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April 2016—Vol.39 No.4
ICG PRESIDENT INTERVIEW NORITAZEH INTERVIEW ENERGY EFFICIENCY I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
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Contents
April 2016 Vol.39 No.4
WWW.GLASS-INTERNATIONAL.COM
April 2016—Vol.39 No.4
2 Editor’s Comment
ICG PRESIDENT INTERVIEW
5 International news
NORITAZEH INTERVIEW ENERGY EFFICIENCY I N T E R N A T I O N A L
12 Company profile: Noritazeh Tableware company looks to increase exports
A GLOBAL REVIEW OF GLASSMAKING
Glass International April 2016
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16 Company profile: Park Cam Ambitious plan comes to fruition 20 Personality profile: ICG president ICG president encourages more youngsters to join the industry 24 Supplier profile: Antonini 70 years in the lehr business
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26 Country overview: UAE Sun shines on UAE as a glass hub
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Front cover image www.pennine.org
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Energy efficiency 29 Alternative concepts for energy efficient container glass melting 32 Reducing risk in cullet quality control 37 Heat oxy-combustion to contribute to COP21 ambitions 40 Energy consumption during float glass annealing 42 Saint-Gobain tests HyGear’s Hy.REC system 44 History
Plus find us on Linked-In and Twitter.
@Glass_Int
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49 Glassman Middle East catalogue 62 Packaging group has it wrapped up 64 Simulation models provide solutions to manufacturers Events world 67 Fired up for Furnace Solutions 2016 70 Technology course has the glassmaking process covered 73 Celebrating 90 years of Germany’s DGG
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45 Chemical distributor at the forefront of UK soda ash industry
74 Diary
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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 Assistant Editor: Sally Love Tel: +44 (0)1737 855154 Email: sallylove@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com
Middle East comes to the fore as a glassmaking hub
Sales Manager: Jeremy Fordrey Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com Production Executive: Martin Lawrence Managing Director: Steve Diprose Chief Executive Officer: Paul Michael
O
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Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com
ver the past few months you may have seen a noticeable increase in the number of Middle East articles published within these pages. Since September last year we have published at least one article in each issue dedicated to the region. These have taken the form of interviews with key maufacturers, country overviews and company profiles, and have focused on countries including Saudi Arabia, Egypt, Iran and, in this issue, the UAE. All this, of course, has been linked with the forthcoming Glassman Middle East hollow glass exhibition and conference that takes place next month. But more than that, it is a reflection of the region’s glassmaking capabilities at the current time. The area has a rich history of glassmaking, with archaeological evidence suggesting that the first glass was made in Mesopotamia (modern day Syria, Iraq and Kuwait) or in Egypt in about 3500BC. Since then, glass has remained an integral part of the region’s heritage with many long-established companies in countries as far apart as Iran and Egypt. As Noritazeh’s Director, Saeed Kalafchi, mentions in this issue, such is the competition among glassmakers in his native Iran that many producers are aggressively looking at export markets. Its products are sold as far apart as
South America and Eastern Europe, as well as neighbouring countries. In each of our recent articles from the region, one thing has stood out: each company and country’s willingness to embrace new technology, to have the highest glassmaking standards and to adopt the most energy efficient and sustainable equipment. As is commonly known, the region is rich in natural resources with vast reserves of gas and oil. For some countries this translates into lower energy costs used in the manufacturing process. It means more money is available to procure the latest innovations from leading European suppliers. It means quality standards are upheld and environmental regulations are met. Global heavyweights such as Arc International and Saverglass have formed sites in the UAE alongside domestic container glass manufacturer Altajir Glass. With its projected rise in exports, its natural reserves of energy and a population with a projected rise in disposable income, the region can consider itself as a glassmaking hub. Many of the region's manufacturers have already registered to attend the Glassman event in Abu Dhabi. We hope to see you there. Greg Morris Editor gregmorris@quartzltd.com
Quartz Glass Portfolio
Monthly journal for the industry worldwide
Directory 2015 Annual international reference source
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Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034. Email: glass@quartzltd.com Website: www.glass-international.com
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Glass International annual subscription rates including Glass International Directory: For one year: UK £164, all other countries £231. For two years: UK £295, all other countries £416. Airmail prices on request. Single copies £45. Glass International Directory 2015 edition: UK £206, all other countries £217. Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK.
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International News
Saverglass sold to investment fund for €560 million
NEWS IN BRIEF
Management change at Zippe Industrieanlagen
Dr Bernd-Holger Zippe has moved from Zippe’s Management Board to the Supervisory Board after reaching the age of 65. He will continue to serve the company as Chairman of the Board, Shareholder and Technical Advisor. His successor as CEO will be his son, Dr Philipp Zippe, who will share the management with Dipl-Ing Gunther Mlynar. No other leadership changes are foreseen.
Bucher Emhart Glass appoints Juan Montes French container glass manufacturer Saverglass has been acquired by the Carlyle Investment Fund for €560 million ($630.5 million). Saverglass is involved in the design, manufacture and decoration of glass bottles and carafes created for premium spirits such as cognacs, whiskies and vodkas, along with premium and vintage Champagnes and wines. In the 30 years since it was formed it has had average yearon-year growth of 10%, and
built seven industrial facilities - four glassmaking plants and three decoration facilities. The latest stages of its development came with the launch of a plant in the UAE in 2013, bringing annual production levels to 700 million bottles, while in 2014 it opened a decoration plant in Arques, in the north of France. In a statement it said: “The group is in a dynamic market with a positive growth outlook. Its production tool has quickly reached a saturation
point, justifying the group’s continued industrial development abroad. “The world’s number three investment fund, Carlyle now accompanies, as the key partner of the management team, the necessary implementation of the ongoing group’s international development.” The company has thanked each of its employees with a profit-sharing payment of €1500. Pictured: The Saverglass site in the UAE
Arc International CEO to speak at Glassman Middle East conference Arc International’s Nicholas Hodler is to provide a keynote speech at the forthcoming Glassman Middle East hollow glass conference. He joins fellow keynote speaker Saeed Kalafchi, Director of Iran’s Noritazeh. The Glassman Middle East hollow glass conference is free to attend and takes place in Abu Dhabi, UAE on May 10 and 11. Mr Hodler will discuss ‘Safety first - protecting our people in a dangerous environment’. Another newly announced speaker is Daniel Schippan,
CEO of German company CM.Project.Ing. He will provide a paper titled ‘The Importance of Innovative and Modern Glass Plant Design’. Mr Hodler is Arc International’s CEO for the Middle East, India and Africa and is based at Arc’s plant in Ras al Khaimah, UAE. The tableware manufacturer produces approximately 4.3 million items each day from its five production sites around the world. Mr Schippan, of CM.Project. Ing, formed the company in 2007 and since then it has gone from strength to strength. It
provides project management and engineering in the design of new glass plants. Speakers confirmed at the FREE-TO-ATTEND conference also include hollow glass industry leading technology suppliers such as Tiama, Sefpro, Eurotherm, Pneumofore and Emmeti. Companies who have confirmed their participation at the parallel exhibition include Zippe, Iris Inspection Machines, Sorg, Antonini, Bottero and FIC UK among many other leading global suppliers.
Bucher Emhart Glass has appointed Juan Pablo Montes as Vice President Logistics & Manufacturing following the retirement of Ed Munz. Juan takes up his new role on April 1 2016 and will be based at the company’s HQ in Cham, Switzerland. Ed Munz will continue in a supporting role until his official retirement on June 30.
Heye International secures Orora contract
Heye International will provide equipment for Australia’s Orora group’s $42 million expansion. Heye will supply three IS-machines and cold end equipment, including the Heye Swabbing Robot, to Orora’s Gawler plant in South Australia. The packaging company recently announced the expansion project and aims to increase its annual glass bottle production at the plant by 60 million.
AGC to build €147m Brazilian glass plant
AGC Asahi Glass (AGC) will invest €147 million (JPY 18 billion) to build a second float glass production plant in the southeast region of Brazil. The new plant is scheduled to be completed by the end of 2018, which will increase AGC’s glass production capacity in the country to 2.4 times the current level.
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International News
NEWS IN BRIEF
Free advice surgery at Glass Focus conference
Glass Technology Services (GTS) will be offering a FREE advice surgery as part of Glass Focus 2016. One-to-one slots are available to any company with a ticket for the Glass Focus daytime conference. (Appointments will last up to 15 minutes.) So if you’ve got a particular challenge you think Glass Technology Services expert team can help with, book in for a private chat.
Fenzi invests in Spain’s Tecglass company
Fenzi Partecipazioni holding company has invested in Spanish digital glass processing group Tecglass. The Spanish company produces digital glass printing machinery and components and strengthens the working partnership of the companies, which have worked together for some time. Tecglass has recently studied, developed and produced a range of digital printing machinery specifically for the glass industry.
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Vetropack’s net sales increase by 9%
The acquisition of a Bormioli Rocco glassworks in Italy has led to an increase in unit sales and net sales of 9% for Vetropack’s 2015 fiscal year. Vetropack acquired the glassworks in Trezzano sul Naviglio (close to Milan), which meant it could increase its market share in Italy. Overall, Vetropack Group sold 4.64 billion units of glass packaging. 162.2 million of these units were produced in Italy.
Agr International opens Bangkok service centre
Agr International has opened a service office in Bangkok, Thailand. Services offered at the centre will include depot repairs and rebuild services for all Agr laboratory products for the glass and plastic container markets.
AGC Glass Europe in €25m Cuneo plant refurbishment AGC Glass Europe is to carry out a cold repair of its Cuneo float glass line in Cuneo, Piedmont, Italy. The refurbishment will allow it to expand its range of products as well as bring environmental and productivity benefits. The revamp will include design improvements that will
boost capacity and reduce its energy consumption, with a corresponding positive impact on its yield and product quality. The reduced energy consumption will also mean a large reduction in atmospheric emissions, with 50% less CO (carbon monoxide) and CO2 (carbon dioxide) and
30% less NOx (nitrogen oxide). The improved environmental performance in turn will make the plant eligible for the energy certification system operated by the Italian government, with subsidies granted over a period of five years in proportion to the energy savings achieved.
O-I wins right to enforce $485 million Venezuelan debt The World Bank’s dispute body has ruled that O-I can pursue enforcement of an earlier arbitration $485 million award against the country of Venezuela, which seized ownership of two of O-I’s bottle-making plants in the South American country in October, 2010. The award includes inter-
est since the illegal seizures by President Hugo Chavez, who died in 2013. The case still could be affected by Venezuela’s request to the World Bank’s International Centre for Settlement of Investment Disputes that the award be nullified. The Perrysburg, Ohio company said it will take vigor-
ous steps to collect the award, which is enforceable in about 150 member states subject to the International Centre’s jurisdiction. However, even with the committee’s latest ruling, O-I said collecting the $485 million will be difficult and it cannot predict how much money it might receive or when.
Carib Glass to double capacity Carib Glass will commission a second furnace in April to double the company’s capacity from 35,000 tonnes to 70,000 tonnes a year. Potential entry into the Cuban market was one of the
reasons which influenced the decision to invest in the furnace. The Trinidad and Tobago-based company is the only container glass manufacturer in the Caribbean with major
exports to the Dominican Republic, Haiti, Puerto Rico and the US. It made the decision to invest $180 million in a new plant about 15 months ago.
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International News
Verallia in €24m VOA furnace investment Verallia has modernised a furnace at its VOA site in France. The €24 million investment at the Verrerie d’Albi (VOA) site in Albi, France includes a rebuild of furnace number 1 and its three production lines. The furnace is dedicated to extra-flint and flint glass production. The installations will also enable VOA to extend its partnerships with many customers who have, over the years, expressed a preference for extra-flint glass, such as Bacardi and the Perrin family, event sponsors for
the furnace n°1 inauguration. The new equipment means VOA is more flexible and can ensure the continuous production of a range of bottles.
VOA is celebrating its 120th anniversary this year and employs more than 300 people. It makes 800,000 bottles a day and produces more than 350 different models a year.
Reha Akcakaya elected chairman of Glass for Europe Glass for Europe, the trade association of Europe’s manufacturers of building, automotive and solar-energy glass, has elected Dr Reha Akcakaya as its Chairman. Dr Akcakaya is Presi-
dent of Sisecam’s Flat Glass Group and takes over the Chairmanship from Mr Houchan Shoeibi from Saint-Gobain. He has served as Vice-chairman for the past
four years. Dr Akcakaya is an engineer and glass scientist by academic training and brings 18 years of experience and knowledge of flat glass to his new role.
Packaging workshop at Glass Focus 2016 conference The Glass Focus 2016 event will include a workshop on packaging design and supply, with speakers from Diageo, Proctor and Gamble, and Glass Technology Services (GTS). Speakers include Diageo’s Vicky Panayiotou, who has worked for Tesco, Marks and Spencer and Biffa Waste Services, and Dr. Simon Elmer, who leads
Procter and Gamble’s luxury fragrance package development. GTS will facilitate the workshop, which will include an opportunity for speakers and delegates to pose questions to one another. Phil Marsh, Business Development Manager at GTS said: “From cutting-edge packaging development and challenges to
trends and innovations in the supply chain – it promises to be a great day for learning and networking. “Our experts are looking forward to facilitating some great discussions and helping companies with their individual challenges.” The Glass Focus event takes place at Dynamic Earth, Holyrood, Edinburgh on May 12.
Glass International April 2016
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International News
NEWS IN BRIEF
Ethiopia’s Atlas to supply Raya brewery
Atlas has secured an agreement with Ethiopian brewer Raya Brewery for the supply of glass bottles, to replace the imported bottles that it currently uses. The bottles will be produced at the company’s planned glass bottling factory in Chancho, 45km north of the capital, Addis Ababa. Atlas and Raya have agreed, subject to confirmation of quality, that Atlas will regularly supply glass bottles to Raya. Both parties recognise the need for the domestic manufacture of bottles, and will work together to finalise a full agreement once the development of the Chancho Project is completed.
Ekran chooses Italy’s Glass Service
Russian manufacturer Ekra has selected Italy’s Glass Service to supply equipment for coloured glass containers. It means Ekran will be the first Siberian company to provide container glass in any colour upon request. Work on the preparation for the launch of the line on its furnace No.2 has already started. The RUS200 million ($2.9 million) investment will mean Ekran can produce up to 60 million coloured bottles a year in blue, green, brown, purple and pink.
www.glass-international.com
Glaston closes US machinery deal
Glaston has closed a machinery deal worth approximately €4 million with a glass fabricator in the United States. The deal includes flat toughening and laminating equipment as well as a Glaston Care agreement. The order is booked in Glaston’s Q1/2016 order book and the lines will be delivered to the customer during the third and fourth quarter of this year.
