule heated ceramic melter used for radioactive waste vitrification.
Feed tubes 10” (25cm)
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12” (30cm)
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glass has been permanently disposed. However, there is a worldwide consensus that deep geologic repositories provide the best solution for the final disposition of immobilised high-level waste. Repository geologies that are deemed suitable include granite/hard rock, clay/shale, or salt. There are currently several national programmes evaluating all these candidate geologies for repository applications.
Future Fig 4. Sellafield vitrified product store (UK).
Direct vitrification of liquid feed
High-level Waste Glass Storage and Disposal
Vitrification is the worldwide accepted technology for the immobilisation of high-level radioactive waste, as glass can accommodate the range of constituents present in the waste into its structure. The excellent durability of vitrified radioactive waste ensures a high degree of environmental protection, and waste vitrification is a demonstrated mature technology at industrial scale. Continued advancements in glass waste forms and nuclear waste vitrification technologies will be key to enabling the widespread deployment of nuclear energy. Additionally, the pressing issues regarding hazardous domestic disposal may also be effectively solved using vitrification technologies. Stricter regulations regarding waste characterisation and land disposal for hazardous wastes will necessitate the need for effective waste treatment methods. The wealth of knowledge gained in the vitrification of nuclear wastes can be readily extrapolated to the treatment of hazardous wastes. The stability and durability of glass waste forms may further provide unique opportunities for recycling or reusing the immobilised hazardous waste.
The liquid, high-level radioactive waste feed is directly added to the surface of the melter in this approach. The waste
Vitrified HLW is currently stored in dedicated storage facilities (Fig 4). To date, no high-level radioactive waste
continued »
Calcination and vitrification
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Zone 5
Fig 3.
Mullfrax 202 Refractory brick
K3 Refractory brick
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Close circuit TV
Calcination is accomplished in a rotary tube that is heated in a resistance furnace. The high-level waste feed is mixed with organic additives prior to introduction into the calciner to minimise calcine agglomeration and control redox conditions. The calcined material drops into the melter simultaneously with glass frit to promote vitrification. A nickel-based superalloy pot is heated inductively to temperatures of approximately 1100°C, and the melter can include mechanical stirring or bubbling to promote mixing. Fig 2 shows a schematic of a hotwalled induction melter. The glass is poured in batches into canisters, and the canisters are decontaminated and welded shut prior to storage.
Glass International April 2014
solution is either mixed with glass frit or glass forming chemicals in a tank prior to introduction into the melter, or is fed to the melter as glass frit is simultaneously fed. Reducing agents are typically added to the feed to control the redox potential within the melt, to avoid foaming or precipitation of reduced metal species. The liquid feed forms a ‘cold cap’ on the surface of the melter that helps to minimise constituent volatility. Glass then forms at the bottom of the cold cap. Joule heated ceramic melters are employed in this vitrification approach. These melters consist of a high chromium content, refractory lined vessel heated by electric current flowing between paired metal electrodes located at the walls of the melter (Fig 3). Bubbling can be used to assist mixing and homogenisation. Glass can be poured continuously via an overflow pour spout or through a thermally operated valve at the bottom of the melter, and the filled canisters are decontaminated and welded shut prior to storage.
nuclear energy_00_GI_0909 4/3/14 8:52 AM Page 3
Nuclear energy
Technical Committee The Technical Committee on Nuclear and Hazardous Waste Vitrification (ICG TC05) was established by the International Commission on Glass (ICG) in 20065. The vision of the committee is to establish a forum to present, discuss and disseminate technical information on waste glass chemistry, vitrification processes, vitrification melter technologies and waste glass environmental performance. The mission and goal of the committee is to facilitate the dissemination of technical information through the promotion of programming at technical conferences, conducting technical workshops, and facilitating publication of information through established channels. Promoting the exchange of technical data is also a goal. The ICG TC05 consists of 22 members from 11 countries. The committee conducts technical programming at international conferences each year and holds committee meetings at these conferences. The committee completed a round-robin study on liquidus temperature measurement that fostered the creation of an ASTM standard. The committee also plans to initiate a roundrobin study on sample preparation for glass corrosion testing. The technical committee will continue to offer a forum for international collaboration and information sharing.
References 1. Immobilisation of Radioactive Waste in Glass. DOI: http://dx.doi.org/10.1016/B978-0-08-099392-8.00017-6. Chapter 17 in: Ojovan M.I., Lee W.E. (2014). An Introduction to Nuclear Waste Immobilisation, Second Edition, Elsevier, Amsterdam, 245-282. 2. Lee W.E., Ojovan M.I., Jantzen C.M. (2013). Radioactive Waste Management
and
Contaminated
Site
Clean-up:
Processes,
Technologies and International Experience, Woodhead, Cambridge. 3. Jantzen C.M. (2011). Development of glass matrices for HLW radioactive wastes. In: Ojovan M. Handbook of Advanced Radioactive Waste Conditioning Technologies. Woodhead, Cambridge. 230-292. 4. Jantzen C.M., Bickford D.F., Brown K.G., Cozzi A.D., Herman C.C., Marra J.C., Peeler J.B., Pickett J.B., Schumacher R.F., Smith M.E., Whitehouse J.C., Zam J.R. (2000). Savannah River Site Waste Vitrification Projects Initiated Throughout the United States: Disposal and Recycle Options. WSRC-MS-2000-00105. 221-240. 5. Waste Vitrification.ICG TC05 web site: http://www.icglass.org/technical_committees/?id=5&committee=TC05 :_Waste_Vitrification (10.02.2014).
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*Materials Science and Technology, Savannah River National Laboratory, james.marra@srnl.doe.gov **Department of Materials Science and Engineering, the University of Sheffield, m.ojovan@sheffield.ac.uk. Current affiliation: Department of Nuclear Energy, International Atomic Energy Agency: m.ojovan@iaea.org
Vitrification: Vitrify: to convert (something) into glass or a glass-like substance, typically by exposure to heat. Late Middle English: From French vitrifier or based on Latin vitrum 'glass'.
21 Glass International April 2014
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Float glass
Can float glass cullet be used in the container glass industry? Mario Bertolin* discusses the quality criteria of float glass and argues that post-consumer float glass could be used as a source of cullet in container glass batches.
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he recycling of glass jars and bottles is currently estimated at 70% in Western Europe (i.e. more than 7 million tonnes), and the benefits this delivers in terms of savings in energy consumption, CO2 emissions and raw materials are well known and understood. The high recycling rate also reinforces the reputation of glass as an environmentally friendly and safe material. Glass containers have typically short life cycles (from one to six months) and the recycling scheme is therefore quite sustainable. Float glass applications have a much longer average lifetime: Window panes or car windshields are not generally available for recycling for many years. Current estimates set a total of 1.2 million tonnes of waste glass per year from building demolition or refurbishment in Europe, while end-oflife vehicles generate about 0.3 million tonnes of glass per year. By contrast, in 2008 float glass production reached 12
million tonnes: The recycling from the two major applications, therefore, represents a mere 10%. Furthermore, post-consumer float glass is often heavily modified and the recovery of â&#x20AC;&#x2DC;pureâ&#x20AC;&#x2122; glass is more expensive. Recycled glass for float glass has stricter quality requirements compared to container glass, pushing the final cost even higher. Therefore, it could be interesting to evaluate the results of post-consumer float glass as a source of cullet in container glass batches.
Case study The recycling of flat glass in Italy stood at comparable levels over a decade while container glass recycling increased steadily (Fig 1). The main source of recycled flat glass is post-industrial and post-consumer cullet including safety glasses, windshields and window panes. A typical stock of unprocessed flat glass cullet is shown in Fig 2. The pressure to reduce landfill
practices for recyclable materials will set new targets for car makers, pushing the percentage of reused/recycled materials in a car from 80 to 85% before 2015. A major car manufacturer has already set a 95% target for recyclable materials with glass representing 7% of the total car weight. Laminated glass is often stored on open spaces for several months to degrade the binding polymer, often PVB sheets. The material is then crushed to separate glass from plastics: The operation is critical and must be tightly controlled to avoid a large production (and loss) of fine material or the incomplete removal of plastics. Roller crushers (Fig 3) are more effective than hammer mills, and the improvements in crushing and separation devices for plastics have reduced the level of organics in the final flat glass cullet. Glass cullet from post-consumer products shows a stable chemical composition even on a long-term comparison. Variations can be found in
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2500000
continued Âť 2000000 Fig 1. Recycling for flat glass and container glass in Italy.
1500000 1000000 500000 0 2002
2003 2004
2005
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22 Glass International April 2014
2006 2007
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2009 2010 2011
Fig 2. Unprocessed safety glass and windshields.
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Float glass
re-equilibrate glass redox giving a still oxidised glass, but a careful evaluation of batch redox is necessary to avoid severe problems in industrial furnaces (Fig 4).
Sizing
Fig 3. Roller crusher for laminated glass.
a
Fig 4. Cooled glass sample from early melting of cullet from post-consumer glass products.
b
Fig 5. a and b Glass cullet as received.
a
b
Fig 6. a and b Sieved and washed glass cullet (> 2.0 mm).
Due to the specific processing, glass cullet from post consumer recycling may be difficult to control because of the high content of particles finer than 2.0mm. The fraction finer than 2.0mm is an effective quality indicator: Good processing will deliver less than 5% of fine particles. Sizing and washing of glass cullet samples provides a clearer appearance of the original glass as well as possible contamination (Fig 5a and b, fig 6a and b, fig 7a and b).
Fine particle contamination It’s quite common to find more than 40% of fine particles: Unfortunately, contaminants like alumina may generate stones with a high stress level even if the original average size is lower than 2mm. A practical and efficient control of fine cullet is possible using a large Petri dish and glycerol as an immersion liquid. Using a backlight observation, foreign materials can be identified as black, non-transparent objects. Image analysis software can provide very accurate measurements on each object: Coloured and transparent objects (such as coloured glass) may be excluded or included in the results with adequate filtering options.
Conclusion a
b
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Fig 7. a and b. Sieved and washed glass cullet (< 0.1mm).
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iron content and residual SO3 after melting as a consequence of different grain size distribution and organics. Glass physical properties however are stable and predictable: The typical R2O content is much higher than silica-sodalime glass used for containers, providing an interesting margin for batch cost reduction.