Encirc invests millions to double soft drinks capacity Encirc has made a multi-million pound investment in blending equipment at its Elton, Cheshire site, doubling its capacity for soft beverage products. The company has installed
a second drinks blending stream, which will increase production capability and allow ingredients to be correctly mixed into syrups at high speeds ready for diluting and bottling.
This will further improve the quality of soft drinks, beer, wine, cider and other beverages containing ingredients with low solubility, such as pectin, which have traditionally been challenging to blend.
Steklarna Hrastnik records 61% increase in profit for 2015 After a period of investment in 2015, Steklarna Hrastnik’s increased production capacities helped the company generate €7.1 million of profit on regular activities, a 61% increase compared to 2014. This is a turnaround for the company, given that as recently as 2009 the Slovenian com-
pany generated a loss of €5.3 million. Besides the expanded capacities, the return on sales, investment in employees, successful cost management and the flexibility of the company have all contributed to the excellent operating results. Last year the company in-
vested in a new decoration machine and an IS machine for the production of special and perfume packaging. The company also reinforced its position in the high quality special glass packaging segment, achieving a 36% growth of revenue and a 54% increase of the rate of return.
Top 10 stories in the news Our most popular news items, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news r 1 Saverglass sold to investment fund for €560 million r 2 Sisecam and P-D plan Turkish glass fibre plant r 3 AGC to build €147 million Brazilian float glass plant r 4 Reha Akcakaya elected chairman of Glass for Europe r 5 SCOUT – the latest inspection technology from Bucher Emhart Glass r 6 AGC Glass Europe in €25 million Cuneo float plant refurbishment r 7 Verallia in €24m VOA investment r 8 Sorg reviews recent Stirom projects r 9 Bottero and All Glass confirm their presence at Glassman Middle East r 10 Heye International secures Orora contract Be first with the news! VISIT: www.glass-international.com for daily news updates
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Company profile: Noritazeh
Noritazeh is the leading tableware glass brand in Iran, with hopes to expand into other sectors and other markets. Greg Morris spoke to Saeed Kalafchi, company Director, to find out more about the Iranian tableware market.
Iranian tableware company looks to increase exports Can you give a brief history of the company?
z Noritazeh produces high end giftware, primarily for Iran and its neighbouring countries.
Noritazeh is a private family-owned glass producer founded in 1997 by M.N. Kalafchi and partners. M.N. Kalafchi has more than 60 years experience in the glass market, mainly in trading, working with major glassware brands from Japan, France and Germany. The first furnace began production in 1999 with a capacity of 30 tons per day and three press lines. Soon after, recognising the capacity gaps in the market, Noritazeh constructed its second furnace in 2002 with a capacity of 120 tons per day with six lines consisting of press, press/blow, spinning and twin table technologies. Meanwhile, a licensing agreement was formed with Soga Glass, Japan, in 2000 to produce Soga moulds in Iran. This Continued>>
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agreement continued up to 2008 when Noritazeh began developing its own products. In 2008 the family exited its trading business to focus on production and moved the company headquarters from Dubai to Tehran. The company was restructured and optimised in 2009 as it went through a management shakeout, downsizing its workforce while increasing productivity to become more competitive. In 2013 the Sakura brand was launched and positioned as a premium glassware brand targeting the imports market segment. In 2014 Noritazeh became the first Iranian company to produce crystalline under the Lisa Mori brand, securing its position as the country’s leading quality tableware producer. Today, Noritazeh operates 10 lines and two furnaces with a daily capacity of 150 tons, making it the second largest producer in the country producing over 100 million pieces per year.
z Noritazeh’s plant in Tehran, Iran.
You have a licensing agreement with Soga Glass in Japan. How does this benefit each company? During the eight years of our licensing agreement with Soga we were able to establish it as a leading brand that dominated the Iranian market, as well as secure Noritazeh’s position as a leading producer using Soga’s heritage. It was a great experience, and beneficial for both sides.
What products do you make and what is your most popular product?
You worked with European suppliers such as Waltec. What expertise has this helped bring to the plant and what was it like to work with the suppliers?
Noritazeh produces a range of glassware and crystalline tableware, from daily basic drinkware to premium giftware. Our strength and focus is mainly on premium giftware.
Most of our machinery and equipment are from leading European suppliers as we have invested heavily in the latest technologies in order to maintain our lead. We work closely with the major European machinery suppliers to help develop the best solutions for our production. At the same time we try to maximise inhouse development to be more economical and competitive.
You recently changed your furnace to a crystalline furnace. What immediate differences have you noticed in the quality of your glass? Despite the many challenges, we managed to convert our smaller furnace to crystalline. Our crystalline has the quality, shine and sound of leaded crystal, with a healthy aspect of being leadfree. It is also much more economical than leaded crystal and therefore we have been able to enter more premium market channels.
What are your main markets? We have 35 active export markets as far as South America, Africa and most of Eastern Europe. However, our main markets are our neighbouring countries such as Iraq, Pakistan, Afghanistan, Saudi Arabia, Turkey and the CIS countries.
“Noritazeh operates 10 lines and two furnaces
Competition is very intense in Iran as production capacity is higher than demand. Therefore producers like us are aggressively looking at export markets as well as fighting for reduced imports to gain market share. However, the competitive economic factors that we enjoy for glass production in Iran have allowed domestic production to exceed imports for the first time during the last few years. The challenge is that this is happening in an inflationary market that is difficult to forecast, amidst a falling consumer spending power that demands better prices.
with a daily capacity of 150 tons, making it the
”
second largest producer in the country
Continued>>
www.glass-international.com
What are the current market conditions for tableware glass in Iran?
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Company profile: Noritazeh
Is there much competition from rival materials in Iran, such as porcelain? Iran has a relatively mature and sophisticated tableware market. Rival materials such as porcelain have a long established history in the country and enjoy their own position. Glass and crystal have their own long history and defined use; therefore we don’t consider other material as competition.
What challenges does the company face? Besides macro-economic and general market challenges, we face challenges in long-term financing and are therefore always forced to use our own capital for new investments and growth. This is due to the high rates of interest that are not suitable for the long-term capital-intensive glass industry.
z The plant in Tehran.
What is the dream scenario for the company in five years time? In five years, Noritazeh would be a diversified glass producer involved in other glass production activities. We would be applying our experience and existing infrastructure to take advantage of the unique economics of glass in Iran, and would export more than 50% of our production. î ˛
www.glass-international.com
Saeed Kalafchi is a keynote speaker at Glassman Middle East, held on May 10th and 11th in Abu Dhabi, UAE. www.glassmanevents.com/mid-east/ www.noritazeh.com
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Company profile: Park Cam
Ambitious Park Cam plan
Turkish container company Park Cam’s ambitious plan to build four 500 tonnes per day furnaces on a greenfield site has already started to reap rewards. Its General Manager Mr Semih Özbay discusses how the plant has achieved a 90% production efficiency, thanks partly to its partnership with Tiama.
www.glass-international.com
C
iner Group has emerged as one of Turkey’s leading industrial conglomerates, contributing to the country’s economic, social and cultural prosperity after domestic business entrepreneur Turgay Ciner established it in 1978. As part of its business interests, its companies are active in the energy, mining, shipping, logistics, tourism and media sectors: the latter are subsidiaries of Park Holding and Ciner Publishing Holding. Ciner Group is also a major producer of natural soda ash in Turkey through its Eti Soda group. In 2015 it began to invest $1.5 billion in new natural soda ash mining in Ankara and, recently, it purchased new mines in the USA. Ciner Group will become the world’s largest supplier of natural soda ash when completed. In 2011 its Park Cam container glass group launched its first greenfield glass plant project in Bozüyük for which Tiama presented a packaged offer that included 51 inspection equipment machines for the first two 500 TPD capacity furnaces. By the end of 2013, the first furnace was running with 500 TPD, then after a 24-month operation, it achieved its targeted pack-to-melt goals of nearly 90%. At the end of 2015, Park Cam started its second furnace and after only a month of production
“This plant will be able to produce all kinds of high quality glass
”
bottles
it reached an average of 90% efficiencies while running all four new production lines. In the past two years Park Cam has manufactured more than 2 billion saleable green bottles with an average weight of 141gr. At present, with two furnaces, the average productivity of the plant is close to 90% with a total of 1000 TPD and a daily production of about 6.5 million saleable bottles, including both flint and green productions.
How excited are you by the future prospects of this plant? Today and in the future this plant will be able to produce all kinds of high quality glass bottles, covering all the international standards. It will be a lighter and a stronger bottle with a completely qualified bottle production process. Our goal is to become the best container glass company in the world, establishing our leadership first in Turkey, and then in the wider region.
The plant recently invested in Tiama technology (MCAL4 (sidewall inspection) MULTI4 (bottom & base) MX4 (latest generation carousel machine) Continued>>
16 Glass International April 2016
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The Bozüyük plant.
comes to fruition 90% productivity. We also don’t need to spend too much time for maintenance on Tiama’s machines.
What is it about Tiama that you particularly like? Our key team has more than 15 years experience in the glass packaging industry and all of them have a good knowledge of Tiama’s equipment. We were in contact with Tiama from the beginning of the new greenfield glass project and discussed and decided together what we need in Park Cam. We appreciate its good cooperation, honest and clear respect of our problems, satisfactory and quick feed-back. Tiama offers good effort when solving problems. Tiama equipment at the Bozüyük plant.
Can you give details about the new furnace? The aim is for the entire greenfield project to cover a total capacity of four furnaces (500 TPD each, total 2000 TPD). Park Cam has made rapid progress in reaching this final goal. In 2013 the first furnace started production followed by the second one in 2015. After the first furnace start-up, our market share represented 12% of total Turkish glass packaging production. After the second furnace our market share increased to 22%. Once the four furnaces are operational, we estimate that Park Cam will produce 40% of the total Turkish glass bottles market. The plant was organised to satisfy domestic demand for mineral water companies. With the second furnace, we began to produce water bottles and some soda drinks. We currently produce flint and green bottles and we can also do colouring in one of our forehearths, which means more colour choices according to customers’ requests.
We know Tiama inspection machines very well as we already have a durable experience together. We believe in Tiama’s products high performances based on several criteria, such as an operator’s friendly environment, easy maintenance (or none), optimised job-change time, high-quality after-sales service, express spare-parts shipments… Park Cam and Tiama work together in confidence with a real partnership.
What benefits has this equipment brought to the plant? In the past 27 months we produced and sold nearly 2.7 billion bottles to the domestic market with zero critical defects. We never received any customer complaints about the production quality. Tiama’s equipment has competently helped us reach our
Who are the plant’s main customers?
Mr Semih Özbay, Park Cam General Manager
Our two biggest customers are local mineral water fillers Beypazarı and Uludag. These two clients require nearly 1.2 million bottles per year which represents the total capacity of one of our furnaces. Uludag group has in its portfolio ‘sprite’ bottles, the company also started to fill still water in glass packaging, and consequently we began to produce 33cl and 75cl flint water bottles. The Uludag group also uses a blue mineral water bottle. Continued>>
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equipped with a plant performance monitoring system (Tiama IQ track). Why did you decide to invest in these particular pieces of equipment?
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Company profile: Park Cam
Our main target is to satisfy the green glass mineral water market in Turkey. Thanks to our second furnace we have some additional business opportunities to develop with similar bottles offered to nearby countries.
What is your most popular product? In Turkey, the most popular product is the green mineral water bottle. Total demand of the domestic market is nearly 5 billion bottles per year. It represents nearly 50% of the total Turkish glass container capacity.
Is the glass industry popular for young people in Turkey right now? Bearing in mind our next furnaces’ developments, we recently increased our workforce to get them prepared and trained so that they could be operational in the future. We need to anticipate it now. When the four furnaces all start, we will have 800 well-trained employees. Today we count 580 people for two furnaces. The glass packaging industry is a heavy industry, it is not popular among young people. It is true that the salary is higher than in other industries but it is still difficult to find skilled, welltrained people, particularly in the Bozüyük area where there are several other industrial activities. The labour market situation is a big problem for our plant and is the reason why we work with more people than we really need.
www.glass-international.com
How would you describe the current situation in the Turkish container glass industry? The mineral water market grows by a minimum 10% every year in regular conditions. Mineral water per capita consumption in Turkey is only 10L a year, which is very low. In comparison, in Europe, the closest mineral water per capita consumption is in the Netherlands with nearly 20L a year. Average per capita consumption in Europe is nearly 100L/year which is a large gap. Only 5 to 10% of the total Turkish mineral water capacity today is bottled. We have a large source capacity in Turkey but in order to meet the annual mineral water’s production growth, Turkey would need to build an additional 500 TPD glass bottle furnace every two years. Still water per capita consumption in Turkey is 150L a year but only 1% of this is bottled in glass packaging. The other 99% is bottled in PET. The annual growth of still water consumption is about 4%. In the next 10 years, we will promote and strengthen the glass bottle industry.
Tiama’s MCAL4 sidewall inspection equipment
Our first goal is to change people’s consumption behaviour where they consume glass bottles only in restaurants and cafes (closed areas). If we succeed, we may have a chance to increase the glass bottled still water consumption to nearly 5%. It also means that Turkey will have to build several additional 500TPD furnaces. Glass consumption is directly linked to the per capita income increase of the population. It represents nearly $10,000 in Turkey today. In the next 10 years when this income increases, the preference for glass packaging over plastic will increase as well. There is no real competition between PET and glass. Once we succeed in changing consumption habits thanks to the education of the population about the fact that glass is healthier, we know that more glass will be preferred.
What challenges does the Turkish container glass industry face? We have to face many challenges. First, recycling. The recycling rate is too low in Turkey. To give you an idea, the average rate is 73% in Europe compared to 10% in Turkey. Also, due to the troubled relations with our neighbours, the export rate of glass packaging is too low. It is also important to keep in mind that the Turkish income per capita is low compared to the rest of Europe. The glass container industry is certainly healthier but the educational level of the population is low and this directly affects glass preferences. Increased education is a necessity.
What is the future plan for the plant? We currently have two furnaces and we need to complete the investment plan we have scheduled for four furnaces. While completing this project, we want to add new technologies to our lines. We deeply wish and we are also committed to producing the world’s highest quality glass bottle in the name of Park Cam.