Quality requirements for postconsumer glass cullet LOI Loss on ignition (LOI) is a simple method to measure total organics in cullet samples. By comparison Chemical Oxygen Demand (COD) measurements are not affected by insoluble organics (i.e. plastics) and the results do not Glass International April 2014
match the actual melting behaviour of cullet. Temperatures between 350°C and 500°C are typically used with sample size greater than 500g. Five years ago the LOI was regularly above 1%, often generating smell and smoke at the charging end of the furnace. Currently, LOI levels are commonly within 0.1%–0.2%, comparable to cullet from container glass. The combination of the high content of organics with the fairly high SO3 contents of float glass was a major issue because of vigorous foaming and localised redox change. Melting fine float glass cullet with high LOI often shows in the early stages of melting – unstable amber colour may develop. The increase in temperature and changes in oxygen availability will
The glass industry is, however, willing to increase recycled glass use as long as the quality is adequate for melting new glass. Post-consumer glass cullet may be integrated in glass batches with interesting economic advantages in coloured or clear container glass production. Due to specific issues related to the recovery of glass from its main applications (windshields, window panes), dedicated controls must be implemented such as laboratory tests (melting, chemical analysis) as well as factory checks (sieving, fine particles contamination). The overall balance may improve the standing of glass as an environmentally sound material while recovering raw materials and reducing CO2 emissions.
*Chemical laboratory director, Vetri Speciali, Trento, Italy www.vetrispeciali.com
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Glass machinery
Lattimer introduces clutch control UK and American precision CNC machinist Lattimer is renowned for supplying more than 20,000 component parts to the glass container manufacturing industry. Managing director Mark Hailwood* explains how the firm’s new component – the Tong Arm Adjuster with Clutch - addresses every glass container manufacturer’s nightmare of machinery collisions.
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L
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attimer is a precision machinist with a 70 year heritage of producing high calibre component parts for the glass container manufacturing industry. The business stretches the Atlantic with bases in Southport, UK, and Vineland, New Jersey, USA. Less than 12 months ago the firm launched another division in Birmingham, UK, called Lattimer Glass Services, specialising in the maintenance, rebuild and repair of machines and equipment used in the manufacture of glass containers. With more than 150 staff working across these sites the firm developed a global brand, with exports now accounting for 80% of all sales. Recent deals have seen Lattimer expanding its presence in the Southeast Asian market, with particular success in the Philippines, Indonesia, Australia and New Zealand. Meanwhile, Europe remains a strong trading market with further sales success in the Americas and China. Over the decades, Lattimer has developed a strong understanding of the challenges machine operators face within the glass container manufacturing industry. The firm strives to deliver component parts which drive greater efficiency and performance in the manufacturing process, through close communication with original equipment manufacturers (OEMs) and glass manufacturers themselves.
Collisions on the IS machine Machine collisions have remained a longstanding issue in the glass container manufacturing industry. These incidents Glass International April 2014
remain all too common, whether it be valve failure, air supply variation or human error, and frequently lead to large losses in valuable production time. The well known adage ‘time is money’ is accentuated in the glass container manufacturing industry, which works at ultra high speeds with machines producing in excess of 600 bottles per minute becoming more common. In the event of an IS section collision, the entire manufacturing operation can come to a halt. Collisions frequently create a domino effect knocking other sections out of sync and causing chaos on the factory floor. This can lead to wide scale damage, with hot unformed glass seeping into manufacturing equipment. Machine operators are then faced with the prospect of having to repair the damage and get the process back on track – in the knowledge that every minute lost is draining production time and cash. In this situation the downtime can be
anywhere up to 45 minutes, in which time tens of thousands of bottles could be produced.
Avoiding the collision course Three years ago Lattimer made the decision to tackle the conundrum of collisions and focused on one of the most common: Between the takeout tong head and the blowhead or neck ring arm. The firm was able to start literally from the drawing board and create a solution through its Computer Aided Design (CAD) team, with decades of experience in the design and manufacture of machine component parts. After a year of test and measurement in the firm’s UK laboratories it unveiled a solution which can disengage the tong arm drive in the event of a section collision. The ‘Tong Arm Adjuster with Clutch’
continued »
Lattimer_00_GI_0909 4/1/14 9:14 AM Page 2
NEED SAVINGS?
CERBERITEÂŽ NEW DESIGN TOT HOLDER is still relatively unheard of in the market. Lattimer is offering the component on trial in a bid to raise awareness of the benefits it can bring to the glass container manufacturing industry. The product is a clutch arrangement contained within a tong arm (takeout) adjustor. The assembly simply mounts onto the take-out mechanism in placement of the standard adjustment arm. In the event of a collision the arrangement allows the tonghead to disengage, preventing damage and reducing downtime. Once the section has been stopped and cleared, the tong head can be easily pushed backed and re-aligned by a machine operator. A collision without the clutch can often merely misalign the tongs, but this is enough to produce reject ware, only to be noticed later when a costly inspection and re-sort operation has to be undertaken. With the clutch fitted the machine operator can see straight away that a collision has occurred. This enables it to be resolved immediately, preventing the costly and time consuming inspection and resort operations. As there is only one position where the tong-head will reengage correctly, positional repeatability of the tong arm assembly is guaranteed. The unit can be used with any takeout arm; belt, gear or chain driven. Transmission components and section variables are protected. The key benefit of this solution is its ability to isolate a machine fault, reduce the knock on effect, and enable a swift repair and re-engagement. This quick and simple solution means lost production time can be slashed from 45 minutes to as little as one minute. This can help manufacturers to save thousands of pounds in lost production time and equipment damage over the course of a year.
Machine compatibility
&%$#"! % % % %"! #% % % &% % !" % # "% # % %!"% ! # % % % % % % % % % "# &% % "%! % % % % % "# &%$ # % !"% % % % % % &%$ # % !"% "! % % % % % % %#!% % %%%%%%%%%%%%%% % % % % %%%%%%%%%%%%%%
cerberite@mersen.com
*Managing Director, Lattimer, Southport, UK www.lattimer.com Glass International April 2014
adressecreative.com
Lattimerâ&#x20AC;&#x2122;s product design team created the product to be compatible with all IS machines operating around the globe. Just one tong arm adjuster is required on each IS section to safeguard against the costly and timely effects of collisions. The versatile concept fits all pneumatic and most servo takeout mechanisms. In a bid to further improve usability, the unit has been designed to accept a sensor which can be linked with the section safe stop if required. Key benefits Section downtime is reduced. Unplanned maintenance time is reduced. Held Ware and re-sort costs are reduced. Once section is stopped it is simple and easy to reset. Eliminates serious, costly damage to machine and transmission parts. Saves time and money.
india focus chalan pilkington_00_GI_0909 4/1/14 9:21 AM Page 1
Country focus: India
Indian glass industry: A journey over six decades Mr C.V.Chalam* shares his experience of the Indian glass industry from the 1950s to the present day.
T
he glass industry was in a low state of technology when India became independent. The glass was melted in small capacity, using direct coal, producer gas and oil-fired furnaces. The industry was mostly centred in UP (then United Provinces of Agra and Audh), Bombay and Bengal. Glass fabrication or production was by mouth blowing and semi-automatic machines. Only sheet glass was manufactured mechanically by the Fourcault process. Production efficiency was low and specific fuel consumption was high (Table 1).
four side faces. The blocks were laid with an expansion gap of 3/32 inches in furnaces being built under technical supervision. In a number of small furnaces the bricklayer built the furnaces on their own. Leaks through the joints were not uncommon and they were checked by directing a jet of air. The common blocks were 24” x 12”
Refractory materials The quality of refractory materials was poor compared to present standards in India and globally. The furnace bottoms were laid with single layer 300mm (then 12 inches) blocks. They had to be dressed on all
continued »
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C.V. Chalam with Lord Pilkington.
28 Glass International April 2014
x 12” and 24” x 18” x 12” in a quality commonly known as Glass Tank Blocks. In contrast, when multinationals such as Pilkington Brothers entered India the bottom blocks were imported from its clay shops in the UK and were geometrically perfect. In the 1950s natural Khasi Sillimanite blocks were used as side wall blocks. The glass depth was mostly 4ft in three layers 18”, 18” and 12”. The refractory life was only one and a half years to three years. The first AZS electrocast blocks were imported from Corhart in the USA. Sodepore Glass Works at Bhurkunda was perhaps one of the first glass manufacturing units who had put up a 60t/day sheet glass melting furnace with design from a Pittsburgh, USA based company in the 1950s.
HPG plant at Asansol.
india focus chalan pilkington_00_GI_0909 4/1/14 9:21 AM Page 2
Country focus: India
Energy consumption Energy conservation is now a prominent concern amongst glass manufacturers, and efforts are being made to reduce energy consumption. The glass industry is continuously improving on production costs, energy conservation and environment.
The fuel movement Since the 1950s through to the second decade of the millennium, the type of fuel used within India’s glass manufacturing industry has evolved from coal furnaces, with the associated hazards of dust, pollution and variation, to producer gas generated from coal, to furnace oil, which made a quantum jump in cleanliness, consistency and ease of operation.
S.No
Fuel
Unit of measure
Typical Kcal/unit
1
Coal
Kg
4500
2
*Producer Gas from Coal
3
Glass (Mt) to fuel ratio
Kcal/Kg of glass
0.5
9,000
Kg
1100 Kcal/M
1 (Coal to Glass)
4,500
* Indian Coal has high Ash content. S.No
Fuel
Unit of measure
Typical Kcal/unit
Glass (Mt) to fuel ratio
Kcal/Kg of glass
1
Furnace oil
Kg
10000
9
1,111
2
LSHS
Kg
10000
9
1,111
3
Natural gas
M3
8500
8 M3/Ton
1060
Table 1. Thermal efficiencies over the decades – different fuels.
Fashion then reverted back to producer gas when furnace oil became economically non-viable, and Low Sulphur Heavy Stock (LSHS) which provides a small economical alternative to furnace oil. Natural gas was next, with another quantum jump towards cleanliness and ease of operation. Finally, electric boost was introduced to add tons of glass to an existing furnace that has reached its limit. We seem to have reached the limit regarding available options, so new entrants now may be solar power, or the efficiency of the existing fuels may be enhanced through better design of furnaces and combustion systems. Segmented melters and oxy fuel burnerswill also be important going forward, as will hybrid systems that will use fossil fuel, electric power and oxyboosted systems in tandem.
has evolved with time as follows: Glass is a super cooled liquid (what this actually meant was a bit obscure but nevertheless it stood). Glass is an inorganic product of fusion, cooled to rigidity, without crystallisation. (This became a bit technical but there were those who differed. Why inorganic? What if organic materials began to display glassy characteristics).
The road ahead
Further definitions have become still more confusing, so the less said the better. From the love story of our six decades with glass, we can only say that we still struggle to understand this entity. Glass is the miracle material produced as a result of a perfectly orchestrated manmade concert; the physical, chemical and thermal characteristics are brought about by the harmony of time, temperature and transformation of base constituents. It is the wonder that ranges from containers and laboratory ware, to architecture and spacecraft, to solar plants, to display systems and touch screens. Which other manmade material can boast of such versatility? The world of glass has entered an era of high tech applications and is now receiving the respect and attention of major industries which it rightfully deserves. The future will belong to those who drive the industry by using the modern tools of data-based real time process controls. The future will belong to the era of instrumentation, PLC controls and the 3 Rs of Recovery, Reuse and Regeneration, whether that be in terms of energy or material sources.
Going back in time and going back to basics, I was thinking of the definition of glass as a material. Even the definition
*Director, C.V.Chalam Consultants, Chennai, India
The refractory movement Over time, refractories have developed dramatically. Fireclay and Sillimanite refractories are now in all areas of the furnace, with AZS electrocast refractories in glass contact areas/95% chrome blocks in critical areas. Basic checkers replace firebrick and sillimanite, and there are chimney blocks for checkers to provide better surface area and heat recovery. Insulation of refractories has improved, platinum cladded throats have been introduced, and multi course bottoms installed for better thermal efficiencies. In the future, refractories could be developed to go up to 1800°C with heavy insulation, so that furnaces could be segmented as required, as well as reduction of fluxes for better durability.
Glass International April 2014
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The raw materials were weighed manually on platform weighing scales and manually shifted to batch mixers. In sheet glass manufacturing units, before the entry of multinationals, glass was manually cut horizontally on the top floor and stacked on ‘A’ frames with the edges on. Even in the 1960s India was still looking for the lowest capacity plants to meet their small market requirements. 2mm sheet glass was the main manufacture and used for photo frames. In some units the glass was cut in small sizes such as 10” x 12”, 18” x 24” common in photoframes and packed in paper bundles. With the passage of time, development has been made in all areas of glass manufacturing. In the 1980s a US company came up with the idea of a mini float process of 100 tonnes per day capacity for developing countries such as India. But the process was not taken up by any Indian companies - float glass was still a dream which would not be realised for another quarter of a century. The pioneers of float, the Pilkington Brothers, had vertical sheet and rolled glass manufacturing units in India but did not consider upgrading into float glass as the market was still too low. Incidentally, it is worth mentioning that Sir Alastair Pilkington, the inventor of the float process, was born in Calcutta. India now produces float glass, bottle glass, glass fibre, TV glass, opal glass, lamp glass, among others to global standards. Though the demand dropped steeply in the developed world a TV glass plant continues to manufacture, and meets global demand.
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Glass full page with bleed_Glass full page with bleed 03/04/2014 08:23 Page 1
RHi_00_GI_0909 4/1/14 9:25 AM Page 1
Refractories
A no-lime silica brick for oxy fuel technology Rongxing Bei*, Klaus Santowski**, Christian Majcenovic** and Susanne Jörg** discuss a no-lime silica brick that has a high corrosion resistance when using oxy-fuel technology.
CaSiO3
° 00 14 ° 00 13
NC2S3
α-CS NC3S6
0° 160
Crs
NC2S3
NC2S3 NS Na2 0
Na2SIO3
2 liquids
β-CS
0° 150 0° 140
° 00 12 NC2S3 ° 00 11
° 00 NC3S6 10 0° 90 N2 870°
Trd
0° 80
60
Na2SIO5
80
70
90
100 SiO 2
wt.%
density (approximately 1.8g/cm3), easy assimilation into glass, and the relatively low price make silica refractories indispensable for constructing the crown and superstructure of glass melting furnaces. Today, typical standard silica bricks have 95–97wt.% SiO2 and approximately 2.5wt.% CaO. The SiO2 exists primarily in the form of cristobalite and tridymite, which together comprise ~94wt.%. The additional SiO2 in combination with CaO forms the wollastonite (CaO·SiO2) bonding phase and accounts for ~5wt.% of the silica brick. During application in the crown and superstructure these silica bricks are subject to chemical attack by vapourised compounds from the glass bath, for example alkalis generated during the soda-lime glass melting process[10].
Fig 1 shows a phase diagram of the SiO2CaO-Na2O system which explains the chemical reaction processes occurring between alkalis in the furnace atmosphere and silica bricks. Ignoring any brick impurities, the standard silica brick composition is represented by the red circle on the SiO2-CaO line in Fig 1. During application at high temperature, the wollastonite dissolves and forms a first melt containing SiO2, CaO, and Na2O, with the composition indicated by the orange circle, at 1035°C. Depending on the supplied sodium content, the equilibrium composition of the bulk system moves along a straight line (green dashed line) towards the Na2O corner of the ternary
continued » Glass International April 2014
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Silica bricks are commonly used by the glass industry. Their corrosion resistance at temperatures of >1470°C, a low bulk
Fig 1. Phase diagram of the SiO2-CaO-Na2O system[11]. All photos sourced from RHI
° 50 12
Standard Silica
CaO
° 00 15
S
ince the 1990s, glass melting furnaces with oxy-fuel technology have been rapidly developed due to the advantages the firing technology provides such as energy savings and increased melting rate as well as environmental benefits[1–3]: However, disadvantages have also been reported, such as higher crown and superstructure refractory corrosion. This is due to the increased NaOH vapour concentration in the furnace, associated with the elevated water produced using oxy-fuel firing[4]. It means traditional standard silica is corroded more rapidly when the furnace is fired with oxygen rather than air[4,5]. To address this issue glassmakers replaced standard silica with fused cast AZS or fused cast alumina to achieve longer furnace lifetimes[6,7]. However, these refractories are more expensive than standard silica. Consequently, the glass industry has been looking for a material that has high corrosion resistance when using oxy-fuel technology at a reasonable investment price. In response to market demands, RHI developed a silica brick without lime bonding (Stella GNL, a no-lime silica brand) for this application[8,9]. The results of postmortem studies performed on standard silica, no-lime silica, and fused cast AZS refractories that had been installed in oxy-fuel fired soda-lime glass melting furnaces are reported in this paper and confirm Stella GNL’s advantages for this application.
31
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Refractories
32
Sample
Refractory
No-Lime Silica
Fig 3. Scanning electron micrograph of the hot face of the silica brick located near the throat.
2.5 Standard silica Stella GNL
2.0 1.5 1.0 0.5 0.0 0
10
20
40
30
Distance from hot face [mm] Fig 4. Na2O diffusion into standard silica and Stella GNL bricks after a three month field trial in the superstructure of an oxy-fuel fired container glass furnace.
SiO2
Na2O
Al2O3
CaO
[wt %]
[wt %]
[wt %]
[wt %]
Stella GNL
98.6
1.0
0.3
0.1
2
Standard silica
95.9
1.0
0.6
2.5
3
Standard silica
95.4
2.0
0.6
2.0
Table 1. Refractory compositions used for the thermodynamic calculations presented in Fig 5.
As described, the corrosion process affecting standard silica bricks in oxyfuel fired furnaces is initiated by alkali vapour causing dissolution of wollastonite in the bonding matrix[13]. The resulting melt then plays an important role in the further corrosion of SiO2. Since a modified bonding system without wollastonite eliminates this weak point in silica bricks, RHI developed a silica brick without lime, Stella GNL. In a field trial, standard silica and Stella GNL bricks were installed in the superstructure of an oxy-fuel fired container glass furnace. After three months the Na2O diffusion was measured in these samples. The results showed that Na2O diffusion into the standard silica was higher than into Stella GNL (Fig 4). Microscopic analysis of a cross section through the Stella GNL brick after the trial showed an inert structure and no sign of attack directly at the hot face surface.
Thermodynamic calculations
1
Glass International April 2014
than the brick from near the throat, the Na2O had not infiltrated further in the direction of the cold face. Consequently the Na2O content in the centre and at the cold face was low (0.7wt% and 0.3wt.%, respectively). At the hot face the CaO level was low (1.0wt.%) because the newly formed SiO2, CaO, and Na2O containing melt had dripped down into the glass bath. It was evident that enrichment of CaO in the direction of the cold face had not occurred, since the CaO content at the centre and cold face (2.4wt.% and 2.3wt.%, respectively) corresponded to CaO levels in an unused silica brick. Due to the lower operating temperature in this region, the main mineral phase in the brick was tridymite.
Fig 2 a and b. Silica crown bricks after 14 years application in an oxy-fuel fired container glass melting furnace. Brick from (a) near the throat and (b) near the doghouse.
Na20 in silica [wt.%]
system. The blue triangles at 1400°C, 1500°C and 1600°C represent the bulk compositions of silica brick + Na2O, which are fully molten at the specified temperature. Fig 2 shows two representative silica bricks from near the throat and doghouse of an oxy-fuel container glass melting furnace after a 14 year campaign life. Chemical and mineralogical analyses were performed on samples taken from the hot face, centre and cold face of these bricks providing comparative data along the temperature gradient when the bricks were in operation. The porosity was also determined for two samples from the brick located near the throat. The brick from near the throat had a lower Na2O content at the hot face (0.4wt.%) in comparison to the centre and cold face (1.3wt.%). This was a result of alkali infiltration from the hot face towards the cold face. Due to dissolution of wollastonite, the CaO content at the hot face was low (0.7wt.%). Whilst melt containing SiO2, CaO, and Na2O had dripped down into the glass bath, part of this melt would also have migrated towards the cold face, resulting in the CaO content being even higher in the centre (3.5wt.%) than at the cold face (2.5wt.%) where the CaO content was comparable to that of an unused standard silica brick (2.5 wt.%). Enrichment of CaO in the brick centre was also reported in the literature[12]. The main mineral phase in all samples was cristobalite, which indicates the brick temperature had become higher than 1470°C during service. The brick was more porous (24 vol.%) at the hot face than in the centre (16 vol.%), as a consequence of melt dripping out at the brick’s hot face. Scanning electron microscopy of the brick hot face clearly revealed sharp edges caused by the melt dripping off and silica grains surrounded by melt in the remaining areas (Fig 3). In the case of the brick from near the doghouse, the Na2O content at the hot face was relatively high (2.5wt.%). Since the temperature of this brick was lower
Thermodynamic calculations were performed using FactSage (Version 6.3) to determine the amount of melt present in standard silica bricks and Stella GNL at Na2O concentrations similar to those occuring at the brick hot face during service in an oxy-fuel fired melting furnace. The three brick compositions examined are detailed in Table 1. Sample 1 represented no-lime silica with 1wt.% Na2O, corresponding to an
continued »
Glass two vertical halves_Glass two vertical halves 03/04/2014 08:53 Page 1
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RHi_00_GI_0909 4/1/14 9:25 AM Page 3
Refractories
100
2.0
3.1
6.1
Melt 2 5.4
6.7
90
8.0
85 Si02(S4)
80 75
Si02(S5)
70 1000
1100
1200 1300
1400
100
95 CaSi03(S)
9.2
CaSi)3(S2)
13.2
85
16.0 19.3
Si02(S4)
80 75 70 1000
1500 1600
Melt 1
6.9 90
Melt 2 4.7
Na2Ca3Si015(S) Phase distribution [wt.%]
Melt 1 95 5.7 6.3 7.0
Phase distribution [wt.%]
Phase distribution [wt.%]
100
Si02(S5)
1200 1300 1400 Temperature [°C]
1100
Temperature [°C]
1500 1600
95
8.2 Na2Ca3Si015(S)
90
10.5
85 80
CaSi03(S2) 17.4 CaSi03(S)
75
Si02(S4)
70 1000
Melt 1
20.4 24.2 27.7
Si02(S5) 1200
1100
1300
1400
1500 1600
Temperature [°C]
Fig 5a, b, c. Results of the thermodynamic calculations performed for Samples 1–3, defined in Table 1, using FactSage (Version 6.3).