Park Cam, Bozüyük, Turkey. www.parkcam.com.tr Tiama, Vourles, near Lyon, France. www.tiama.com
18 Glass International April 2016
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03.02.16 11:52
Personality profile: ICG president
ICG President encourages more youngsters to join the industry Dr Manoj Choudhary was recently elected new ICG President. He spoke to Greg Morris about the opportunities and challenges facing the glass industry, particularly the task of encouraging young talent to the sector. Congratulations on your recent appointment as President of the ICG. How have you enjoyed the past few months since your appointment? These have been a very busy past few months. As you may know, ICG does not have anyone on its payroll. So the effectiveness of the ICG as an organisation depends on the dedication of its officers and, as the President, I, more than anyone else, need to set an example. Having been associated with the ICG for some two decades and being on its Management Board for three years prior to becoming the President, I was well aware of our challenges and the exciting prospects that we can exploit. I am happy and satisfied with all that has happened in the past few months. On becoming the President I had pledged to serve ICG with all my passion, energy, and intellect. I have kept my pledge.
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What are the ICG’s strengths? How does it differ to other glass organisations or national glass associations? The support of our National Participating Organisations (NPOs), some of whom have been with ICG since its founding in 1933, the Technical Committees, road-mapping workshops (and the resulting reports) on long term and strategic issues of interest to the global glass community, and Summer and Winter Schools are our key strengths. As for the second part of your question, ICG is, in effect, a federation of national glass associations. By its very nature it transcends national boundaries and is a premium organisation for promoting collaboration and communication among the members of the global glass community. Its broad ambit includes glass science and technology, as well as glass history and education. It is not an alternative for national organisations or specific groups. It welcomes and embraces them, and provides them with a global platform for collaboration for the benefit of us all.
Why did you want to be President? When I was approached to become the President, I took several weeks to ponder my decision. I was honoured to have been offered the position, and
zDr Choudhary was appointed ICG President at the recent ICG meeting in Bangkok, Thailand.
“On becoming President I had pledged to serve ICG with all my passion, energy and intellect. I have kept my
”
pledge.
follow in the footsteps of the past Presidents I have known and admired. I had led several major professional organisations prior to becoming the President of the ICG, for one of which (the Glass Manufacturing Industry Council) I was also one of the ‘founding fathers’. So, I was confident of my leadership and managerial abilities. However, I wanted to get a good sense of the ICG as an organisation, its management culture, the challenges facing it and the potential for building on its strengths. I consulted ICG colleagues from all over the world about these items. From all this and particularly encouragement from three past Presidents, and support from my company, Owens Corning and the American Ceramic Society, I concluded that I would be an effective leader of this venerable organisation.
What plans do you have for the role? I have outlined several initiatives for us to pursue during my presidency. These were spelled out in my inaugural statement and were later sent to the ICG community. The initiatives are vital for the future of the ICG and some of them will allow us to tap into our great strengths as an organisation. The initiatives include an enhanced focus on our members, attracting and retaining younger Continued>>
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Personality profile: ICG president
colleagues, strategic orientation for the technical committees and expanding the global educational outreach of ICG. In addition, we want our decision-making process to be inclusive. I routinely consult a wide cross section of ICG representatives. None of the topics is a quick fix item, but I am pleased that we have initiated action on all of them. On items such as membership focus and inclusive decision-making we are making progress.
What can the ICG do to encourgae young people to theindustry?
Are there any particular geographic areas of focus for the ICG currently? How important is Asia to the ICG? Yes, we had a spate of recent ICG activities in Asia. Tremendous credit for that goes to my predecessor Prof. Shou Peng, Honorary President Dr. Nicoletti and ICG officers for supporting those activities. That focus was demanded by the economic dynamism of many parts of Asia and the opportunities for ICG to grow and expand. Being a global organisation, we want the ICG to serve the interests of our members in all geographic areas they represent and we tend to focus in areas where ICG can catalyse glass-related activities. Such opportunities may exist, for example, in some parts of Europe, as well.
zDr Choudhary and other ICG members at the Bangkok
Iran has become the latest country to join the ICG. How important is this? Iran’s membership was unanimously accepted by the ICG Council. We are very happy to have Iran be a part of ICG and look forward to our Iranian colleagues fully participating in the Technical Committees.
meeting.
How does glass ensure it remains ahead of competitor materials?
“We can hardly lament the lack of glass industry focused education and research, if professors do not have the funding and encouragement for these
”
tasks
It is to ensure the viability and vitality of glass that ICG develops roadmaps with a long term vision for Glass R&D. Recently in Madrid we conducted a workshop to give strategic directions to our Technical Committees to ensure that we work in relevant areas. So I can give a fairly elaborate answer to this question with many specific details. But I will refer you and your readers to ‘Making Glass Better’ 2nd edition published in 2014 and ‘Making Glass Better’ Special edition published in 2015. Information on obtaining these and other publications may be obtained from www.icglass.org. In rather simplistic terms, the way to ensure glass, a very ancient and yet highly modern material, can continue to remain important and ahead of competing materials would be by adding functionalities to overcome limitations and impart attributes for meeting the needs of the society in areas such as sustainability, communication, health and infrastructure.
Can you give me a brief background of your career in glass? I entered the field of glass from ‘outside’. My undergraduate and masters degrees were in Chemical Engineering and doctorate was in Materials Science with a focus on metals. On joining Owens Corning in 1982, I became involved with glass melting and forming. Later in my career, I got involved with mechanical and optical properties of glasses, especially as they pertain to an assembly of glass fibers. In a career spanning over three decades, there are, naturally, a number of things that I am proud of. I am one of the founding fathers of mathematical Continued>>
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This is an issue that is of concern to many glass organisations as well as the industry itself. As I noted earlier, attracting and retaining young colleagues is an important initiative for ICG and we have set-up a Youth Outreach Team to help us with it. That team recently submitted its first report that, among other things, describes challenges in attracting young talent to careers in glass science and technology and offers some strategies for the ICG and others to use. Let me note, very briefly, that one of the key things we need to do, and I am quoting from the report here, is “to show to the future generations of students that glass is truly a material of the future, that there are still a lot of opportunities and challenges to overcome, and that one can make a great career in this field.” To this end, ICG and other organisations can develop specific strategies centred on educational outreach, training, communication, lobbying for glass, etc. – but let us not forget that industry needs to do a lot too. Academies cannot train or convince young talents to join industry unless the industry is willing to provide requisite resources for this purpose. We can hardly lament the lack of glass industry focused education and research, if professors do not have the funding and encouragement for these tasks. ICG and other organisations can certainly help by identifying opportunities, developing infrastructure, organising industry efforts and lobbying for glass related programmes.
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Personality profile: ICG President
modelling of glass melting and forming processes in Owens Corning. During the first 15-year period of my career there, I was involved in all of the significant glass technology developments that culminated in a three-fold increase in the melting capability (tons per day/m2), 40-50% decrease in specific energy consumption (Joules/ton), the doubling of furnace life, in conjunction with compositional developments, a 20-50% drop in batch cost, and implementation of oxy-fuel melting. Subsequently, I got involved with a variety of insulation products and developed a fundamental understanding of their thermal and mechanical properties. In recent years, my work on thermal performance of insulation assemblies has been adopted by the American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) to develop energy performance standards for the metal buildings (non-residential or commercial buildings). In addition to glass, I have also been involved with extrusion and forming of polymeric foam insulations and done some groundbreaking work for Owens Corning in these areas. Working in industry poses, understandably, serious limitations on publications. Nevertheless, I have been able to publish some of the first papers in literature on comprehensive mathematical representation and modeling of glass melting and delivery processes. My favourite glass form, no surprise here, is fiber.
What is it about glass that you enjoy so much? No material combines utility and beauty like glass!
You have spent most of your career working for Owens Corning. What do you like most about the company? There are naturally many things to like in Owens Corning to make an over three-decade career. Ability to develop and apply fundamentally based approaches for innovation, and having great colleagues have certainly been for me two very important factors at Owens Corning.
What do you hope to have achieved by the end of your presidency? www.glass-international.com
In response to your question 4, I mentioned some key initiatives we want to pursue. At the end of my presidency, I hope to have made significant achievements in those areas and leave the ICG stronger, nimbler in exploiting its strengths, more members focused, and more relevant than ever as the premier platform for collaboration and communication for the global glass community. r
International Commission on Glass http://www.icglass.org
22 Glass International April 2016
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25/02/16 10:08
Supplier profile: Antonini
70 years in the lehr business This year marks the 70th anniversary of Italian lehr manufacturer, Antonini. Sally Love visited Barbara Antonini at the company’s plant in Empoli, Tuscany, to mark the occasion. What do you attribute your success to? I think that there is a combination between tradition and modernisation. We still have some workers who have been here for 40 years, as well as very young people. I think it is this combination. Even when people have reached the age of retirement, some have remained working with us teaching the new generation, which is very important. Maybe another thing was to choose to have a manager who is not part of the family. This is important, because unfortunately it’s not always easy to grow up in peace for a family business company. At first it is the father who creates the company, then the sons inherit, sometimes the wives, sometimes the nephews and so on, and the family grow up. It can be difficult to get a peaceful situation combined with the choice of leadership. For us, the solution was to have a manager who has worked a long time in the company, but is not part of the family. This is helpful, especially for the changing of generations.
How many people does Antonini employ now?
“I think that there is a combination between tradition and
”
modernisation
www.glass-international.com
Can you give us any background to Mr Fosco Antonini and how he came to create the company? He started the company because he was working in a glass factory near here. This was an area very rich with glass factories after the Second World War. Then he built a small company that made and repaired small accessories for the glass factories. In the 1970’s he started to manufacture lehrs. So, Antonini as a lehr maker started around 1970, but the company was founded in 1946 and was upgrading existing lehrs, for example, or electric switchboards and moulds, things like that. My cousin Francesca, who is chief of the technical office, and I are the third Antonini generation working in the company. My grandfather and my father and my uncle would probably have preferred to have all sons instead of daughters, but we are mainly daughters!
At the moment we are 60, just working here. Then we have some small companies working for us and making, for example, control cabinets. We are around 100 people, taking into account the small companies.
Are there any particular trends in the annealing and decorating lehrs market at the moment? This is a good moment for the market; for the past three years we have been busy in production. We have had little time to dedicate to innovation, but we are preparing a new burner and we want to pay attention to energy consumption. The first change we have made is the method of assembling these burners. We have strongly reduced the assembling time. We send one of our technicians and they make the assembly – this is an important cost for us, because it takes at least six or seven days to assemble and start up the lehr. So, this new burner has a speedy assembling time, and also it’s so easy that if the customers want they can do it by themselves.
How much has the assembly time reduced by? Antonini’s new burner, which has a significantly reduced assembly time.
I suppose we can say that it takes one day less to assemble, depending on the length of the lehr’s burners. Continued>>
What caused the company to change tack in the 70’s? The market progressed, and I think also that the two sons, Massimo and Cesare started working in the company and gave their father the strength to grow the company and begin a new adventure. I think they gave him a lot of ambition.
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Supplier profile: Antonini
z Work done on site at Antonini’s plant in Empoli, Tuscany. The company wants to invest more in R&D.
How much of your production is exported? 95% is for export. At the moment, the most important geographical market is Latin America and South America – Latin America first, then Brazil.
What geographical regions do you see as being most prominent for your business over the next five to ten years? For the past two or three years, the largest part of our production has gone to Latin America and Brazil. We see something moving in Bolivia and in Ecuador. South East Asia is a big market too. We also have business in Europe: Turkey is a good market, France, and there is something in Poland. We are selling a lot of decorating lehrs in Latin and South America, particularly in Latin America. We have also this year had a couple of big projects in India, and India is a new market for us. There is also something in the Middle East, with Saudi Arabia and the Emirates, but the most important is Latin America, both for annealing and for decoration, it has both the production of glass and the decoration - and very large lehrs, such as 4.8 metres width and 30 metres in length.
What plans does the company have for the future, in terms of technical development? We would like to dedicate more attention to the research department. We would like to separate the technical office from the research office, maybe increasing the number of engineers that are working there, and maybe having another one or two that would be dedicated only to research. I think this is important as with our machine, the lehr, there is no big mechanical or technical engineering and in the last few years we haven’t seen a lot of innovation. I think if we focus on it, we can find something. Maybe to optimise consumption; maybe to reuse the heat in a way that saves energy; maybe to optimise the assembling of the machines on site. We would like to invest more time and money on the research department. r
Antonini, Empoli, Italy. www.antoninisrl.com Glass International April 2016
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Country overview: UAE
Sun rises on UAE as a glass hub The UAE has only recently become a place of interest to the hollow glass industry, with the first plant starting production in Dubai as recently as 1997. 20 years on, there are five companies operating out of the region producing tableware and bottles for the food, beverage, perfumes, pharmaceutical, and spirits sectors. As Glassman Middle East comes to Abu Dhabi, Sally Love provides an overview of the companies in the country.
T
he UAE’s oil reserves are ranked as the seventhlargest in the world and the surrounding region’s bountiful supply of natural gas, cheap labour, tax incentives and location all add up to make it a desirable place for glass manufacturers to set up production. The UAE has the second largest economy in the GCC (after Saudi Arabia), however its economy remains predominantly reliant on oil. With this in mind, in recent years the rulers of the UAE have made concerted efforts to attract foreign business and encourage an economy less dependent on the price of oil. The efforts have been rewarded, with four of the five glass plants in the region being foreign-owned companies that have started in the area. As well as the financial incentives offered by the country’s freezones, the UAE is strategically close to the African, Indian, and Asian markets and its neighbouring MENA region, including the recently accessible Iranian market (Fig. 1). Over the last 20 years five hollow glass plants have sprung up across Dubai and Ras al Khaimah, producing glass for a variety of sectors.
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Altajir Glass The only Emirati company out of the five plants, Altajir glass factory is based in Dubai’s Jebel Ali industrial freezone and was the first container glass plant to start production in the region in 1997. Altajir Glass exports approximately 70% of its production to the Gulf region and across the world, and since its inception the company has had two phases of major investment. The first expansion was in 2003 when a third line was installed at the plant in just 85 days. Altajir Glass invested $27.2 million and increased capacity from 1.5 million bottles a day to 2.25 million, or 540 tons per day (t/d). The second phase of the plant’s expansion began
in 2003 and was completed in 2005. This doubled the plant’s production, resulting in a capacity of 4.5 million bottles per day and a wider range of bottles including wide-mouth food jars. A line was put in to produce decorated, refillable bottles and the plant now has the ability to produce more than 1 million decorated bottles per day. In total, the company has spent $300 million on investments since its inception, although investment has slowed in recent years. Owens Brockway Glass provided equipment for the Altajir plant when it was being constructed in 1996 and remained an advisor throughout the company’s expansion. Altajir Glass also contracted Italy’s All Glass, Bucher Emhart Glass, Zippe Industrieanlagen, Siemens Energy, Horn and AGR International to name a few, to supply its equipment.
Frigoglass
Fig 1. The UAE is strategically close to the African,
Indian and European
markets.
In 2011 Frigoglass expanded its container glass manufacturing facilities by acquiring Jebel Ali Glass’ plant in Dubai. The plant, which had been producing glass in the Jebel Ali freezone since 1997, had already established exports to South and East Africa. This fit with Frigoglass’ existing portfolio, as its other plant is located in Nigeria and mainly caters to West Africa. Jebel Ali Glass also exported to Asia and Europe, allowing Frigoglass to enter these markets. Frigoglass’ Nigeria plant has three furnaces and produces more than 600t/d, while the Dubai plant has a 360t/d capacity. Frigoglass acquired the plant for $6.8 million, taking on a net debt of $23 million. In 2015 Frigoglass entered into an agreement with Mauritius’ GZ Industries to sell the Nigeria and Dubai container glass plants for $225 million. This deal fell through recently, as GZI were unable Continued>>
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Country overview: UAE
to secure the necessary level of debt financing and Frigoglass rejected its amended offers.
the Luminarc and Arcoroc brands, as well as for the RAK Glass brand, which is distributed in the Middle East, Africa and Asia.
Arc International
RAK Ghani Glass
“Over the past 20 years five hollow glass plants have sprung up across Dubai and Ras
”
al Khaimah
A joint venture between Pakistan’s Ghani Glass, Saudi Arabia’s Swicorp, Ras al Khaimah’s industrial freezone RAKIA, and Pakistan’s JS Group, RAK Ghani Glass produces a range of pharmaceutical items exporting to 30 countries. The plant was established in 2010 and has a capacity of 40,000t/a, producing 600 million light-weight pharmaceutical glass containers per year to accredited European Standards.
Saverglass Saverglass is the most recent addition to the UAE’s hollow glass industry, setting up in Ras al Khaimah in 2013. The company invested $93 million into the facility, which covers 100,000m2 and has a staff of approximately 180. Also based in the RAKIA free zone, Saverglass chose the UAE as its first and only location outside of France due to its ease-of-access to the Middle East, Asian and African markets. The company also said that proximity to raw materials and energy, as well as low labour and construction costs, swayed the decision towards the UAE. The plant makes and decorates luxury bottles and glassware, and has the capacity to produce approximately 150 million bottles per year. Arc International will provide a keynote presentation at the Glassman Middle East conference. See www.glassmanevents.com/mid-east
www.arc-intl.com/Accueil.aspx www.frigoglass.com www.rakghaniglassllc.com www.saverglass.com/fr
www.glass-international.com
Arc International began operations in the UAE in 2004 with the aim of targeting the Iranian market. Choosing Ras al Khaimah as its base due to the emirate’s stable regime and proximity to Iran, initially exports to the country accounted for close to 80% of the plant’s business. Arc acquired the plant along with two furnaces from RAK Ceramics and immediately added a third furnace. In 2011 production started on a fourth, and today production is split with three furnaces producing flint soda-lime glass and one producing opal glass. The plant also has a large decoration facility that provides services from fully automated to manual detail, depending on the requirement. When trade restrictions came into force with Iran, Arc’s direct exports to that country ceased – however export rates from the plant still account for around 95% of production, primarily to the Middle East (with an emphasis on Saudi Arabia), Africa (especially South Africa) and the Indian subcontinent. The domestic UAE market accounts for 4-5% of sales. With the recent lifting of trade sanctions with Iran, the company anticipates the market opening up again for Arc hopes that the country will account for around 20% of sales in the future. Arc International was bought by an American investment group in 2015 and since then the company’s finances and production have improved, with investment and transformation in its plants around the world. There is not yet any word on investments that may be injected into the RAK plant, perhaps because, surprisingly, gas prices in the Emirate are relatively high. This is a situation that is expected to be resolved. The factory primarily manufactures items for
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Energy efficiency
Alternative concepts for energy efficient container glass melting Christian Roos* and Guenter Lubitz** discuss several concepts which help reduce energy consumption during the glass melting phase. This is an abridged version of a paper at the forthcoming 90. Glastechnische Tagung event in Goslar, Germany in June at which Mr Roos is due to present.
cullet usage are available. Some are so called no-brainers. These include good housekeeping, maintenance of melting furnaces and existing auxiliaries such as regenerators or recuperators, improved insulation, avoiding false air-leakage and so on. Other measures require investment.
flue gas
U-flame furnace
Flue gas losses: 30%
Enthalpy of glass melt: 45%
Structural heat losses: 20%
Enthalpy for melting reactions: 3%
Evaporation: 2%
Cullet The addition of cullet reduces energy consumption mainly due to the more favourable heat-radiation input into the batch-materials. This is due to their IRradiation transparancy and due to the fact that they have already released their CO2. So increasing the cullet content is a route pursued by many container glass manufacturers to at least somehow cope with increased energy costs. The recent drop in energy costs was caused by hydraulic fracturing (colloquially called fracking) of shale oil resources but this decrease is only temporary and in the mid-term prices will rise again. Other options to save energy beside
viewing the mandatory life time of such systems of more than 10 years. When aiming for completely new melting or energy-recovery systems, one has to compete with an old system, the regenerative U-flame furnace, which has been optimised to a high level.
z Fig 1. A modern regenerative U-flame furnace, running at 4.000 MJ/ton of molten glass at a 75% cullet level.
Devices for flue-gas heat recovery include regenerators, recuperators, batch and cullet preheaters (BCP) or systems such as the thermo-chemical regenerator or thermo-chemical recuperator. Apart from regenerative heat recovery systems, none of the above systems has been comprehensively accepted in the container glass industry. This is due to high investment costs, the complexity of the system or even skepticism when
Investigations structural have shown that the system of a highly optimised regenerative U-flame furnace (which requires a large enthalpy investment) meltingcan lead to energy consumption of about 3.300 GJ/ton of molten glass at 50% cullet. Thisevaporation is a very good level, as the theoretical limit for melting glass, governed by thermodynamics, is about enthalpy 2.700 MJ / ton of molten glass when 100% batch is used and about 2.000 MJ / ton of molten glass when 100% cullet is used. In these cases zero percent (structural and flue-gas) losses are considered, which is not achievable. Looking at a modern regenerative U-flame furnace, running at 4.000 MJ/ ton of molten glass at a 75% cullet level, the situation is approximately as shown in Fig. 1. 50% of the energy offered in the process is inherently connected to the glass and its particular composition, leaving few options for improvement, except to decrease the water content of the batch and to choose low-enthalpy batches. No major decrease in energy consumption can be enabled here. Importantly, choosing an intelligent batch composition and raw-material Continued>>
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W
e all are surrounded by glass in many different areas of our daily life, yet rarely do we realize that we are dealing with glass in that particular situation. Maybe more than in any other glass industry this is valid for containerglass. Even fewer people realize the high energetic effort that is put into a single beverage bottle. Energy consumption at the beginning of automated glass-container manufacturing was about 12.000 MJ per ton of molten glass. Today it is in the region of 4.000 MJ per ton of molten glass, sometimes less, depending on the cullet ratio. Melting glass is still an energy intensive process. The energy required to melt a typical 0.33l beverage bottle is in the range of 0.8 – 1 MJ, which equals roughly the energy content of 20ml of gasoline, which could fuel an efficient car for nearly half a kilometre distance.
29 Glass International April 2016
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Energy efficiency
mix should be the standard at a highlydeveloped container plant. Let’s have a look at the remaining 50%. These comprise the structural losses, which account for circa 20% and the flue-gas losses which account for circa 30%. The insulation of furnaces has been improved, which has led to fewer structural losses but limits have been nearly reached here. Wall losses can sometimes be reduced to less than 3KW/ m2 excluding construction items such as joints or sealing. Including construction items, best practice wall losses are in the range of 3 to 5KW/m2. So, the low hanging fruits here have already been harvested and furnace operators sometimes worry about highly sealed furnaces, because corrosion might be increased. But looking at the structural wall losses, even if an additional 30% improvement was enabled (which would be a quantum leap), this would account for only an additional saving of ca. 250 MJ. This is not to be neglected, but owing to circumstances, larger investments are necessary to enable such high quality insulation.
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Energy losses What remains are the energy losses due to the flue-gas leaving the furnace. Taking an end-port fired U-flame furnace after the regenerator, these losses are in the range of 1.000 MJ / ton of molten glass or more. This depends on numerous things such as design, size and age of the regenerator, false air (which by the way is strongly influenced by furnace pressure, a parameter which is rarely considered in detail by furnace operators) and more. For an oxy-fuel furnace, even considering the fact that no flue-gas heat recovery is usually available, the flue-gas losses are lower than 1.000 MJ/ ton of molten glass, mainly due to the tremendously lower flue-gas volumes per ton of glass. A comparison is shown in Table 1. This comparison and the aforementioned fact that only minor improvements can be achieved by optimising structural losses, means two roads can be pursued: a) Optimising flue-gas heat recovery for U-flame furnaces; and b) Develop intelligent heat-recovery systems for oxy-fuel furnaces. To deliver for a) a more accepted approach is batch and cullet pre-heating
Air-fuel furnace
[MJ/ton of glass]
Oxy-fuel furnace
[MJ/ton of glass
at 50% cullet Total
at 50% cullet
4.300
Total
Glass inherent (Water, Hchem, Hex)
2.107
Glass inherent (Water, Hchem, Hex) 2.100
3.436
Structural losses, upper and lower tank
817
Structural losses, upper and lower tank
636
Structural losses, Regenerator
129
Structural losses, Regenerator
0
Flue gas losses
1.247
Flue gas losses
700
z Table 1. Comparison between and air-fuel and oxy-fuel furnace. (BCP). Yet, BCP is a cost intensive measure which is implemented after the regenerator. Continuous availability and reliability of the system also needs to be assured. An additional energy recovery of about 300 – 500 MJ / ton of molten glass can be gained here. A widely accepted heat recovery for an oxy-fuel furnace still needs to be developed. Systems such as the aforementioned thermo-chemical regenerator or thermochemical recuperator are available but not accepted as a standard heat-recovery system, in the same way the regenerator is for air-fuel furnaces. Too many worries about the complexity of such a system prevail as well as the considerable additional costs that need to be taken into account for oxygen generation. High oxygen costs are the main reason why oxy-fuel furnaces in Europe are not widely used in container glass melting. Oxy-fuel melting yields many advantages, such as a higher heat capacity match between combustion space and batch, respectively glass melt, a better heat transfer from combustion space to melt, low to zero levels of NOx, more compact furnace designs and lower investment costs. Interesting alternatives are in reach if a future perspective in oxygen generation is regarded. The membrane separation of oxygen with mixed conducting ceramic membranes needs high temperatures but low additional energy. The technical feasibility of this process is proved, upscaling is pending. The energy demand of the membranedriven process is only 40-60% compared to conventional cryogenic air separation. All this would lead to a large drop in oxygen generation costs, facilitating the wider acceptance of oxy-fuel fired furnaces in the container industry.
Faster glass throughout An option to save energy is to develop melting concepts that enable a faster throughput of glass at the same quality. This would at the same time decrease
the energy needed per ton of glass. The main issue to target is the convective flows in a melting tank. The conventional understanding is that this convection is required in a glass furnace to efficiently transfer heat to the batch from the melt below. The melting-in of batch (here most of the energy is required) is one crucial part. The energy demand for the batch-tomelt conversion is high (typically 1.800 MJ/ton molten glass at 50% cullet) and its time demand is typically <60min, so the batch blanket is an area of high power demand of 40-80KW/m2 from each side. Hence, the general belief is that the convection of the glass-melt under the batch is required to efficiently melt the batch. The next critical stage is the dissolution of sand grains. Strong convection and mixing is preferred but temperatures should not be too high. What are the consequences of these convection flows? Even in furnaces with the highest energy efficiency, the average residence time of the melt is much longer than required for batch-wise melting processes. The average residence time in container glass melting is about 25 hours. A system with this leverage, to reduce the residence time of glass in the melting tank, to decrease the energy consumption per ton of molten glass, and to still keep the required glass-quality, would be revolutionary. A more flexible glass melting system that enables rapid colour changes and therefore indirectly save energy would be useful.
Summary In summary, energy consumption has decreased due to the up-scaling of melters and better insulation. Large melter volumes may give low specific energy consumption, but this is only possible when the heat loss through the walls is low such as due to extreme insulation. All conventional fossil fuel-fired container glass furnaces have a wide residence time distribution for the melt
30 Glass International April 2016
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Energy efficiency
(and mostly also poor space utilisation for sand dissolution and bubble removal). The most important reason for the wide residence time distribution is the strong re-circulation glass melt flow, which is much stronger than the net pull. Without this return glass melt flow, the batch blanket heating and consequent melting rate is too slow and batch might cover the complete surface area. Without changing the heat transfer mechanism to the batch blanket or without changing batch treatment, it is hardly possible to reduce the need of the return glass melt flow. Different measures on an evolutionary basis are recommended to improve furnace performance: a) Improve the insulation and sealing of the furnace (furnace pressure has a significant impact on air leakage and hence energy consumption). b) Change batch composition/structure so that it requires less energy for batch-to-melt conversion. c) Recover as much as possible of the flue-gas heat (regenerator, BCP). d) Use more effective fuels and oxidants (e.g. oxygen instead of air). e) Control the process and operate the furnace at its optimum working point.
ELECTROGLASS THE KEY TO IMPROVED
ENERGY EFFICIENCY
Under most optimal conditions an energy consumption of ca. 3.300 MJ / ton at 50% cullet is achievable without any batch and cullet preheating. This is considered as the maximum energy efficiency that can be realised in an air-gas end-port fired U-flame furnace. If further improvements are targeted, more revolutionary measures need to be taken, such as: a) Reduction of volume of the glass melting system to decrease average residence time and structural heat losses. b) Reducing average residence time and tank volume. This is only possible by increasing batch blanket heating & melting kinetics or by improved heat transfer without a strong return flow from the fining zone. c) The change from the conventional system with relatively large tank volume to a compact system with a more narrow residence time distribution. This requires advanced batch pretreatment and/or advanced batch heating techniques. d) A decreased average residence time to less than 10h seems to be necessary (and feasible). This decrease in residence time can for example result in about two times smaller total tank volume for the same glass production capacity. In summary, demands should be addressed to research and development departments at universities and institutes and to suppliers to glass-melting industries. Break-through technologies are necessary in the following fields: r More compact/alternative furnace designs; r Cost-efficient batch selection or pre-treatment methods; r Batches with enhanced melting kinetics; r Better heat recovery from flue gases; r More efficient oxygen generation systems (these are desperately needed to not only be more energy efficient but also to be more sustainable). r
*General Manager, IPGR, Bulach, Switzerland. www.ipgr.com **Vetropack Holding, B端lach, Switzerland. www.vetropack.com
HIGH EFFICIENCY ALL-ELECTRIC FURNACES, FOREHEARTHS & BOOSTING FOR ALL GLASS TYPES
The Specialists in Electric Glass Melting and Conditioning
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Glass International April 2016 BENFLEET, ENGLAND
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Energy and Environment
Reducing risk in cullet quality control Cullet is one of the most important raw materials in the glassmaking process and quality control procedures are particularly stringent. Geert Jacobs* reports on ways of reducing the risk of cullet contamination.