approximate situation that can occur at the brick hot face during service (Fig 4). Sample 2 was standard silica also containing 1wt.% Na2O, providing a direct comparison to Sample 1. Sample 3 was standard silica containing 2wt.% Na2O, which is a realistic composition for the hot face of a standard silica brick during service (Fig 4). The thermodynamic calculations were performed over an appropriate temperature range and the different phase amounts (wt.%) were plotted against the specific temperature (Fig 5). In the case of Sample 1 (Stella GNL) there was hardly any CaO, and therefore only SiO2 solid phases (trydimite up to 1470°C and cristobalite above 1470°C) and melts with two different compositions were formed. The wollastonite (CaO·SiO2) that was present in standard silica dissolved at 1310°C (Sample 2) or 1215°C (Sample 3).
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Sample 1 No-lime silica STELLA GNL containing 1wt.% Na2O Total melt amount 1400°C: 9.8wt.% 1500°C: 13.4wt.%
34
Sample 2 Standard silica containing 1wt.% Na2O Total melt amount 1400°C: 16.0wt.% 1500°C: 19.3wt.% Sample 3 Standard silica containing 2 wt.% Na2O Total melt amount 1400°C: 24.2wt.% 1500°C: 32.4wt.% In Fig 5 the exact amount of each melt is indicated as a % on the curves. For example, at 1400°C Sample 1 (Stella GNL) had 6.7wt.% of Melt 1 and 3.1wt.% of Melt 2, a total melt amount Glass International April 2014
of 9.8wt.%. However, at the same temperature (1400°C) the total amount of melt in Sample 2 (standard silica with 1.0wt.% Na2O) was 16.0wt.%, and in Sample 3 (standard silica with 2.0wt.% Na2O) it was even higher at 24.2wt.%. At 1500°C, all the samples had a higher amount of melt than at 1400°C, but the Stella GNL (Sample 1) still had the lowest level of melt compared to standard silica. This demonstrates why Stella GNL has a higher corrosion resistance than standard silica if the furnace atmosphere is alkaline.
[5] LeBlanc, J. Impact of Silica Attack on Soda Lime Oxy-fuel Furnaces. Presented at Ceramic Industry
Manufacturing
Conference
and
Exposition, Pittsburgh, USA, Oct., 11, 1995. [6] Godard, H.T., Kotacska, L.H., Wosinski, J.F., Winder, S.M., Gupta, A., Selkregg, K.R. and Gould, S. Refractory Corrosion Behaviour Under Air-Fuel and Oxy-Fuel Environments. 57th Conference on Glass Problems: Ceram. Eng. Sci. Proc. 1997, 18, Issue 1, 180-207. [7] Duvierre, G., Zanoli, A., Boussant-Roux, Y. and
Nelson,
M.
Selection
of
Optimum
Refractories for the Superstructure of Oxy-Fuel Glass Melting Furnaces. 57th Conference on Glass Problems: Ceram. Eng. Sci. Proc. 1997, 18,
Conclusion
Issue 1, 146–163.
Corrosion resistant refractories for crown and superstructure applications in oxy-fuel fired soda-lime glass melting furnaces have been continuously improved. The first generation material – standard silica – was replaced by a second generation – fused cast products. However, the new generation – no-lime silica – combines the advantages of standard silica such as the low weight, no exudation, and economic price with high corrosion resistance.
[8] RHI Product Information: Stella GNL – A New Silica Brick Without Lime Bonding. Glasstec Exhibition 2006, Düsseldorf, Germany. [9] Mulch, C., Weichert, T. and Postrach, S. Neuer keramisch
gebundener
Werkstoff
für
den
Oberbau von oxy fuel beheizten Glaswannen auf SiO2-Basis.
Presented
at
Hüttentechnische
Vereinigung der Deutschen Glasindustrie e.V., Meeting, Niederdollendorf, Germany, March 2006. [10] van Limpt, J.A.C. Modeling of Evaporation Processes in Glass Melting Furnaces, Ph.D., Thesis, Eindhoven University of Technology,
References
Netherlands, 2007.
[1] Kobayashi, H. Advances in Oxy-Fuel Fired
[11] Morey, G.W. and Bowen, N.L. High SiO2
Glass Melting Technology. Presented at XX
Corner of System Na2O-CaO-SiO2. J. Soc. Glass
International Congress on Glass, Kyoto, Japan.
Technol. 1925, 9, 232–233.
Sept., 26–Oct., 1, 2004.
[12] Faber, A.J. and Verheijen, O.S. Refractory
[2]
Gridley,
Performance
M. of
Philosophy, Oxy-Fuel
and
Corrosion Under Oxy-Fuel Firing Conditions.
57th
57th Conference on Glass Problems: Ceram. Eng.
Design
Furnaces.
Conference on Glass Problems: Ceram. Eng. Sci.
Sci. Proc. 1997, 18, Issue 1, 109–119.
Proc. 1997, 18, Issue 1, 1–14.
[13] Beerkens, R., Verheijen, O., van Limpt, H.
[3] Ibbotson, A., Hunter, J., Brown, J.T. and
and Smits, B. Evaporation of Alkali Compounds
McMahon, A.K. The Development of a Large
and Silica Corrosion in Glass Furnaces. Presented
Oxy-Fuel Glass Melter and an Assessment of its
at HVG-NCNG Colloquium on Operation and
Performance
Modelling of Glass Melting Furnaces, Aachen,
and
Potential.
Presented
at
European Seminar on Improved Technologies for
Germany, Nov. 8, 2005.
the Rational Use of Energy in the Glass Industry,
*RHI, Industrial Division, Wiesbaden, Germany. **RHI Technology Center, Leoben, Austria. Website www.rhi-ag.com
Wiesbaden, Germany, Feb., 4-6, 1992. [4] Faber, A.J. Corrosion of Refractories Under Oxy-Fuel
Combustion.
Glass
Production
Technology International. 1997, 61-66.
food recycling_00_GI_0909 4/1/14 9:33 AM Page 1
Glass recycling
Turning food waste into glass The Colorado Center for Advanced Ceramics (CCAC) has recently demonstrated for the first time the potential of turning food waste into glass. This is an abridged version of a paper due to be presented at the forthcoming DGG-ACerS conference in Aachen, Germany in May. Dr. Ivan A. Cornejo, Dr Ivar E. Reimanis & Dr. Subramanian Ramalingam explain.
A
Feasibility
The melting stage: Scientists working on transforming food waste into glass. Images courtesy of the Colorado School of Mines.
Global production of new glass (excluding recycled cullet) in 2011 was about 100 million tons, with flat glass accounting for approximately 55 million metric tonnes of this. Flat glass is typically about 70wt% silica, and so using these figures we can calculate that currently 36.4 million metric tonnes of silica is needed to satisfy the global demand. The worldwide production of the main three grains consumed by humans in 2011 was 2,173 million tons worldwide. These grains, of rice, wheat, and corn, produce waste in the form of husks, stems, and cobs, and they are about one fifth of the total production by weight. This figure amounts to about 435 million tons of waste, which will on average be 15% silica. Therefore, using these figures, in 2011 65 million tons of silica could have been obtained from these three waste streams alone. This figure is much more than was needed for the entire production of flat glass globally that year.
continued Âť Glass International April 2014
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recent report published by the Food and Agriculture Organisation (FAO) of the United Nations indicated that approximately one third of all food produced for human consumption in the world is lost or wasted[1]. In the US alone, according to the US Environmental Protection Agency 2013 report, a total of 250 million tons of municipal solid waste was generated in 2011 and about 34.4% (86 million tons) is of an organic form (excluding paper and paperboard)[2]. The recent discovery that commercial glass and glass-ceramics can be made entirely from foods or agricultural waste with unusual physical and chemical properties[3] is the first demonstration of making glasses and glass-ceramics from unusual mineral sources. A sustainable and environmentally attractive process, the trash-to-glass concept proposes harvesting the mineral portion needed to make glass from organic food waste, thus treating waste as a mineral with which to make advanced materials[4-5].
35
food recycling_00_GI_0909 4/1/14 9:33 AM Page 2
Glass recycling
Is it glass?
XRD
0.004
2000
0.002 dl/Lo
2500
1500
Tg ~ 525°C
0.000
1000
-0.002
500
-0.004
Average CTE: 10.2 ppm/ºC from 50ºC to 500ºC
-0.006
0 20
40
60 2θ (degrees)
80
100
0
100
200
500 300 400 Temperature (ºC)
600
The glass was made by conventional melting technique, and the characterisation of the two compositions are displayed on Fig 1 and Fig 2, demonstrating that the material produced from the food waste is both amorphous and has a glass transition or transformation region. This proves that the material is glass, and therefore glass can be made from organic food and agricultural waste products such as peanut shells, rice husks, egg shells and corn husk stems. The CCAC exists to serve as a focal point with the State of Colorado for interdisciplinary research and education on ceramics and related materials including their synthesis, processing, manufacturing, properties and performance. It was established in 1988 with help from CoorsTek and is based at the Colorado School of Mines.
3000
dilatometre
XRD 0.006
Average CTE: 9.7 ppm/ºC from 50ºC to 500ºC
0.005 Tg ~ 620°C
0.004 2000
dl/Lo
Intensity (a.u.)
2500
1500
0.003 0.002
1000 0.001 500 0.000 0 20
40
60 2θ (degrees)
0
100
80
100
400 500 300 200 Temperature (ºC)
600 700
Fig 2 A and B XRD and dilatometre’.
Oxide
Target wt%
Raw materials
SiO2
74.0
Rice husk
Al2O3
0.5
Al2O3
CaO
18.0
Eggshells
Na2O
7.5
Table salt
SiO2
55
Rice husk
CaO
20
Eggshells
K2O
25
Banana peels
Composition 1
Composition 2
Table 1 - Targeted compositions.