T
he use of cullet is crucial to a glass manufacturer. It saves money in virgin raw material consumption and about 2 to 3% of melting energy savings can be achieved for each 10% of cullet that replaces primary raw materials, as no reaction energy is required when melting cullet. As carbonates are replaced by cullet, less CO2 waste gases are generated. However, for the glass manufacturer, there’s a disadvantage: cullet may contain harmful contamination that disrupts the glass manufacturing process and can generate glass defects. This leads to glass failure and breakage. There is a growing trend to use more cullet in, for example, container, float, cellular and glass wool production because it brings so many benefits. As a result, there is an increased need for good quality cullet and for more accurate, precise quality control procedures.
Cullet quality control
Minimising risk A precise and accurate quality control (QC) procedure is at the interest of the cullet supplier (the producer) and the glass manufacturer (the consumer): r Cullet supplier: a poorly designed QC procedure results in a higher producer’s risk for rejecting a goodquality lot by the glass manufacturer. This results in needless cullet production losses, additional costs for transport and rework and unjustified quality image losses for the cullet supplier. r Glass manufacturer: a poorly designed QC procedure results in a higher consumer’s risk for an unacceptable cullet quality being accepted, resulting in glass production problems and/or glass quality losses at the glass plant.
Fig 1. OC curve with producer's risk (PR)
C.R.
80% 60% 40% 20% P.R. 0%
0
10
all cullet quality specifications, it is in the interest of the cullet supplier and the glass manufacturer to agree on the maximum acceptable consumer’s and producer’s risk level. If both parties agree e.g. on a maximum 5% consumer’s and producer’s risk, they agree that according to their applied QC procedures, the probability for a wrong QC result is lower than 5%. Using cullet quality specifications, sample size, granulometry, concentration and weight of the impurities, a so called ‘operating characteristics curve’ must be calculated to determine the consumer’s and producer’s risk levels.
Operating characteristics An operating characteristics curve shows the quality of the lot along the X axis and probability of rejection (or acceptance) along the vertical Y axis. For example: a 500kg sample is taken from a 1000 tonne cullet lot. The maximum allowable amount of CSP is 20 grams per
Continued>> #1
#2
Complementary to an agreement on
OC Curve
100%
Probability rejection of lot
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Cullet contamination usually consists of ceramics, stones and porcelain (CSP); metals (ferro and non-ferro) such as lead, aluminium and iron; organic impurities such as paper, plastics, food scraps; and incompatible glass such as vitro-ceramics in soda-lime glass. Contaminations have a direct negative impact on the glass manufacturing process and the quality of the glass
product. Contamination levels are usually set very low such as <5g metals/ tonne cullet or <20g CSP/tonne cullet. While the main cullet quality characteristics such as glass type, granulometry and colour composition are relatively simple to determine, checking cullet contamination is time consuming and costly. Low concentrations of impurities (<5-20g/t) must be identified by checking huge quantities of relatively small glass pieces.
20 30 40 Cullet quality: g/tonne CSP (in lot)
50
60
Legend
Sample size
Cullet Impurities
(weight)
and consumer's risk
z Fig 2. Schematic representation of lot #1 and
(CR). Input data: 500
lot #2 having impurities (red stars). Both #1 and #2
kg sample; CSP spec-
have the same (weight) concentration of impurities.
ification: < 20 g/tonne;
The weight of each impurity in lot #2 equals three
CSP particles of 2g;
times the weight of the impurities of lot #1. Taking
granulometry cullet:
randomly samples (blue rectangles), we see that
> 20mm 40%; 12-
samples taken from lot #2 have a higher probability
20mm: 35%; 6-12mm:
to be more representative for the lot quality than
15%; 3-6 mm: 10%.
samples taken from lot #1.
32 Glass International April 2016
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Energy and Environment
500kg
80%
1000kg
60%
1500kg 2000kg
40%
5000kg
20%
10000kg
20
0% 0
Accepted 95% Rejected 95% Specification
40 g/tonne CSP
Probability rejection of lot
95% probability correct QC result - sample size. maximum 20g/tonne CSP 60
OC curves - sample sizes
100%
0 5
10
15
20
25
30
35
40
45
500
50
Quality of cullet g/tonne CSP
2000
4000
6000
8000
10000
Sample size (kg)
zFig 3. OC curves for different sample sizes. Input parameters: CSP < 20g/
z Fig 4. 95% probability for correct QC result (acceptance and rejection of the
tonne; granulometry cullet: > 20mm 40%; 12-20mm: 35%; 6-12mm: 15%; 3-6
lot) in function of sample size. (input data: specification: maximum 20g/tonne
mm: 10%; 2g CSP pieces.
CSP; granulometry cullet: > 20mm 40%; 12-20mm: 35%; 6-12mm: 15%; 3-6 mm: 10%; average weight of CSP pieces is 2g.)
Real quality of lot
Average weight
(g/tonne CSP)
of CSP particles
2
2g.
5g.
1,75%
~ 0,00%
0,02%
5
0,03%
0,91%
9,02%
10
3,18%
10,88%
26,42%
15
22,36%
32,25%
44,22%
20 (= Specification)
54,21%
55,95%
59,40%
25
Producer’s risk
1g.
20,14%
25,30%
28,73%
30
Consumer’s risk
6,99%
13,21%
19,91%
50
0,02%
0,53%
4,04%
100
~ 0,00%
~ 0,00%
0,05%
z Table 1. Producer and consumer risks for different lot qualities and for different CSP impurity weights. Used input data for statistical calculations: sample size is 500kg; quality specification <20g/tonne CSP; gran-
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ulometry of the cullet: >20mm 40%; 12-20mm: 35%; 6-12mm: 15%; 3-6 mm: 10%.
tonne. Taking into account the quality of the cullet, grain-size and weight of the cullet and CSP pieces, all probabilities for acceptance or rejection of the lot are calculated and an operating characteristics curve is determined (Fig. 1). Producer and consumer risks are indicated in Fig. 1. If for example the cullet contains 15 g/tonne CSP, the producer’s risk equals 32.25%. There is also a similar consumer’s risk: a poorquality lot with for example 25g/tonne CSP has a 25.30% chance to be wrongly accepted. In Fig.1, if the consumer’s and producer’s risk specifications are set to a maximum 5%, the lot will be accepted when the QC result is lower than 8g/ tonne CSP. When finding (more than) 37g/tonne CSP, there is a 95% (or higher) probability that the cullet lot does not conform to the maximum 20g/tonne CSP specification.
Grain-size matters Table 1 shows QC curve calculation results for different CSP grain sizes, i.e. 1g, 2g and 5g CSP particle weight.
The statistical calculation results of Table 1 show that the probabilities for an unacceptable quality to be accepted and for an acceptable quality to be rejected increase significantly with increased weight of the impurities. For example, for an acceptable lot quality of 10g per tonne CSP, containing CSP pieces of 1 gram, the probability for lot rejection is 3.18%. For a similar lot pollution (i.e. 10g/tonne CSP) consisting of larger, 5g CSP particles, the producer’s risk increases strongly to 26.42%. Fig. 2 demonstrates schematically the relationship between consumer’s and producer’s risk and CSP particle weight. Two lots (#1 and #2) of identical CSP concentration are shown. Lot 1 contains less, but heavier particles than lot 2. If samples from each lot are taken, the samples taken from lot 1 have a higher probability of containing a large CSP particle, which equals three small CSP pieces as present in lot 2. As less particles are present in lot 1, there is a higher probability for lot 1, compared to lot 2, to find zero CSP particles in the sample. Both results (i.e. one large piece = three small particles and zero particles) are
poorly representative for the identical CSP concentration of lot 1 and lot 2. So, consumer’s risk and producer’s risk are higher for lot 1 than for lot 2. This decreasing statistical relevance of the sampling with increasing CSP weight explains why perfect quality cullet suppliers will have the highest probability to have a perfect quality lot wrongly rejected when it contains (a few) large CSP pieces. It needs to be emphasised, that the decreased statistical relevance of the sampling is equally disadvantageous for the glass manufacturer. Tab. 1 shows that consumer’s risk is also higher when dealing with larger CSP pieces.
Uncertainties Taking into account the cullet quality specifications for each harmful contamination, a sampling plan, cullet granulometry and average weight of the contaminating pieces, a complete set of operating characteristics curves can be determined. Fig. 3 shows an example of QC curves for different sample sizes. Using the input parameters of Fig. 3, the 95% probability limits to accept and reject a lot in function of the sample size was calculated (Fig. 4). The gap between the acceptance and rejection limit narrows with increased sample size. Fig. 4 shows that taking large samples (>3000kg) has limited effect on the 95% reliability level.
Stringent specifications Increased cullet ratios in glass batches and the introduction of cullet in glass production such as high value float glass lead to stringent cullet quality specifications. Cullet treatment plants need to evolve accordingly. Continued>>
34 Glass International April 2016
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Thin Glass
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Energy and Environment
Quality of
2g CSP pieces
lot (g/tonne CSP) Cullet specification: g/tonne CSP
<20
<
<20g/ton <10g/ton
5g CSP pieces
10g/tonne CSP Cullet specification: g/tonne CSP
<20
<
10g/tonne CSP
<20g/ton <10g/ton
∆risk
∆risk
2
0,02% 1,44%
+1,42%
1,75% 18,13%
+16,38%
5
0,91% 13,15%
+12,24%
9,02% 39,35%
+30,33%
10 10,88% N/A
N/A
26,42% N/A
N/A
12 18,47% 42,32% N/A 33,74% 30,12% N/A 15 32,25% 27,71% N/A 44,22% 22,31% N/A 20 30
N/A 12,47% 13,21% 2,03%
N/A
N/A 13,53% N/A
-11,18% 19,91% 4,98%
-14,93%
zTable 2: Producer’s risk (purple colour) and consumer’s risks (red colour) for different lot qualities (1st column) and 10 - 20g/tonne CSP specification. Consumer’s risk and producer’s risk changes (∆
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risk) are shown in the 4th and 7th column. Granulometry cullet: > 20mm 40%; 12-20mm: 35%; 6-12mm: 15%; 3-6 mm: 10%.
Thanks to increased performance of the cullet sorting machines and the growing know-how of glass recycling companies, most cullet suppliers are able to supply perfect quality cullet. What if the CSP specifications are maximum 10g/tonne instead of 20g/ tonne CSP? As probabilities for correct quality control depend on the quality specification levels, producer’s risk and consumer’s risk need to be recalculated. Table 2 shows the consumer and producer risks for different cullet qualities for a 20g/tonne and a 10g/tonne specification (dealing with 2g or 5g CSP particles). Suppose the cullet treatment plant produces an excellent 5g/tonne CSP cullet quality. Table 2’s results show there is a 0.91% (for 2g CSP pieces) to a 9.02% (for 5g CSP pieces) producer risk. For the same excellent cullet quality, applying a more stringent maximum 10g/ tonne cullet specification, the producer risk increases from 0.91% to 13.15% for 2g CSP pieces and from 9.02% to 39.35% for 5g CSP pieces. So, for a 5g/tonne lot quality, that perfectly conforms to stringent specifications of 10g/tonne CSP, the producer risk increases to unacceptable levels if the QC procedure is not adapted to more stringent quality specifications. The probabilities to find a certain amount of CSP in a sample do not depend on the specifications. However, as the gap between real quality and quality specification decreases, applying more stringent specifications, the producer’s risk will of course increase, while leaving no possibility for the cullet supplier to maintain its security margin (15g/tonne in our example) as there is an obvious physical barrier of zero gram CSP in the lot. From the results of Table 2, the consumer’s risk, applying more stringent specifications, decreases as the gap between specification and quality
increases when dealing with a nonconform cullet lot. For results close to the specifications, the consumer’s risk remains unacceptably high, even when large samples are taken (Fig. 4). When specifications become more stringent it is necessary to adapt the QC procedure accordingly to avoid a strong unacceptable producer’s risk increase for all cullet suppliers, perfectly capable of delivering the requested quality (Table 2).
Improved QC procedures A typical QC procedure analysis and improvement project consists of detailed extensive statistical calculations for each situation, based upon the parameters and data. This includes: cullet specifications: maximum amount of harmful impurities (CSP, metals, vitro-ceramics), grain size distribution of the cullet, grain size and weight of the impurities, sample size(s) and the agreed maximum consumer and producer risk level. Using these input data, the operating characteristics and risk levels are determined to obtain a detailed acceptance and rejection limits table. This table defines the conditions for rejection and acceptance according to the maximum consumer’s and producer’s risk level(s) agreed between cullet supplier and glass manufacturer, taking into account the cullet grain size, weight of the impurities and sample size. Taking advantage of our independent position, we develop a fair, transparent, verifiable and statistical relevant quality control procedure. As the cullet specifications also include risk level limitations, agreed by cullet supplier and glass manufacturer, the most important source of cullet quality disputes (according to our experiences) is radically eliminated. Beyond avoiding QC conflicts, being an independent 3rd party, we also strive to combine quality control procedures
of supplier and customer for further optimisation such as further risk reduction.
Conclusion Cullet is for many glass manufacturers one of their most important raw materials, so quality control (QC) errors must be kept to a minimum. For cullet treatment plants and glass plants familiar with six sigma quality objectives, a 95% reliable (≈2σ) cullet QC is a must. However, the above realistic cullet QC examples prove that probabilities of making quality control errors, such as when dealing with relatively large contamination particles, are often much higher, resulting in unacceptable risks. Complementary to an agreement on cullet quality specifications, it is in the interest of both cullet supplier and glass manufacturer to agree on the maximum acceptable risk level. More stringent cullet quality specifications require precise and accurate quality control procedures to avoid an unacceptable increase in risk, affecting suppliers capable of delivering the requested high-quality cullet. Using our statistical calculation programmes, taking into account cullet quality specifications, sample size(s), grain size distribution and weight of the contaminating pieces, we determine the operating characteristics curve(s) and the corresponding acceptance and rejection conditions according to agreed maximum risk level(s). Combining cullet quality specifications and agreed maximum risk level, a fair, transparent, verifiable and statistical relevant cullet quality control procedure will be developed. r
Geert Jacobs, Consultant, GEM-Projects, Nijlen, Belgium www.gem-projects.be
36 Glass International April 2016
GEM energy environ.indd 3
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Energy efficiency
Heat oxy-combustion to contribute to COP21 ambitions Air Liquide’s energy-efficient technology was awarded at the recent conference on climate change in Paris. Luc Jarry* and Taekyu Kang** report on how heat oxy-combustion technology can be used to meet environmental needs.
Meaningful change Decarbonisation for fossil fuel-based industries has proven to be difficult. Although industrial intensity (energy consumption per unit of value added) has fallen in developed countries since the 1990s, there still aren’t enough alternative energy sources or innovationbased solutions available. Therefore, the development of new technologies is crucial. On the occasion of the COP21, the France-China Committee awarded heat oxy-combustion technology its 2015 Innovation Award focused on ‘Climate Solutions’[2]. Heat oxy-combustion, based on oxycombustion, is a technology that aims to reduce the environmental impact of the glass-melting process. It is recognised as one of the best available technologies for reducing CO2 through fuel savings, while also reducing NOx and dust emissions. Oxy-combustion is widely used within glass and metallurgical industries to improve the combustion process, reduce air-pollutant emissions and save fuel. The
main principle of heat oxy-combustion is that heat extracted from the combustion fumes is used to heat oxygen and fuel, thereby improving oxy-combustion performance by 10%. Compared to air combustion, this technology provides up to 50% energy savings and up to 50% CO2 emission reduction (excluding emissions generated for oxygen production). Unlike current oxy-fuel technologies, which don’t take advantage of wasted energy recovery from combustion fumes, heat oxy-combustion recovers a substantial portion of the heat lost through flue gases by indirectly preheating fuel and oxygen (Fig. 1). To develop this patented technology, safe and reliable equipment is designed and fully integrated with glass-melting furnaces. This equipment is made of specific materials suited for hot reactants. For more than 10 years, various materials had to be tested for cyclic oxidation, ignition and flame propagation with
Heat oxy-combustion consists of the following technological components: r Oxygen supply: Liquid Oxygen storage (LOx), or low pressure gaseous state through floxal oxygen, an on-site oxygen-production solution that provides the required quantity of oxygen supply. r Glass melting technologies: A unique and patented combination of heat exchangers: one recovers heat from hot fumes to air; others transfer heat from air to fuel and oxygen. r Burners: non water-cooled oxyfuel burners made of specific materials to accommodate high-temperature fuel and oxygen. r Valve trains: are automated control systems to monitor oxy-fuel burners and their fuel and oxygen supply systems.
hot oxygen, as there was no industrial standard for hot oxygen-compatible materials (>200°C) [3]. Safety studies and analyses of oxygen hazards have been extensively performed with top-notch institutes and experts from Germany and the United States to build know-how in hot-oxygen handling. Three glass manufacturers – Pasabahçe Bulgaria EAD, AGC France and AGC Czech Republic – have validated the concept of preheating oxygen to 550°C and natural gas to 450°C for oxy-fuel combustion[4].
flexibility helps to reduce energy-sourcing dependency and associated risks.
Compatible with many types of fuel, all types of glass and a variety of furnaces, the technology can also operate with air, cold oxygen or cold fuel in backup mode. Such
Proven As a new technology, heat oxycombustion is improving in efficiency gains and competitive equipment cost. In the near future, manufacturers can expect higher preheating temperatures, enhanced design and materials, and greater cost-efficiency. Continued>>
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L
ast December, the United Nations Conference of the Parties, better known as COP21, reached an agreement[1] to combat climate change. Together, the EU along with 185 nations pledged to limit the global average temperature to a rise ‘well below’ 2°C (3.6°F) compared to pre-industrial levels and to pursue efforts to limit the temperature increase to 1.5°C. Such an ambitious goal will require not only the immediate halt of greenhousegas emission increases, but also a serious effort to decrease emissions throughout the rest of the century. This global agreement will put immediate pressure on industrial processes, which account for one-third of global energy use and 40% of CO2 emissions worldwide.
37 Glass International April 2016
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Energy efficiency
HEAT RECUPERATION
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VALVE TRAINS
38
Heat oxy-combustion technology can also be implemented with energyrecovery systems, such as a compact Organic Rankine Cycle (ORC), which will be implemented on the discharged hot-air line after the oxygen/natural gas heaters to produce electricity. The remaining hot air can be used for other purposes such as drying fibres or heating buildings of the plant and warehouse. Heat oxy-combustion equipment is then sized to maximise heat extraction from the fumes to supply hot air accordingly. Many new greenhouse gas-reduction technologies were developed to recover the energy contained in the flue gas of industrial furnaces, such as steam boilers, electric generators, steam/ORC and synthesis gas CO-H2 production by thermal or catalytic decomposition or load preheating. For glass furnaces, most heat-recovery solutions have the major drawback of a lengthy pay-back time, sometimes equalling the full life of the installation. They also lack flexibility. For example, a power-generation unit with an ORC cycle, installed to a glass furnace, reaches a maximum efficiency (20%) at a full-furnace pull rate, but decreases rapidly (15%) as soon as the furnace reduces capacity. Others, such as syngas or load preheating, lead to changes in furnace operation. For broader deployment, heat-recovery technologies will need to manage capital-investment costs to achieve ROI in less than three years. Among these technologies, heat oxycombustion helps to reduce Capex thanks to its way of transforming wasted energy into value. The equipment needed to preheat lower volumes of combustion oxygen and fuel is less expensive than what is needed to preheat larger volumes of combustion air. Unlike other combustion-related technologies, heat oxy-combustion requires no DeNOx system to treat combustion fumes in the majority of cases, so manufacturers avoid all the extra investment, operating costs and waste associated with such a system.
Making strides Taking into account the main crossmedia effect of oxy-fuel combustion, represented by the upstream emissions of a power plant using electrical energy to produce oxygen, on average the reduced CO2 emissions with oxy-combustion
Fumes
GOX
MELTING BURNERS
Ho
LOX
ta
ir Air
Ho
ta
ir
Depleted air
Fuel
Fuel Depleted air
CUSTOMER SCOPE AIR LIQUIDE SCOPE
outweigh the emissions associated with the oxygen production itself. CO2 from oxygen production is extremely difficult to quantify and varies greatly depending on the case. The environmental impact of oxygen production is mostly due to the emissions associated with electricity generation. Estimating it requires taking into account the oxygen consumption, the method of oxygen production and the average emissions from electricity production as reported by national statistics.
GOX
HEATERS
Its energy improvements have been validated by three industry references. A large reduction in NOx and particulate emissions was also reported. This new technology is universal in that it can be applied to any type of glass or glass furnace. In addition, thanks to the simple concept of preheating oxygen and fuel with wasted energy from flue gas, the ease of operation makes the solution more attractive practically. Combining this concept with patented process and component technologies from 10 years of R&D, heat oxycombustion is safe, robust, flexible and affordable, and is expected to be rapidly deployed. r
*Glass Market Manager and **R&D Project Manager, Air Liquide, Paris, France. www.airliquide.com/
References [1]
“Adoption
of
the
Paris
agreement—
Proposal by the President—Draft decision -/CP.21”
z By heating pure oxygen and fuel with fumes,
[2]
combustion performance is increased by 50%.
COP21: Air Liquide wins an Innovation Award
Press Release, Paris, December 7, 2015,
from the France-China Committee for its Heat
In addition to CO2 reduction in proportion to energy savings, by preheating the natural gas and oxygen CO2 emissions from combustion are reduced by an additional 10%, and CO2 for oxygen production (compared to traditional oxy-combustion) adds another 10% reduction on top of that. Global carbon footprint must be evaluated on a case-by-case basis. However, for every heat oxy-combustion reference, it has been demonstrated that the technology reduces CO2 emissions. In conclusion, heat oxy-combustion will enable the glass industry to comply with environmental regulations.
Oxy-Combustion technology [3]
AlglassTM Heat recovery :an advanced
Oxy-combustion technology with heat recovery makes sustainable performances for glass furnaces. Y. Joumani, r. Tsiava, Air Liquide Research and Development, B. Leroux, Air Liquide Altec O. Douxchamps, A. Contino AGC Glass Europe CRD. VOL.16 N°5 • DECEMBRE 2010 Verre. [4]
Oxygen and natural gas preheating for oxy-
float glass. Glass international July/August 2010. The authors thank the European Commission, which has partly financed this work through the Life+ programme. http://www.ecoheatox.com/ http://www.oxyfuel-heatrecovery.com/
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Energy efficiency
Energy consumption during float glass annealing Hans Strauven* explains how to reduce energy consumption during the float glass production process. on the heat exchanger of zone A reduces the energy consumption by 0.3kWh/T, while the lehr without improvements (classic type) consumes 8.5kWh/T of energy. Below 400°C, a forced convection to cool the glass is used, with hot air in the RET-zones and ambient air in the F-zone. The simplest way to reduce the energy consumption is to lengthen the forced convection zones. Doubling the length of the forced convection zones (RET, F) and so increasing the length of the lehr from 123 to 165m brings the energy consumption down to 2.2kWh/T or a gain of 74%. However, this involves an important extra investment in steel construction, rollers and building. Nevertheless, lengthening in some cases will makes sense, depending on future energy prices. A study of the pressure drop in the forced convection zones allowed improving the energy consumption from 8.5kWh/T to 5.9kWh/T.
Larger ducts, changing the direction of the flow with curves, optimised distributors and nozzles are the basic ingredients of these improvements, involving a lot of steel work labour, extra engineering and a minor extra use of steel. On top of that, by using direct drive fans with inverters, an extra improvement down to 4.8kWh/T is possible. Together, an improvement of 43% without increasing the length of the lehr by thinking, calculations and extra labour was obtained.
Ambient temperature Another improvement is to lower the ambient temperature. Today, the F zones on the glass is blown in with (warm) inside air. In case outside air is used and filters to clean this air are invested in, the efficiency of the cooling process is improved. Lowering the air temperature by only Continued>>
Top glass surface temp. (D.C)
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A
classical lehr for a 600TPD float glass line may consume about 10 kWh/T electricity or 25 kWh/T primary energy. A typical float glass line consumes about 7500 MJ/T of primary energy. As a consequence, a float glass lehr contributes to only 0.33% of energy used to produce float glass. But, when the price of electricity is 0.1€/kWh, a 600TPD lehr consumes in one campaign of 17 years €3.7 million of electricity, which is of the order of the investment in the lehr. In the following, the energy consumption of the float lehr in the different parts of the temperature curve is explained. It is demonstrated how this energy consumption can be halved and even eliminated by extending the investment. Typical soda lime glass enters the lehr at 600°C and is cooled to 400°C in an insulated tunnel (zone A, B1, B2 and C). The heat in these zones is extracted with air-cooled heat exchangers. These heat exchangers are fabricated in stainless steel due to the high temperature and SO2 atmosphere in the lehr. In that way, they reflect a large part of the energy, radiated by the glass because stainless steel has a low emissivity. This effect was always partially compensated by working with an array of tubes to promote internal reflections. In other words, the apparent emissivity was increased in a geometric way, which requires a much larger air flow.
Emisshield A ceramic high emissivity coating called Emisshield is applied on the stainless steel heat exchangers to eliminate the reflection and improve the efficiency. Fig 1 shows that by applying Emisshield
Length (M)
z Fig 1. Typical 600TPD float glass lehr curve.
40 Glass International April 2016
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Energy efficiency
TEMPERING LINES on belt Opal - Borosilicate - Soda-lime glass
5°C in the F-zones lowers the energy consumption from 8.5 to 7.7kWh/T or 9%. Depending on season and continent, an ambient temperature decrease of up to 20°C is possible or about 35% less energy consumption. Today, a lehr simulator allows the customer to predict the influence of the ambient temperature on the consumption. A future improvement will be the use of the extracted heat in the process instead of emitting in the air. For the lehr in Fig 1 in zone A , B,C and RET, about 2966kW heat is extracted from the glass. Converting this heat into electricity with only 10% efficiency would generate about 300kW while in the optimised case, the lehr in Fig 1 consumes only 120kW. Instead of consuming energy, a lehr should generate electricity, used in other parts of the process. Converting low temperature heat into electricity is typically done with the Organic Rankine Cycle. While the standard Rankine cycle works with water and needs at least 600°C heat, a low boiling point (organic) liquid is used. However, 10% efficiency can only be reached by extracting the heat with water (or thermal oil) cooled heat exchangers inserted into the lehr. Today, glass manufacturers don’t like piping with liquids in their lehr due to the 17 years-long campaign.
Stirling system For that reason, a lot is expected from the future Stirling motors. The system works with hot air without any liquid in the lehr, only cooling the heat sink of the Stirling motor may involve water. Inserting this system into the exhaust of the fans in zone A, B and C and directly into the RET would be an elegant energy recuperation system. The current state of technology allows already working with a lehr, which generates electricity instead of consuming electricity. However, a combined Capex/Opex approach is required to leave our easy way of consuming (still cheap) energy with a minimum of Capex. But primary energy consumption during the production of float glass will be improved by 0.5% thanks to efforts with the float glass lehr.
*Hans Strauven, R&D Manager, CNUD EFCO, Zellik, Belgium. www.cnudefco.com Glass International April 2016
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Energy efficiency
Saint-Gobain tests HyGear’s Hy.REC system Saint-Gobain Glass is currently testing HyGear’s Hy.REC system in its facility in Herzogenrath, near Aachen, Germany.
T
he Hy.REC system is designed to recover the used hydrogen-nitrogen gas mixture so it can be reused in the glass production process. Saint-Gobain is continuously seeking for technologies to optimise the glass production process and improve glass quality. One of these technologies is the Hy.REC system, developed by HyGear. Saint-Gobain is testing the system on performance and reliability. “It is great to work with such a leading company as Saint-Gobain”, stated Mr Niels Lanser, Sales Director at HyGear. “Saint-Gobain has provided us with valuable input during the design phase of the Hy.REC. Its feedback on the system performance is also of great relevance for the further improvement of the system”.
Advantages of gas recycling The Hy.REC system was developed to recover the gas mixtures from the tin bath in float glass production and the metal industry. Currently, substantial amounts of the hydrogen-nitrogen gas mixture, in combination with pollutants, are currently left at the exit of industrial
processes and left unutilised. The Hy.REC system can recover this used and polluted mixed gas atmosphere from the process in a cost-effective way. By feeding the polluted gas mixture into HyGear’s gas recovery system, a large fraction of the hydrogen and nitrogen can be recovered and reused as a new reductive gas mixture. This reduces costs and improves the product quality due to the increased atmosphere refreshment rate.