Eggshells
Rice husk
Glass&1
Glass&2
0.11
97.8
6.55
80.6
68.43
Al2O3*
0.02
0.26
2.87
7.67
Fe2O3
0.02
0.16
0.04
0.06
7.66
10.60
Oxide SiO2
Banana Wt%
CaO
98.6
0.58
3.21
FAO 2013
MgO
0.81
0.24
1.26
0.3
0.97
2. United States Environmental Protection
K2O
0.07
1.33
67.6
0.42
11.30
Na2O
0.13
BaO
0.15
Natural Resources, ISBN 978-92-5-107752-8, ©
Agency, Office of Solid Waste (5306P) EPA530R-13-001 May 2013. Municipal solid waste in the United States: 2011 facts and figures 3. IA
Cornejo,
IE
Reimanis,
and
S.
Ramalingam, “Methods of making glass from
8.1 0.03
ZrO2
0.12
Patent No.61/873,696 (2013)
0.02
4. http://ceramics.org/ceramic-tech-today/
ZnO
0.01
P2O5
3.37
CI
17.4
new-approach-to-mining-extractingglassmaking-raw-materials-from-food-waste 5. http://www.thedenverchannel.com/news/
0.15
local-news/colorado-school-of-mines-
* Alumina seen in resultant glasses is a contamination from crucible used
professors-turning-garbage-into-glass
Table 2 - Composition analysis (XRF).
Glass International April 2014
0.03
0.02
TiO2
SrO
organic waste food streams,” US Provisional
700
Fig 1 A and B ‘Dilatometre’. 3500
1. Food Wastage Footprint: Impacts on
www.glass-international.com
0.006
Analysis
Research compiled by Dr. Ivan A. Cornejo, Dr Ivar Reimanis & Dr. Subramanian Ramalingam, from the Metallurgical and Materials Engineering dept, Colorado School of Mines.
36
dilatometre
3000
Intensity (a.u.)
Glass is an amorphous solid which exhibits a glass transition or transformation region. Therefore, we must demonstrate that the material produced from this waste is amorphous and has a glass transition or transformation region. Table 1 shows the targeted compositions for two of the glasses that were made from organic waste, and Table 2 shows an analysis of the composition of each type of glass produced.
0.97
heye_00_GI_0909 4/1/14 9:56 AM Page 1
Quality control & inspection
A plant management system Gerd Schuetz* outlines a data collection system which identifies a plantâ&#x20AC;&#x2122;s efficiency and how it could be improved.
The Plant Management System supports: The group director who wants to know the performance of all plants, primarily by a mobile device; The plant manager, to monitor plant efficiency and quality level; The department manager, to manage his department in terms of maintenance and improvements; and The operator, so that he can react quickly and target-oriented. The information flow starts with operational information and will be aggregated for the strategic level. Managing quality levels is important, resulting in more demanding customers with high-speed filling lines. So tracking and tracing is key. All existing data are safely stored in a database. That gives the opportunity to get information about former production runs. These will be helpful for comparisons and for a later proof of the production quality level at a certain moment.
Different modules The solution consists of different modules. The events of the last 24 hours will be displayed by a line sheet. It includes occurred defects, works/adjustments carried out and the realised efficiency split in Hot End and Cold End. The inspection equipment will be displayed on a separate page. A summary of the detected defects helps check the current production status. All data are linked to the cavity number, which allows the operator at the Hot End to react quickly. Trace the success of improvements by long term trend charts. The trend charts are useful to see how stable the production is. The person responsible
the tools at the IS-machine will be changed, the operator documents the reason for the change in the system. The information will be displayed in the mould shop module. So the workers of the mould shop know what happened with the tool and can carry out targetoriented repairs. Assisted by time stamps, it is possible to calculate the run time of the tools. By using this information, it is possible to create a uniform run time over the whole mould set. The mould shop module can build a history of the tools, including life time.
Systems Integration Available interfaces to common ISmachine control units as well as to
The plant management system collects all relevant data in real time.
can prevent poor efficiency. Be prepared for the daily production meeting by using the predefined reports. The reports summarise the daily production data. How much downtime occurred and why? Which defects, classified in categories such as risk and critical arose? Evaluation sheets build the basics for trouble-oriented assessments. The evaluation sheet will help figure where the trouble comes from. In addition it tracks the result of the improvement measures. Do they remove the problem or do they make it worse? Essential hints can be found by checking these sheets. A clear documentation is key for success, e.g. the mould shop module. If
common inspection machines already exist. The HiShield QCLab software for the laboratory can be linked to the system. Hence, the off-line inspection data can also be integrated. The HiShield Production Management System is an evolution of the Heye Information System (HIS). It is performed as a browser based system. That means, particular software at the workstations is not required and the existing ITinfrastructure can be used. This builds the base for further developments such as a mobile version.
* Product Manager Cold End, Heye International, www.heye-international.com Glass International April 2014
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H
ow is our efficiency, what trouble do we have and why? Where do we lose production and which defects are produced? These are the key question for a plant manager today. The HiShield Plant Management System is a designated software solution which helps to centralise, structure and display all this data. The glass plant generates information for the production process: At the Hot End, where the bottles are produced, and at the Cold End, where the bottles are inspected and packed. Information is also generated in the laboratory for statistic measurements and in the mould shop. But the information is widespread over the plant rather than centralised. All the data will be aggregated to get a complete overview of production. The operator can comment each event in the system. The next shift can see what happened and why in the previous shift. The group director can compare different plants.
37
LESS EMISSION. BETTER PERFORMANCE. THE EME-NEND® BATCH CHARGER.
NEW GENERATION OF BATCH CHARGER INTRODUCED
The new EME-NEND® generation features chargers with one, two or three screws. Small melting furnaces can now enjoy all benefits of the world´s best charging technology. In addition the charging performance and lifetime was increased again.
• Completely sealed Doghouse • No uncontrolled entry of false air into the furnace • Reduction of NOx emissions and of energy consumption • Considerably less dust formation due to the transport by means of screw conveyors • Optimal batch distribution in the glass melting • Quick and easy exchange of the screws • Even huge melting furnaces can be operated with one charger and a single doghouse
EME Maschinenfabrik Clasen GmbH • E - M a i l : c o n t a c t @ e m e . d e • w e b s i t e : w w w . e m e . d e
tiama_00_GI_0909 3/31/14 12:43 PM Page 1
Quality control & inspection
A vision sidewall inspection solution for round engraved articles Laurent Barel* identifies a sidewall inspection system that helps solve the challenging topic of engravings.
Dynamic zones Based on the marketâ&#x20AC;&#x2122;s most powerful image processing electronic boards, a
Fig 1.Typical inspection setup avoiding high sensitivity in the engraved area.
Fig 2. Dynamic zones (yellow and white) following the engravings position.
Fig 3. Examples of sensitivity cartography taking into account the article orientation.
real time communication and information consolidation is now possible between the different cameras inside a MCAL4. These internally developed Calia boards and the corresponding software
Fig 4. Stone, blisters, grease marks and birds wings detected inside the engraved area.
allow the MCAL4 to dynamically follow the position of an engraved area on round articles. After an automatic
continued Âť Glass International April 2014
www.glass-international.com
A
s the global amount of round engraved articles constantly increases it has been difficult for glassmakers in recent years to reach their customer quality target. In fact, more engraving usually means better perceived quality for the end consumer. This does not allow any global quality degradation related to these engravings, as the trend in beer and wine markets shows a huge increase in the amount of engraved wares. Engravings have always been one of the most challenging topics for sidewall quality inspection systems. In the recent past, the only available solution on round engraved articles was to apply inspection zones setup with a huge loss in sensibility wherever the engravings could be (Fig 1). This was a unique solution allowing an acceptable false rejection versus quality balance. This solution was far from perfect, as many defects inside or outside the engravings were not detected because of the poor detection sensitivity applicable in these areas of the article. Tiama has carried out three major steps, now available within its MCAL4 product range.
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tiama_00_GI_0909 3/31/14 12:43 PM Page 2
Quality control & inspection
learning by the operator of the article area followed by the software, the engraving’s position (up to three dedicated dynamic zones) will be recognised and found by the software. The position of the relevant zones will be displaced around the article to match the exact position of the logo. It represents a huge improvement, as the area outside of the logo is now inspected with the best possible sensitivity. Any area outside of the engraving will thus be processed as if there were no engraved parts in the article (Fig 2).
Dynamic masking
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The technology was developed to drastically improve the detection performances on non-round engraved articles. It consists of a continuous learning of the production articles, leading to an exhaustive cartography of the article. This cartography, called a ‘mask’, will be used by the image processing software to detect any foreign object in the engraving. Based on what has been learned from the production flow, the software will decide on its own what pixels can stay
40 Glass International April 2014
sensitive, and what ones have to use a decreased sensitivity to avoid good ware rejection. This approach of a pixel-dedicated sensitivity is to be considered as a real game changer in the vision based inspection field. On non-round articles (or in the finish and heel of round articles) the benefits of such an approach are obvious. As it drastically increases the potential defect detection sensitivity, it also reduces the impact of a human operator’s skills, as the learning is automatically and constantly made by the software: Two operators will get the exact same result in the shortest possible time.
3D dynamic masking It is now possible to combine those two technologies to obtain a 3D Dynamic Masking Feature. As the zones will continuously follow the engravings, a 3D masking learning process will be achieved: The sensitivity cartography, or mask, will also be displaced around the article. The mask learning thus takes into account the article orientation to update
the sensitivity mapping and to search for defects into the engraved parts. This is a significant step in detection capability as the best possible sensitivity is now also available inside the more complex zones (Fig 3). In terms of defect detection capability, no defect position will be out of the scope of the MCAL4, whatever the position of the defect. Defects outside of the engraved area are of course possible to reject but small stones or critical defects located inside the engravings are now possible to be rejected, without affecting the global false rejection rate of the line (Fig 4). As a main player in the hollow glass market, Tiama continuously invests in R&D (10% of turnover per year). Innovation and new solutions are fully part of its business model. With the 3D Dynamic masking technology Tiama answers the challenge of inspecting customised, complex production without affecting productivity.
*Vision and Hot-End Product Manager, Tiama-msc &sgcc, www.tiama.eu
agr_00_GI_0909 4/1/14 9:58 AM Page 1
Quality control
The best things come in small sizes The latest version of the Agr’s Dimensional Sampling Gauge (DSG), the DSG-P is targeted towards manufacturers of small ware, writes David Dineff*.
Measurement features Weight measurement: The DSG-P provides the capability of monitoring individual bottle weights to a high level of accuracy of +1g. Finish and body measurements: The finish and body dimensional measurement station is the central function of the DSG-P and offers unlimited measurement capabilities. The DSG-P incorporates multiple, highresolution, telecentric cameras to perform measurements over the entire container body and finish. Bottles are placed in the finish and body station by the robot, then positioned in front of
the cameras by a high precision table with 360 degree rotational capabilities. A complete circumferential scan is performed on each bottle, providing a comprehensive image for measurement processing. This makes it possible to process simple as well as very complex measurements at multiple locations to a very high degree of accuracy and repeatability. All measurements are completed within 30 seconds regardless of the number and complexity of measurements specified for the job. ID/bore and pushup measurements: For ID/bore measurement, the DSG-P features a special small-bore gauging system that can measure bores as small as 11mm. Functions can be programmed
approach where measurements are performed simultaneously in all stations. The robotic handling system precisely moves containers through each station, providing smooth bottle transition, automatic centring and positioning for precise measurement. The user interface on the DSG-P incorporates touch screen technology for ease of operation. Measurement information is displayed on a highresolution, colour monitor in a number of formats that enable an operator to monitor critical areas of a container and quickly assess testing in progress. Typical bottle measurement routines are pre-programmed and customised tests can be easily created, providing great
The DSG-P is targeted towards manufacturers of small ware.
for multiple level measurements or a continuous scan to a depth of 40mm. A graphical representation of the finish profile is provided for quick evaluation and visualisation. Push-up measurement is also performed in this station. Thickness measurement: As an option, the DSG-P can be fitted with Agr’s Thickness 360 measurement gauge. This high-precision device, accurate to + 0.02mm, utilises the visual scan data gathered by the DSG-P imaging system to position the thickness sensor for optimal measurement.
versatility in job creation and setup. The DSG-P is available in several configurations including: 1. Stand-alone measurement station for automated laboratory applications in the laboratory, or along the production line. 2. Or, as part of Agr’s OmniLab automated sampling station, it can be connected to the line via a sampling conveyor, and configured to work with other online devices to receive select containers at regular intervals for automated dimensional measurement.
Fast throughput
*Product Marketing Director, Agr International, Inc., USA. www.agrintl.com/
Throughput of up to 100 bottles per hour is facilitated via a pipe-line
Glass International April 2014
www.glass-international.com
T
he DSG-P is configured for the handling and measurement requirements of small format ware such as pharmaceutical vials, cosmetic containers and related products. Retaining the same capabilities of the standard DSG, this version specifically addresses the precision measurement needs of manufacturers of this type of ware including very small finish attributes as well as body and ID measurements. Like the standard Dimensional Sampling Gauge, the DSG-P provides accurate, repeatable and comprehensive measurement of critical dimensions, with a special focus on measurements of ware down to 38mm in height and diameters under 70mm. The automated, self-contained testing station can process a complete set-out of bottles and work unattended to perform a number of critical dimensional measurements, in a single hands-free operation. The system design offers a modular approach that includes a robotic handling system as well as measurement stations for body/finish dimensioning, weight and ID/Bore/Pushup. An optional station incorporating Agr’s Thickness 360 wall thickness measurement system is also available. Data from each station is correlated by the system to mould number and available in one consolidated report via the user interface.
41
igr germany_00_GI_0909 4/2/14 12:53 PM Page 1
Quality control
Wet chemical analysis of the redox state of glass Germany’s Institut für Glas- und Rohstofftechnologie (IGR) was founded in January 2008 and has developed to become an efficient service provider to the glass industry. Here, IGR* gives an overview of its work, focusing on Fe2+ analysis.
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A
42
s an independent and neutral institute, IGR carries out physical and chemical analysis on glass and raw materials, as well as on waste glass from glass recycling. Another focus of activity is on analysis in the identification and fraction analysis of glass splinters. IGR operates as a consultant to renowned glass melting factories, raw material suppliers and glass recycling companies advising on batch, melting, and moulds process as well as cooling, and hot and cold coating issues through the entire technology chain. In addition, its consultants advise on production optimisation and overcoming defects. IGR prides itself on its research and development, internal and external training programmes and laboratories. The institute uses an IGR internal Quality-Management-System that complies with DIN EN ISO/IEC 17025. Additionally, IGR analyses construction materials and fire retardant materials as well as examining harmful materials such as asbestos or mineral fibres. Founded in 2008, IGR won the Göttingen, Germany innovation award in 2010, 2011 and 2013. It has 10 employees and its analytical services include: REM-EDX for inclusions, cords, particles, asbestos and mineral fibres; ICP-OES for chemical analysis from glass, raw material and heavy metals (50 elements, included B); FTIR for synthetic material and oil analysis; OH in glass, Glass Internationa April 2014
detection from Cold end coating and varnishing. Other services include specific glass analysis (glass fracture, seeds, blisters, strains, homogeneity,density, inclusions, several corrosion tests, migration, splinters identification,several stability verification and laboratory glass melting). The institute also samples analysis from heterogeneous glass recycling waste, among other things, to assess the quality from recycled glass.
Wet-chemical analysis In recent years, there has been considerable demand at IGR for reproduceable Fe2+ analysis in silicate material from the glass manufacturing industry. The negative environmental impact on the analysis is a well-known problem. A possible methodology has been suggested by DIN EN ISO 14719, entitled ‘chemical analysis for non-flammable material, glass and varnishes – the spectral – photometer determination from Fe2+ and Fe3+ with 1.10-
phenanthroline (ISO 14719:2011); German edition EN ISO 14719:2011’. However, current research using this methodology, including those of S. Bartolomey, (Aachen, Germany), has proved inconclusive. Since the beginning of 2013, IGR has worked on the practical implementation of the Fe2+ analysis in silicate raw and basic materials. Initially it undertook extensive literature reviews, most notably articles written by P. Brosch and H. Hahn (1992) and those detailing the ICG method (1999). Following this, the IGR spent several months working on the practical implementation of the Fe2+ analysis, and on defining a methodology based on the Norm. The resulting analysis is robust and free from negative environmental factors (such as UV radiation, shielding gas application), as well as interference by polyvalent elements in the glass matrix. Table 1 lists the wet chemical Fe2+ analysis in accordance with the IGR method of various soda-lime glasses (KNG) and borosilicate glass (Boro). The 5th column shows the traditional Fe2+ values, taken using conventional transmission measurements. These can be directly compared with the results of the wet chemical Fe2+ analysis in column 3, gained using the IGR method. In addition to the expected variations in the
continued »
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EVOLUTION IN IS-MACHINES HEYE SPEEDLINE
HIGH SPEED AT HIGH QUALITY FOR MANY YEARS TO COME High safety and high usability to protect staff and equipment Clear interfaces for fast installation and exchange of parts Clean design to fulfil HACCP requirements Flexibility through modular design Same core â&#x20AC;&#x201C; same variables
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22.01.14 16:44
igr germany_00_GI_0909 4/2/14 12:53 PM Page 3
Fig 1.
Chemical fe2+ - analysis based in the norm )wt %)
1000,0
-40,0
90,0 -30,0
80,0 70,0
-20,0
60,0 -10,0
50,0 40,0
0,0
Redox number for 2000kg siO2
Quality control
Sources 1 DIN EN ISO/IEC 17025, Allgemeine Anforderungen an die Kompetenz von Prüfund
30,0 10,0
20,0
Kalibrierlaboratorien,
(ISO/IEC
17025:2005); German and English version EN ISO/IEC 17025:2005
10,0 0,0 0,000
Economy of energy and raw material supplies Reduction of necessary decolorising Detection of colour cords in brown glass
20,0
2 DIN ISO 14719, Chemische Analyse von feuerfestem Werkstoff, Glas und Glasuren –
0,050
0,100 brown green white
0,150
0,200
0,250
0,300
0,350
0,400
0,450
0,500
Spektralphotometrische Bestimmung von Fe2+ Fe3+
und
mit
1,10-Phenanthrolin
(ISO
14719:2011); Deutsche Fassung EN ISO
Chemical SO3 - analysis with the ICP-OES (wight %)
14719:2011
results for coloured glass, there were also large differences recorded for white glass. Furthermore, column 6 of the table includes the redox numbers (RZ), calculated using the chemical Fe2+ analysis in accordance with the IGR method, based upon the findings of M. Nix and HP Williams (1990) for 2000kg SiO2. Column 4 sets out for comparison, an internal IGR Fe2+ model, resulting from various calculations of transmission values for UV-VIS analysis and several chemical parameters from the ICP-OES analysis. Further analysis of the Fe2+ results that were determined by the wet-chemical IGR reproducible method are listed in Fig 1. The dependencies can be seen between the ICP - OES values with the corresponding SO3 concentrations. The graph also shows the corresponding redox numbers to the respective SO3 concentrations. It shows not only the results for the typical white,
green and brown soda-lime glass, but also the foliage coloured and highly reduced white glass. Thus for example, the graph shows that a green glass with a Fe2+ score of 36wt%, which was determined using the wet-chemical IGR method, has a corresponding redox number of +2. In particular, this graph devised by the IGR shows the reproducible correlation of the three individual parameters Fe2+ SO3 - RZ as well as the overlapping of the corresponding curves. In conclusion, the IGR method to determine the wet chemical Fe2+ analysis is reproducible, largely free from negative influences, and can lead to big improvements in the assessment of the redox state of glass melting units. These include: Detection of the redox potential Earlier detection of unwanted glass staining Control of Fe2+ concentration
3 P. Brosch/H. Hahn (1992), Kolorimetrische Bestimmung von Fe(II) und Gesamteisen in Silikat- und Boratglas, WW III – Analytische Labor – 1-2“ Institut für Werkstoffwissenschaften (Glas und Keramik) Erlangen - Nürnberg 4 ICG Verfahren, Glass Technology 40,1999, No. 1, 24-28 5 M.
Nix/H.
P.
glass -
batches containing recycled cullet 6 Bamford/Hudson,
www.glass-international.com 44
ilis
GmbH,
Spektralanalyse und Farbmessung in der Glasindustrie Mai 2002 S.50
*Institut für Glas- und Rohstofftechnologie GmbH (IGR), Göttingen, Germany www.IGRgmbh.de
Redoxnumber (RZ)
modelled calculation
transmission
RZ
from the transmission
after Bamford/Hudson
2000kg SiO2
DIN EN ISO 14719 source: [2]
and the ICP
Source: [6]
wet chemical analysis
smelter from IGR based in the norm
KNG white
GS1
22,7
23,5
24,5
9,3
KNG eco white
GS2
34,3
33,5
25,4
3,8
GS2
65,6
64,5
26,3
-16,1
glass reduced in green
GS3
62,5
57,3
32,1
-13,8
KNG green
GS4
24,1
22,2
17,9
8,7
KNG brown
GS5
80,7
78,2
5,3
-26,4
Boro 3.3 white
GS6
30,8
27,8
7,6
5,9
KNG white - by waste glass reduced in coal-yellow KNG white- by waste
Table 1. lists the wet chemical Fe2+ analysis in accordance with the IGR method of various soda-lime glasses (KNG) and borosilicate glass (Boro).