Other gas recovery systems HyGear is not the first company to offer a gas recovery system. The reason for the limited market penetration of previously launched systems is the low internal rate of return, caused by the high capital investment and high-energy consumption. Since the economical viability of industrial gas recycling systems depends on the value of the recovered gas in relation to the energy consumption of the system, the Hy.REC mix is designed to consume the lowest possible electricity, which results in a higher economical rate of return. A key part of the integrated post-treatment module is the advanced
z Fig 1. Saint-Gobain’s Herzogenrath facility. Temperature Swing Adsorption (TSA) with an ultralow pressure drop to further reduce operational expenses.
Working principle In the first section of the Hy.REC, dust and contaminants are removed from the gaseous mixture. In the second stage, sulphur and oxygen are removed from the main stream. The third gas recovery stage is the post-treatment module. A key part of the post-treatment is the TSA to dry the hydrogen-nitrogen stream. The customer’s waste heat can optionally be used for the regeneration phase to increase the energy efficiency even further. r
Hygear, Arnhem, The Netherlands www.hygear.nl
Dust Filtration section
Desulphurisation
H2S
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Deoxidiser
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Atmosphere conditioning module
Recovered hydrogen nitrogen gas mixture
Hydrogen nitrogen gas mixture
Gas mixing station Fresh hydrogen supply
z Fig 2. Molten float glass.
Optional
Fresh nitrogen supply
z Fig 3. Process and working principle of the advanced Hy.REC technology.
42 Glass International April 2016
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History
Prof. John Parker Turner Museum of Glass and ICG
Current affairs Prof John Parker* discusses the use of glass in the development of electrical applications.
M
any of us as children will have experimented with electricity by rubbing a comb on our sleeve and then using it to attract scraps of paper. This relies on friction to strip electrons from their source, building up a static charge on the non-conducting comb. If you’ve never done it, do try it before continuing. The Greeks knew this effect and indeed both ‘electron’ and ‘electricity’ derive from their word for amber. Glass behaves similarly, being an excellent insulator under standard conditions and was widely used in early studies of electricity. By the 18th century well-to-do and inquisitive gentlemen scientists were studying such phenomena and creating exciting spectacles for their friends and family using large rotating sulphur or glass spheres and metal chains to capture the surfaces charge generated. While attempting to tame it, they found that charge could, like a genie, be captured in a glass bottle. Charge was transferred from a generator into the jar using, for example, a nail through its cork. Inside were liquids such as impure water with a significant electrical conductivity. Later, conducting metal foils lining the vessel wall proved more effective. A conducting layer outside the vessel, linked to ‘earth’, was also needed; often this was the experimenter’s hand. Strong men were allegedly hurled across rooms if they accidentally discharged their devices.
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Storage vessels These electrical storage vessels were discovered independently in 1744 by a church deacon (von Kleist) in Germany and scientists working in Leyden in Holland (von Musschenbroek and Kuneaus). Von Kleist’s assistant was one who suffered such a shocking experience when he short-circuited the container by touching the conductor dipping in the contained liquid while holding the outside of the vessel. The capacitor had been discovered, now such an important
component of most electrical and electronic systems, but the term coined then was a Leyden Jar. A century later glass again had a vital role. The creation of a national electrical grid required that metallic conductors be suspended safely from metal pylons with no risk of current flowing to earth. This could only be achieved with insulating supports and one solution was glass, which offered an ideal strength-to-weight ratio. Many designs were developed and ardent collectors still seek these out, actively supporting e-bay (http:// www.collectorsweekly.com/tools-andhardware/insulators). In both the Leyden Jar and the insulators used in the grid an important property of the glass component is low electrical conductivity. Its electrons are firmly anchored in the bonds between the atoms, none free to wander and transport charge. The energy stored in the early capacitors resided in small opposing movements of electrons and positive charges about fixed positions in a strong electric field i.e. polarisation. A low surface conductivity was also necessary, a property linked to chemical durability. Similar behaviour is also important in the lighting industry. Light bulb envelopes, both incandescent and fluorescent, must accommodate electrical wires to heat the contained filaments. Such bulbs become hot in use and the glass electrical conductivity must remain low to avoid a current short-circuit. At higher temperatures though, even as low as 100°C, sodium ions become increasingly mobile and can take on the role of charge carriers. So glasses with larger and less mobile potassium ions are used. But the increasing mobility of charged sodium ions in hot commercial glasses can be put to good use. Resistive heating with alternating current becomes possible and underpins all-electric furnace design. High melting point molybdenum
electrodes are normally used as the current source. More recently the electrical behaviour of a wider range of glasses has been investigated, e.g. semiconducting chalcogenide glasses. Here sulphides, selenides and tellurides replace oxides and their electrons are less tightly bonded. Indeed they can be thermally excited even at room temperature, allowing electrical conduction. Many novel applications are possible such as xerography, which relies on the activation of electrical conduction by light and fast but stable electricallyswitched memory devices. Another interesting development has been glasses with unusually large electrical conductivities. These Fast Ion Conductors (FICs) are often analogues of crystalline materials such as AgI, which transforms at moderate temperatures from an insulating to a conducting state where the Ag ions are the charge carriers moving freely through a network of iodine ions. The glasses have no such sharp transition but exhibit useful conductivities even at room temperature. Research has widely extended the compositions available and new glasses have Li+, even Na+ as the conducting ion. One important application is in high power density Li ion batteries for transport where they can replace the dangerously flammable organic chemicals used presently. Such batteries need 104 times the stored energy of a smartphone cell. The role of glass in electrical energy storage is being reinvented. r
Bibliography Glass – The Miracle Maker, C J Phillips, Pitman & Sons (1947) Making Glass Better Vol 3, Bange, Jain and Pantano, ICG (2015)
*Curator of the Turner Museum of Glass, Sheffield University, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk
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Company profile: Newport Industries
Chemical distributor at the forefront of UK soda ash industry
S
oda ash is imperative to glassmaking, and more than half of the soda ash mined worldwide is used to produce glass. Soda ash acts as a flux and plays a vital role by reducing the furnace temperature necessary to melt the silica used, thus reducing the energy required to produce glass. Newport Industries is a global chemical importer and distributor, and is the UK’s largest importer of soda ash. It represents Turkish chemical group Eti Soda and currently imports about 180,000mt of Eti’s soda ash, of which about 89% is for the glass industry. The container, flat glass and glass fibre sectors are the three main recipients of the raw material, which is mined at Eti Soda’s Beypazari Trona Bed and shipped to the UK. Newport Industries currently imports the material into four relatively small ports in the UK: two in England and one each in Scotland and Northern Ireland.
£7 million investment The company recently announced plans to build a £7 million bulk handling facility at the Canada Branch Dock, in Liverpool, UK. The dedicated facility will have the potential to supply the entire UK glass market’s soda ash requirements. The
z Artist’s impression of the £7 million handling facility
Mr Raj Patel, Managing Director of Newport Industries
facility will have an initial capacity of 500,000 tonnes by 2017, with an additional 300,000 by 2020. The facility will also handle materials including sodium bicarbonate, calcined caustic magnesia and other minerals for the glass industry. The site will also have six large silos for storage purposes. Construction of the bulk handling facility will be completed in several phases. The first phase, including the construction of a pneumatic ship discharger, a Vigan ship vacuum offloader and two 7500 tonnes capacity silos is expected to be completed by 2018. The further construction of four silos and a pallet warehouse will be completed by 2020. The UK glass industry’s requirement for soda ash increases by 2 to 3% a year due to natural growth, however the closure of the Tata Chemicals site in Winnington in 2013 meant that the UK became a net importer of soda ash. Out of the 500kt of soda ash that is used for glass, about 60% of it is imported. By shipping all the soda ash into one port it means the industry becomes more sustainable by reducing truck mileage.
Continued>>
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Soda ash importer Newport Industries recently announced a £7 million investment in a bulk powder handling facility in Liverpool, UK thanks to increased demand from the UK glass industry for the crucial raw material. Its Managing Director Raj Patel spoke to Greg Morris about the impact this will have on the UK glass industry.
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Company profile: Newport Industries
Mr Raj Patel, Managing Director of Newport Industries, said the investment would allow the company to take advantage of a purpose built facility with direct deep-water access. The company has been a customer at Peel Ports’ Runcorn Docks site since 2009. The new equipment at the facility will make the discharge process much more efficient. He said: “Even though we are a net importer of soda ash at the moment for the glass industry, soda ash is here to stay and we’re making the process more efficient.”
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Handling The terminal will be able to handle larger vessels of 20 to 25,000 tonnes rather than the current 5 to 7,000 tonne ships used by the smaller ports. In mainland Europe there are shipping terminals specifically for soda ash, but there is no such facility in the UK. The facility will be open 24 hours a day, just like the glass furnaces it supplies. The soda ash will be drawn out of the ship’s cargo using a pneumatic discharge method rather than a bulk discharge method. The advantages of a pneumatic method include a more rapid discharge, less contamination risk, less dust and lower labour costs. The six silos massively reduce the risk of contamination. There are numerous sources of contamination in warehouses, from bird droppings to more serious risks such as the possibility of contaminants from other sheds containing fertilisers or animal feeds blowing into the soda ash holding area. Most organic materials can be burnt off but furnace operators would rather not have problems such as this. Contaminations that cause the most problems for glass companies are metals such as nickel and chromium. These can cause unplanned discolouration or weaknesses of the final product, particularly flat glass.
z Fig 1. The facility will have an initial capacity of 500,000 tonnes by 2017, with an additional 300,000 by 2020.
in 2009 and has the second largest known reserves of Trona in the world. The $400m plant is located between Ankara and Istanbul and uses solution mining to extract the natural soda ash. The site has reserves of about 40-50 years and currently produces around 1 million tonnes a year. Newport Industries was a pioneer in bringing Eti Soda’s soda ash to the UK, taking one of the first vessels from the Beypazari facility. Western Europe consumes approximately 6.5 million tonnes of soda ash a year, while Europe as a whole consumes about 16 million. Eti has also invested $1.4 billion in a new plant in Kazan, about 88km from Baypazari, which will be fully operational by 2018. It will bring total production to 4 million tonnes a year of soda ash, which should impact the European glass market. Mr Patel said: “Glass manufacturers are happy about this. It should lower their costs, so they’re very happy! It comes at a time when the glass container industry has been under pressure in terms of margins and profits from aluminium cans: The cost of a can is nothing compared to a glass bottle. “The flat glass industry should also be happy with this. It has been in crisis since 2008 with a flat market and plant closures. It comes at an opportune moment for them. They’re looking at it strategically because there’s a potential to reduce costs in future.”
Natural versus synthetic There are two types of soda ash: natural and synthetic. Newport deals in natural soda ash. According to Mr Patel, natural soda ash has 1/7th of CO2 output compared to synthetic. Synthetic requires more energy to manufacture, so its price is likely to rise when the price of oil and coke increases again. Natural soda ash is also more sustainable and, compared to synthetic, relatively straightforward to mine. Mr Patel said: “The largest trend globally at the moment is towards natural soda ash and this is Continued>>
Eti Soda There are only four places in the world where commercial production natural soda ash, referred to as Trona, exists. These are in Wyoming, USA; Magadi, Kenya; Inner Mongolia and in Turkey. Eti’s Beypazari Trona Bed facility was established
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Company profile: Newport Industries
z Fig 3 and 4: The bulk discharge method produces more dust than the pneumatic handling method.
because of its sustainability. A lot of shareholders and directors look at this and it’s an important issue. Everyone is looking for sustainability in their business and I would say that natural soda ash is sustainable.” Mr Patel added: “There is a lot of amalgamation between drinks manufacturers at the moment, so strategically they’ll have more power over container glass manufacturers for procurement of the glass. It is the same with soda ash – the process filters down! So there is a trend for larger soda ash manufacturers.” The most eye-catching of these in the soda ash industry was Ciner Group’s acquisition of OCI Resources in July last year. It gave Ciner, which is Eti Soda’s principle, control of the Green River site in Wyoming and its 2.27 million tonnes a year capacity. Its investment plans and acquisition will make Ciner group the second largest global producer of soda ash in 2018, when new capacity comes on stream.
Future The next few years look set to be an exciting time for Newport Industries. The company plans to continue its good relationship with its glass customers as well as bring all the efficiencies of the new facility to UK glass manufacturers. r
*Managing Director, Newport Industries, Richmond, London, UK. www.newport-industries.com www.drybulk-powder.com
Fig 5. A Vigan ship offloader.
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Glassman Middle East Catalogue
GLASSMAN MIDDLE EAST VENUE: ADNEC, Abu Dhabi, UAE
Opening hours: Tuesday 10th May 2016 10.30 - 18.00 Wednesday 11th May 2016 10.00 - 16.00
who will be giving an overview of the Iranian tableware market - something that will be of great interest to those wanting to learn more about this recently accessible market. Next year there will be two Glassman exhibitions, and we are happy to announce that following on from the success of last year’s show in Mexico we will be reutrning to the region with our first show of the year in Buenos Aires. We are also returning to Lyon, France later next year. Both of these regions proved fruitful for both our exhibitors and visitors recently, and we look forward to replicating that success for all attendees. To find out more about these exhibitions you can get in touch with either Jeremy Fordrey (jeremyfordrey@quartzltd.com) or Ken Clark (kenclark@quartzltd. com). We hope you enjoy the show, and are able to mix business with leisure in the UAE’s capital.
ORGANISER: Quartz Business Media Ltd
www.glass-international.com
Welcome to Glassman Middle East in the UAE, a region that has developed into a glassmaking hub over the past two decades thanks to its large natural supply of gas and its excellent transport links to India, Africa, South East Asia, and its neighboring MENA region. The UAE is home to five hollow glass manufacturers, that between them produce products for the tableware, pharma, perfumes and food and beverage industries. We are pleased to welcome the CEO of one of these plants, Nicholas Hodler of Arc International’s MENA operations, as a keynote speaker at the Glassman conference which, as ever, runs alongside the exhibition and is free to attend for all visitors to the show. Mr Hodler will be discussing staff safety and highlighting Arc International’s excellent record in this respect, and how the company achieved this. He will be joined as a keynote speaker by Saeed Kalafchi of Iran’s Noritazeh,
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EXHIBITOR LIST COMPANY NAME
STAND No
All Glass
GC5
Antonini
GC5
Bohemi Chemicals
GB6
Bottero
GC5
COMPANY NAME Glass Machinery Plants & Accessories/Glass Online
STAND No
COMPANY NAME
STAND No
GC19
Pennekamp
GD3
Glass Service
GB1
Pneumofore
GB17
Henry F Teichmann
GD7
Reckmann
GB7
Horn Glass Industries
GB16
Revimac
GC5
GA3
ilis
GC15
Ruitai Materials Technology
GC5
Electroglass
GD6
Impianti Novopac
GC14
Sefpro Saint-Gobain
GB5
EME Maschinenfabrik Clasen
GA1
Iris Inspection Machines
GB2
Sipac
Dukhiram Maurya Engineering & Refractory works
GC21
Emmeti
GC21
LWN Lufttechnik
GC4
Stara Glass
GD5
Falorni Tech
GC11
Mega Enterprise
GC5
Techglass
GC5 GC5
FIC (UK)
GB1
Messerssi
GC5
Tiama
Flammatec
GB1
Nikolaus Sorg
GA1
Vidromecanica
GC20
Forma Glas
GB12
Nils & Abbas
GC12
Zippe Industrieanlagen
GB11
www.glass-international.com
Exhibitor information correct at time of going to press.