Glass Internationa April 2014
(1990),
Calculation of the redox number of glass
Fe2+ (%) Glass
Williams
Glastechnische Berichte 63K S.271-279
glasstec copy_00_GI_0909 4/2/14 10:41 AM Page 1
Architectural glass
Individualised media façades can be realised by incorporating LEDs in glass laminates. This photo shoes an application where the “powerglass” product by German producer glas platz gmbh & co.kg was used. Photo: PopSign.
Glass functionality
G
lass products are used for more applications than ever and their performance range is growing. New applications require the optimisation of existing and the development of new glass types with specific functionalities. The transparency of this material continues to be of importance, but the versatile applications are today determined by the add-on functions achieved by specific manufacturing and finishing technologies. A variety of functional glass has stood the test of time in windows and façades for decades. In the past ten years glass products have boomed in interior design thanks to the successful development efforts undertaken by glass companies and glass machine manufacturers. Highly developed manufacturing and finishing techniques make for highperformance functional glass with properties tailored to customer needs for exterior and interior use. For building skin applications, performance characteristics such as thermal insulation, solar protection, sound-proof and security are in the foreground. Thanks to the use of coating and lamination technologies the products in this market segment push the limits of technical feasibility. For interiors, design considerations play a pivotal role. Here, too, the
positive developments can be attributed to new processing and treatment technologies.
Switchable glazing Switchable glazing now also provides attractive potential use for both outdoor and indoor applications. Various versions are available on the market: For instance, LC or PDLC glass (liquid crystal/polymer dispersed liquid crystal) turns opaque at the push of a button. This glass function is based on a polymer-liquid-crystal film laminated between two glass sheets and connected to a power source. While no voltage is applied the glass remains non-transparent, but as soon as electricity flows the liquid crystals of the polymer align in such a way that the glass sheet turns transparent. This allows the glass condition to be changed between transparent and opaque in fractions of a second. Such a variable functional glass is ideal for using in partition walls or for ensuring flexible privacy for conference rooms. Integration in insulation glass for windows and façades is also possible. This glass, however, is not suitable for solar protection due to its complete opacity. Efficient solar protection is provided by electrochromic glass. Depending on the direct current applied, the functional glass takes on shades of blue thereby
allowing variable sun shading. Here the wafer-thin electrochromic coating does not change colour spontaneously, but the process takes from several seconds up to minutes. Once the polarity of the voltage changes, the glass turns transparent again. While there is no current flowing it retains its given colour. Electrochromic solar protection glass is designed for use in windows and glass façades and has already been used successfully for several years such as LC glass. The third group of switchable glass types is thermochromic glass. This changes its light transmission characteristics without any human intervention. Its function is based on thermochromic materials that react to temperature changes. As soon as the glass panes heat up when exposed to solar radiation, the film containing the thermochromic substances laminated between the two glass sheets changes colour automatically. If the solar energy decreases, the glass laminate cools and turns transparent again. This functional glass is also suitable for integration in insulation glass and therefore qualifies for window and façade applications.
continued » Glass International April 2014
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Thanks to on-going research and development glass products can take on more functions. Glass panes can be transformed at the press of a button, upscaled to radiant media glazing or be used as high-performance displays.
45
glasstec copy_00_GI_0909 4/2/14 10:41 AM Page 2
Architectural glass
Luminescent glass New possibilities for realising lighting concepts or creating individual room atmospheres also come care of LED glass. The combination of glass and lightemitting diodes produces impressive light effects but LEDs only require little energy. There are various LED glass systems on offer. One version allows the LEDs to be positioned freely on the glass surface, thereby realising individual motifs and lighting concepts. To protect the light-emitting diodes from outside impact they are embedded in a cast resin between two glass sheets and supplied with power through an invisible, conductive glass coating. Available in white or RGB colours, the LEDs can create single or multi-coloured motifs. Even moving motifs can be realised by connection to a computer control unit. Another product solution is LED illumination of surfaces. Here the light-emitting diodes are not laminated between glass sheets but emit light from the sheet edge. Unlike with the glass shelves known from furniture, this product is illuminated across its entire surface rather than only around its edges. The effect is produced with the
help of a laser-cut diffusing glass. LED screens like this make for individual illumination of glass panels. Motifs printed on to the front panels virtually radiate through this direct backlighting. Since the glass panels lit with this technology are thin, they are also suited for retrofit-designs of ceilings and walls. This product only became possible through new laser technology for large-area glass engraving.
New LED generation Experts forecast great future potential and versatile applications in electronics, but also in the field of glass interior design for organic LEDs. Organic Light Emitting Diodes – OLEDs – are luminescent thin-layer components from organic, semi-conducting materials that light up when electrically stimulated. OLEDs can produce any number of colours, are highly efficient in energetic terms and – compared to inorganic LEDs – can be applied using thin-layer technology. This makes it possible to produce thin products with brilliant colours. The new technology, for which
experts see a market worth billions, is suited for self-luminescent displays in Smartphones or tablet PCs. Even largescreen TV sets are already offered with OLED technology. Unlike liquid-crystal displays (LCDs) OLED displays no longer require backlighting. This saves a considerable amount of energy and makes the products even thinner. The organic material is applied using tried and tested printing techniques (ink-jet or offset printing) and can be applied to plastics, glass and other materials. If sufficiently thin materials are selected, OLED colour displays can be easily bent or even rolled up. The extent to which this technology has found its way into the glass industry will be revealed by glasstec 2014 in Düsseldorf. From the 21st to 24th October the glass trade show will showcase not only current product innovations in the international glass sector but also the entire field of manufacturing technology and latest applications.
glasstec, 21st-24th October, Düsseldorf, Germany www.glasstec-online.com
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46 Glass International April 2014
Call today or visit our website for more information. Tel: +1.724.482.2163 • agrintl.com • E-mail: sales@agrintl.com
Vipotron_00_GI_0909 4/2/14 10:06 AM Page 2
Architectural glass
Defect scanners in architectural glass processing Rainer Feuster* discusses scanner based defect detection, which started in the industry ten years ago. The aim was to ensure an objective and equal evaluation of the visual quality of single glass components was executed during at least one part of the production process.
Goods entry In the goods entry or the cutting area the material is first checked to avoid contaminated or defected glass being processed and scrapped later on in the workflow, after having had value added to it. For controlling raw glass, Viprotron has brought out the Jumbo Controller, a device which is able to scan defects in brightfield transmission and reflection even with Lucite on the sheet. The device is placed between the tilt and cutting table. As there is no space for a washer in that area, a small blower/exhauster device cleans the upper surface roughly to take off Lucite aggregations and dirt. The lower surface can be cleaned by standard brushes. Single Lucite particles, required as separators on the glass, can remain. The scanning device blinds out these particles and concentrates on glass and/or coating defects. Depending on the connected PPS software and the way of storing the glass after breaking (sequential or free with slot racks), the use of such a device in
different levels of automation/workflow is possible: 1. Sequential storage on A or L racks: The detected defects can be shown on the breakout monitor and manually evaluated by the operator. The glass can then either be scrapped or directly reported for a recut. 2. Slot rack storage: The defects are reported to the PPS software and reoptimised within the given cutting plan by moving/turning/mirroring traverses. With this, the reoptimisation tries to lay the cuts, waste areas or smallest sheets on the detected defects. The result is shown on the breakout monitor and the operator can work according to level 1 3. Automatic slot rack storage: If the cutting area is completely automatic, including slot racking and residual plate storage, the defect detection results can be reported to the PPS system to be included in the general glass optimisation process. Then the optimisation takes into account the defect detection results and optimises cuts around defects for glass out of the complete stock of orders for the next raw glass. Alongside the detection of defected raw glass coming into the production process, is the documentation of the results and their use as a base ‘supplier evaluation’ guide. After a while, it will be
clear which supplier delivers the better raw glass quality, and therefore enables a smoother workflow and less recuts.
Middle of the process Most scanning devices are currently placed behind a washer in different production processes: In processing behind the grinding lines; in laminating before the clean room; and in IGU lines before the inspection area. These places guarantee the best possible detection results for two reasons: 1. There is a washer before the scanner so the glass is clean and all detection channels can be used properly. 2. With monolithic glass, all detection channels can be used. Having mentioned that in the cutting area the brightfield channels can be used without a washer by blinding out Lucite,
continued » Glass International April 2014
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D
efect detection generally happened in the middle of the complete production process, e.g. behind the washer of a double edger in the typical processing plant, or behind the washer in an IGU line in a unit manufacturer’s plant.
47
Vipotron_00_GI_0909 4/2/14 10:06 AM Page 3
Architectural glass
the scanning device is only able to focus in transmission on defects rich in contrast (such as bubbles or inclusions) or in reflection on coating defects (such as scratches or flakes). The use of the darkfield channel without a washer is impossible, because too many defects would be shown, especially on the surface of the sheets. Often, people want to inspect glass directly behind a toughening oven with the best possible results. In the oven, sulphur and other residues from the quench will lay down on the surface and create areas, which will be seen in the darkfield channel as contaminated. Monolithic glass allows the possibility of illuminating it from all sides. In finished IGUs, the spacer frames or possible Georgian Bars will create shadowed areas or reflective surfaces, which can hardly be taken into consideration by the system. To get the best possible results from the system the glass has to be free of frames or uncovered by any other material. As checking washed monolithic glasses delivers the best detection results, this is the best place for a quality
be secured by a much lower level of accepted defects at this point.
Final product control
evaluation of the glass, and also of the complete production process up to that point. Here, the operators can decide whether the defected sheets can be reworked or not, and can easily scrap the glass and report breakage for a recut. In addition, the operators can document the defects to determine and eliminate the root cause. The result will be an improvement of the workflow and of the glass quality. With regards to setting quality standards for the product, this area is key. In laminated glass or IG units two or more glass sheets come together as a sandwich. Any remaining defects will add up in the end. The quality standard of the final laminated glass or unit can
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Penico Neckring Dovetail Calibrator
Penico Gauges Ltd, Albion Works, Keighley Road, Bingley, West Yorkshire BD16 2RD UK T: 01274 511044 penicogauges@yahoo.co.uk www.penico.com
48 Glass International April 2014
The architectural glass branch cannot exercise 100% control over the final products. The European standard EN 1279 will seek to change that over the next few years. In Part I Annex D the visual guidelines will change from an ‘informative’ to a ‘normative’ level. This is not only for the above mentioned IGUs made of float/lowE, but also for toughened and laminated glasses as well. That means that in the future, the EN will state the normative quality level and with this a juridically accepted base for claim management. In central Europe a trend can be seen towards the introduction of scanners for the final control, in addition to existing scanners in the middle of the production process. These scanners only serve to ensure that the negotiated quality is delivered, and that data is available for the claim management.
*Vipotron GmbH, Germany www.vipotron.de
The Neckring Calibrator is a new concept in the measurement of the Neckring Dovetail. The traditional way of inspecting the Neckring Dovetail is to use a Neckring Dovetail Profile Gauge with a Go & No Go feature. This is the tried & trusted way of inspecting this vital feature. The disadvantage of using a traditional gauge is that the gauge will only inspect one standard. A different gauge is needed for Cast Iron, Bronze & the variations between. As we all know sometimes adjustments have to be made to the dovetail to make the Mould Set run. This is where the Neckring Calibrator has the advantage. The Neckring Calibrator gives an actual reading of the dovetail width. This unique gauge can be used on any variation of pinch diameter & dovetail height. It is not tied to one type of Neckring dimensions! It can be used at the same time on machines running cast Iron on one machine & Bronze on another. It can also be used to adjust an individual neckring to suit a troublesome Mould. If a Neckring has to be polished to make the problem Mould work then a measurement can be taken of the dovetail adjustment needed. The next time a Neckring is needed for this Mould the fit required can be replicated. No more guesswork! For Neckring manufacturers the gauge will enable them to set their machines quicker, predict toolwear. SPC studies & full inspection reports can be produced. The Neckring Calibrator is provided with a setting master. You can be assured that your gauge is always correct. No more concerns about the calibration status of your gauges. The Penico Neckring Dovetail Calibrator will be an invaluable asset your inspection department.
glassman review_00_GI_0909 4/2/14 12:55 PM Page 2
Glassman review
Glassman South America This year’s Glassman South America was held in São Paulo, Brazil. As media partner to the event, Glass International was there to co-host the conference. Sally Roberts reviews the show.
Exhibition The exhibition was sold out, with more than 80 companies displaying and discussing their latest technological developments and achievements. Visitors from international and domestic glass manufacturers such as Nadir Figueredo, Wheaton Brasil, and O-I attended the event. The UK was well represented by the likes of FIC, Pennine and ParkinsonSpencer, while the US also commanded a large presence with companies such as Quantum Forming, Ramsey Products, and Pyrotek. European companies were there in abundance, including Zippe, Xpar Vision and Fives Stein, and further exhibitors and visitors came from countries worldwide such as Brazil, China, Mexico, the Middle East, and Turkey
among others, to take part in the event. You can’t visit Brazil and not experience a bit of carnival, and so the exhibitor party which was held at the end of day one featured live music and entertainment from a samba group, which was very well received by all.
Conference For all of day one, it was standing room only at the well-attended conference, with presentations from engineers and experts from the container glass industry on the latest developments in areas such as heat recovery, IS machines, hot and cold end equipment, and inkjet printing. Speakers from Heye, Area Impianti, Fosbel, O-I, and Verallia among others appeared on day one, while day two included representatives from Xpar Vision, Verallia Germany, Bucher Emhart Glass, and the VDMA (the German Engineering Federation). Luis Sousa from Picvisa discussed the company’s first automatic recycling plant, while Daniel Amarel from O-I shared the company’s view on innovation in glass packaging. Abividro, the Brazilian association for the glass industry, also delivered presentations dealing with information necessary when doing business in Brazil, such as the Brazilian law on waste emissions. The two closing presentations from Isimat and Rosario, which dealt with
glass decoration using UV inks and high speed inkjet printing on glass containers respectively, were very interesting and demonstrated the developments in the technology that allows for the evergrowing trend of printing directly onto glass. The informative and varied talks were attended by engineers, scientists, and industry experts from companies such as Coca-Cola, Nadir Figueredo and O-I, and countries as diverse as the US, China, Brazil, and Europe. The majority of presentations are available to view online at www.glassmanevents.com/south-america conference or http://www.abividro.org br/noticias/confira-palestras-apresentadas -22o-encontro-tecnico-na-glassmansouth -america-2014
Coming up 2015 is set to be an exciting time for the glass industry, as indicators show that economic conditions around the world will continue to recover, and emerging markets are set to grow larger and stronger. We look forward to welcoming all our existing attendees to our next event, along with those who missed out this year. Glass International will be exclusively revealing Glassman’s next destination in the coming months, so stay tuned.
www.glassmanevents.com/south-america/ Glass International April 2014
www.glass-international.com
F
rom March the 12th - 13th the Fecomercio exhibition centre in São Paulo transformed into a hub of international business for the container glass industry. The two floors were packed full of global players, such as Interglass, Zippe, Bucher Emhart, BDF and Sorg, and the conference hosted speakers from renowned companies such as Verallia, O-I and Heye International. As the Glassman exhibition returned to Brazil for the second time, visitor numbers were up on 2010’s visit, and the conference excelled itself.
49
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Events world
Furnace Solutions 9 This year’s Furnace Solutions event takes place on Thursday, June 5th in Stokeon-Trent, UK. It will be preceded by a training day, themed Combustion of Fuel in Furnaces.
T
he annual Furnace Solutions conferences deal entirely with ‘practical’ glassmaking issues and are targeted at glassmakers, furnace equipment and specialist materials suppliers. The conference’s informal format allows delegates to share their experiences, and discuss solutions to some of today’s glass melting challenges. The conference venue is Lucideon (formerly Ceram), in Stoke-on-Trent, UK and takes place on Thursday June 5th, 2014. It is preceded by a training day titled Combustion of Fuel in Furnaces, on Wednesday June 4th. The programme so far includes papers from Erik Muijsenberg, of Glass Service Inc with a paper titled ‘Complete model based control glass production;’
Neil Simpson, of BOC Industrial Gases who will talk about ‘Hotspot boosting as a Lifeboat;’ James Crowe, of Johnson Matthey who will discuss ‘Platinum Coated Furnace Blocks;’ and Celsian’s Andries Habraken who will talk about the ‘Cheetah Energy Efficiency Improvement Strategy, a step forward in low-carbon glass production process.’ Other confirmed speakers include Zippe Industrialagen’s Philipp Zippe, Donald Park of Magneco/Metrel and Ardagh Group’s Sven Roger Kahl. The training day includes talks titled ‘Combustion in Glass Furnace Basics’ from Peter West; ‘Regenerator and Recuperator Design’ by Mike Davies; ‘Regenerator Burner Systems’ by Richard Pont, ‘Oxy-Fuel Combustion’, Neil Simpson; ‘Forehearths’ , Alan Stephens;
and ‘Control Systems’ from Stuart Hakes. With its excellent conference facilities, proximity to motorway and rail links, and being within 90 minutes of both Birmingham and Manchester airports, it has proved to be popular with all delegates. The conference fee, including a buffet lunch and refreshments, is £110.
For further information, visit http://www.furnacesolutions.co.uk or contact The Society of Glass Technology, 9 Churchill Way, Chapeltown Sheffield, S35 2PY, UK, Tel: +44 (0) 114 263 4455 E-mail: info@sgt.org
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50 Glass International April 2014
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diary page_00_GI_0909 4/2/14 10:28 AM Page 2
Events world
The glassmaker’s diary
2014 Glass Focus Conference - Organised by British Glass with the theme ‘Innovations within glass and the supply chain’. May 16th 2014 Grange St Paul's Hotel, London, UK CONTACT: Web: www.britglass.org.uk/glass-focus-conference 1st Joint Meeting of DGG – ACerS GOMD - 88th Annual Meeting of German Society of Glass Technology (DGG) and the Glass & Optical Materials Division Annual Meeting (ACerS GOMD). May 25th - 30th 2014 Aachen, Germany CONTACT: Web: www.dgg-gomd.org 14th Glass Stress Summer School - An intensive two-day course containing lectures, equipment demonstrations, practical stress measurements and informal discussions. May 29th - 30th 2014 Nordic Hotel Forum, Tallinn, Estonia. CONTACT: Web: www.glasstress.com/gsss.htm Mir Stekla 2014 - 16th International exhibition for glass products, manufacturing and finishing technology. June 4th - 6th 2014 Moscow, Russia. CONTACT: Web: www.mirstekla-expo.ru Furnace Solutions 9 - Organised by the Society of Glass Technology. The event will be preceeded by a Training Day on 4th June 2014. June 5th 2014 Ceram, Stoke-on-Trent, UK. CONTACT: Email: christine@sgt.org Web: www.sgt.org CelSian – NCNG international Glass Technology A five-day Glass Technology training course focused on industrial glass production. June 09th -13th 2014 Toledo, Ohio, USA CONTACT: Email: elize.harmelink@celsian.nl 10th ICCG (International Conference on Coatings on Glass and Plastics) June 22nd -26th Dresden, Germany CONTACT: www.iccg10.de Living Glass and GLASSAC - Society of Glass Technology conference for the glass community.. September 10th -12th 2014 University of Durham, UK CONTACT: www.durham2014.sgt.org glasstec International fair for the glass industry, machinery/equipment, skilled trade, architecture. October 21st -24th 2014 Düsseldorf, Germany CONTACT: www.glasstec-online.com
Glass International April 2014
CLASSIFIED april_Layout 1 4/1/14 9:50 AM Page 1
CLASSIFIEDS ANNEALING LEHRS
HEAT-UP SERVICES
FURNACES
ANNEALING ANNEALING & D DECORATING ECORATING LEHRS LEHRS ffor or Containers Containers aand nd Tableware Tableware
TTEMPERING EMPERING LLINES INES O ON NB BELT ELT / SSPINDLES PINDLES ffor or Tableware Tableware and and Stemware Stemware
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DECORATING MACHINES KBA-KAMMANN GmbH Bergkirchener Str. 228 D-32549 Bad Oeynhausen (Germany) Fon +49 (0) 5734 5140-0 Fax: +49 (0) 5734 5140-5130 mail@kba-kammann.com www.kba-kammann.com
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Tel +44 (0) 1506 657310, Fax +44 (0) 8704 799975 Email Sales@globalcombustion.com Web www.globalcombustion.com
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COMBUSTION EQUIPMENT
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INDUSTRIAL GAS ENGINEERS UNIT D2, BROOKSIDE BUSINESS PARK, GREENGATE, CHADDERTON, M24 1GS, UK TEL +44 (0) 161 654 7700 FAX +44 (0) 161 655 3812 EMAIL SALES@MONTSELAS.CO.UK WWW.MONTSELAS.CO.UK
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Special cast irons and alloys for glass moulds
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Fonderie Valdelsane S.p.A.