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Exhibitor information correct at time of going to press.
FLOOR PLAN
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GUIDE TO EXHIBITORS
www.glass-international.com
All Glass Via Cesare Sarti 20, Traversetolo (PR), 43029, Italy +39 0521 340810 sales@allglass.it www.allglass.it Booth: GC5 Nowadays All Glass is recognised as a worldwide leading supplier of conveying lines and palletisers in the cold-end area of the glassworks industry. Numerous references in installations for international glassworks allowed All Glass to make a name for itself as a reference partner in this sector. In the last few years, all the glassworks that chose All Glass were satisfied in terms of excellent performance, efficiency and service. Considering that the production of a glass furnace never stops, All Glass uses only first-class components and long-term tested elements in its machinery. All Glass’ technical structure is organised to guarantee a constant assistance during all the steps of design, assembling and start-up, and to assure a prompt after-sales support during the maintenance periods. Making use of consolidate synergies, All Glass is the ideal partner to entrust the service of complete engineering for new turn-key solutions and for retrofits or relocations of existing installations. The key to the All Glass team’s success is constant research in direct symbiosis with its clients to develop tailormade, customised solutions, as well as the after-sales assistance and support that makes All Glass the ideal partner in terms of performance and reliability.
Antonini Via Medaglie d’Oro della resistenza, Empoli - Loc Ponte A Elsa, Florence, Italy +39 0571 93221 antoninisrl@leonet.it www.antoninisrl.com Booth: GC5 Antonini s.r.l., founded in Empoli, Florence, in 1946 by Fosco Antonini, was born as small, artisan business endeavour that manufactured tools and small equipment for the handmade and semiautomatic made glass articles. The Company then specialised its production manufacturing into annealing and decorating lehrs for hollow glass, gaining prestige at both local and national level. A rapid expansion abroad followed during the 80’s and the 90’s, when Antonini srl demonstrated its high competitiveness affirming itself in the markets of all five continents.
Nowadays, Antonini srl is among the world leaders in its branch and boasts the presence of over 1500 installations in 80 Countries. The winning policy is defined by meeting a diversity of market needs and always putting customers’ requirement first, thus developing that great flexibility and dynamics which characterises the business.
Bohemi Chemicals Via XX Settembre 9, Zibido San Giacomo, Milan, 200080, Italy +390290005047 bohemi@bohemichemicals.com www.bohemichemicals.com Booth: GB6 Bohemi Chemicals is committed to supplying its clients with the products and services they need to produce the best glass containers and bottles. Bohemi Chemicals: hot end and cold end treatments certified by a European institute for contact with food. A versatile cold end treatment on the market is Polyglas D 4218M and Polyglas D 4450, an optimum treatment for Champagne bottles and other heavybottomed containers. Polyglas D 4450 offers maximum protection during transportation, even over long distances. STARTIN S is a hot end treatment based on stabilised MBTC for low-dosage use in hot coatings. If your clients don’t return discarded bottles, your manufacturing costs will be reduced.
Bottero Via Genova 82, Cuneo, 12010, Italy +39 0171 310611 mauro.ferrero@bottero.com www.bottero.com Booth: GC5 Bottero Hollow Glass, with its associate Revimac, has been a success story thanks to its drive to deliver innovative glass container solutions to customers, from glass conditioning to the transport of wares. The Hollow Glass Unit designs and realises electronic and mechanical gob feeders, for different production needs, IS machines for every kind of glass containers and a complete set of controls and automation systems. Revimac, besides the overhauling and the reconditioning of IS machines, develops and realises forehearths, accessories, fittings and complementary equipment for the hot end of glassworks.
Dukhiram Maurya Engineering & Refractory Works B-304, Universal Business Park, Kamani Oil Mill Road, Chandivali, Andheri East, Mumbai, India +912228579788 info@dukhiram.in www.dukhiram-enggfurnace.com Booth: GA3
Electroglass 4 Brunel Road, Manor Trading Estate, Benfleet, Essex, SS7 4PS, United Kingdom +44 1268 565577 info@electroglass.co.uk www.electroglass.co.uk Booth: GD6 Electroglass is an independent specialist in all-electric glass melting, conditioning, electric boosting and related systems. Based on decades of experience and ongoing technical development, Electroglass provides the most up to date technology for Electric Furnaces, Forehearths and Boost Systems for all glass types, as well as Precision Control Bubblers and ancillary equipment, such as Glass Level Sensors, Throat Heating and Drain Systems. Our scope of supply includes design and specification, equipment supply and installation, plus commissioning of individual specialised equipment or complete system packages. All Electric Furnaces ranging from 200kg to over 250 Tonnes/day provide operating economy and glass quality assurance. High efficiency Convection Current Control Boost systems improve furnace pull and glass quality and enable significant tonnage increases with simultaneous reductions in electrical consumption. All Electric Forehearths for both volatile and non-volatile glasses offer substantial energy cost savings compared with other all-electric and gas-fired designs. Electroglass’ high quality, insulated, water-cooled electrode holders are available for horizontal and vertical applications. Based in south east England we offer worldwide service to our customers in all five continents with local representation in many regions.
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Falorni Tech
Wockerather Weg 45, Erkelenz, Germany +49 9352 507-0 contact@eme.de www.eme.de Booth: GA1 EME Maschinenfabrik Clasen GmbH is a leading supplier of batch preparation plants, cullet handling equipment and batch charging technology to the global glass industry. Established almost 100 years ago, the company has a long and proud history of service to the glass industry. Customised solutions ranging from single component supply through to complex turnkey batch plants are on offer. EME has world-class solutions for container glass, fiber glass, thin glass, float glass, speciality glass and tableware, for any environment. The EME batch-charging technology provides for a completely sealed doghouse, reduced dust, lower energy consumption, fewer emissions and less rouge air entering the furnace. All benefits of the EME-NEND batch-charging family are available with a screw or a vibratory tube transport system. Since 1987 EME has been part of the SORG Group. The SORG Group, comprising EME, Nikolaus Sorg and Sorg Keramik Services (SKS), has the capability to supply all the necessary equipment and technology required in the complete batch and melting process, starting with the delivery of the raw materials right through to the transfer of the conditioned glass to the forming process.
Viale IV novembre15, Empoli, Firenze, 50053, Italy +390571922333 info@falornitech.com www.falorniglass.com Booth: GC11 Falorni Tech is the industrial division of Falorni Gianfranco Srl based in Italy and operating in hollow glass technologies and services since 1958. Falorni Tech is fully focused on supplying solutions for high capacity industrial glass plants, delivering integrated technologies for batch plants, glass melting furnaces and glass conditioning systems. The approach to every project is inspired by long experience but aimed at the future, and merged with modern designing tools, updated technology assets and harmonised partnerships in a combination of integrated solutions that fully accomplish the needs of glass manufacturers. Falorni Tech delivers to glass plants, responding to all technical needs from feasibility study, batch analysis, plant conception, furnace design and execution of projects respecting all specifications, quality requirements, deadlines and costs. The technology solutions offered are: batch plants - regenerative, recuperative and oxyfired melting furnaces - glass conditioning and coloring systems - ancillary equipment for melting and conditioning. Falorni Tech provides a complete programme of technical assistance and supervision, supported by teams of professional technicians from the beginning of project development. Assistance is provided during all phases of execution, achieving in terms of performance, quality standards, cost efficiency and durability.
Emmeti
FIC (UK)
Via G. Galilei, 29, Montecchio Emilia (R.E.), Italy +39 0522 861911 emmeti@emmeti-spa.it www.emmeti-spa.it Booth: GC21 30 years of activity with hundreds of successful installations worldwide. This is our business card for those customers who have not yet had the opportunity to handle their glass containers with our fully automatic equipment. Emmeti designs and produces palletisers, shuttle cars, packing and automatic tracking, labelling and warehousing solutions.
Cuxhaven Way, Longrock Industrial Estate, Penzance, Cornwall, TR20 8HX, United Kingdom +44 1736 366962 general@fic-uk.com www.fic-uk.com Booth: GB1 F.I.C. (UK) Limited designs and supplys all-electric furnaces as well as electrical boosting systems for a wide range of glass types and manufacturing processes including TFT, float, fibre, container, and borosilicate. We also have a wide range of electrode holders including our High
‘Q’ holder in which the cooling circuit is replaceable in under 10 minutes, and our Maxi ‘Q’ weld-free holder in which there is no weld inside the furnace refractory blocks making it ideal for more aggressive glasses. In addition, we specialise in a number of glass conditioning options such as our Isothermal unit for glass conditioning in the forehearth or distributor to eliminate top-to-bottom and side-to-middle temperature differences. This system will significantly improve thermal homogeneity in coloured glasses and high productivity forehearths in flint glass. We also offer heat extraction systems to extract heat from the glass to aid glass conditioning and reduce gas consumption by the use of removable water-cooled tubes. In addition, these water-cooled tubes can be used to prevent premature shutdown of a furnace by rendering safe worn refractories.”
Flammatec Rokytnice 60, Vsetin, Czech Republic +420 571 498 566 info@flammatec.com www.flammatec.com Booth: GB1 FlammaTec, spol. s r.o. (Czech Republic) and its daughter company FlammaTec GmbH (Germany) have become leading suppliers of advanced burner technology for glass furnaces. FlammaTec was founded by two partner companies (STG Combustion Control GmbH & Co KG, and Glass Service, Inc.) as a joint venture. The long-term knowledge of how to supply optimal and flexible heat into the glass can be found back in the advanced burner concepts. Since its start in 2008, FlammaTec has already supplied well over 2,300 burners to over 120 projects on float, container, tableware and special glass furnaces. Such a strong reference clearly shows the benefit of this innovative combustion technology that offers high performance solutions to FlammaTec customers. FlammaTec offers the following advanced LoNOx burner types: • Underport Gas Injector, Flex or Freejet • Underport Gas/Oil Dual Injector, Flex of Freejet • Underport Heavy Oil Injector (also can be used for backup solutions) • Sideport Gas Injector, Flex • New Oxy/Gas Burner
Forma Glas
Salzburgerstraße 1, Neukirchen, Austria, 5145 +43 7729 20299 info@formaglass.com www.formaglass.com Booth: GB12 Forma Glas is an innovative manufacturer of glass production machines for stemware, tumblers and press articles from Austria. With more than 120 years of experience, we build individual machines and complete production plants. Production lines for: stemware production - tumbler production - vases and bowls - ophthalmic lenses - car headlights - thermos flasks - laboratory glass articles - lamp bulbs - press glass lines - glas processing machines - blowing machines - IBS with 8 up to 32 stations for the production of stemware bowls, tumblers, laboratory articles, lamp bulbs, thermos flasks, vases and bowls etc. up to 60/pc. /min - Presses type ISP with 8 up to 20 stations hydraulic or servo for the production of stems for stemware (with bottom), ophthalmic lenses and smaller pressed glass articles - double stations presses up to 14 double stations (ISP 14/2) - presses type RPH, hydraulic or servo, with 6 up to 16 stations for the production of pressed table glassware - presses for the production of technical glass (car headlights) - cold processing machines - automatic cracking-off, grinding and polishing machine type ASA with 15, 30 or 45 stations for the finishing.
Glass International Magazine
Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK +44 1737855000 glass@quartzltd.com Booth: TBC www.glass-international.com Leading trade magazine for the hollow glass industry.
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www.glass-international.com
EME Maschinenfabrik Clasen
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Glass Machinery Plants & Accessories - Glass Online Via Antonio Gramsci 57, Cormano, Italy +39-02-66306866 publications@glassonline.com www.glassonline.com Booth: GC19 Glass Machinery Plants & Accessories is a bi-monthly international magazine for the hollow glass industry. GlassOnline.com is a leading international website dedicated to the world of glass.
www.glass-international.com
Glass Service Rokytnice 60, Vsetin, Czech Republic +420 571 412 626 info@gsl.cz www.gsl.cz Booth: GB1 Glass Service (GS), headquartered in the Czech Republic with offices in the Netherlands, U.S.A, China and Slovakia, is a leading consultant in the field of glass melting, furnace control, operation, troubleshooting, and optimising furnace designs. GS programmers have developed in-house mathematical modeling software enabling the optimisation of glass melting and combustion processes in glass furnaces and forehearths. More than 700 different projects have been completed using GS software. Presently a new version of furnace modeling software (GFM 5.0) is being developed. GFM 5.0 uses a new generation of non-orthogonal mesh, which enables proper representation of all geometric features and local refinement. GS has its own laboratory for glass defect analysis and analyses more than 2,000 defects yearly. Additional testing capabilities utilise basic and applied research in the field of glass melting, and GS has invested considerable effort into developing a new technology called a ‘Supervisory Advanced Control System’ using our proprietary software known as the Expert System - ESIIITM. More than 90 installations have been successfully deployed worldwide. GS supplies high quality selected raw materials to the glass industry. GS has registered lead silicate.
the glass industry in 1947. Our engineering, technical service, purchasing, construction and project management team is committed to providing turnkey services for batch plants, complete glass plants, electric furnaces, container glass furnaces, float glass furnaces, fibre glass furnaces, foam glass furnaces, sodium silicate furnaces, pressed glass melting services, TV glass furnaces, hand glass processes, tableware and lighting products. In our 68 years we have serviced over 1,000 projects worldwide. Our engineering staff has provided furnace designs utilising regenerative package furnace, cross-fire furnace, end-fire furnace, electric furnace and oxy-fuel melter technologies.
Horn Glass Industries
Bergstrasse 2, Ploessberg, Germany +49 9636 9204 0 info@hornglas.de www.hornglass.com Booth: GB16 Horn Glass Industries AG has a lot of expertise in the engineering, design and manufacturing of different glass melting furnace types, distributors and forehearths. Furthermore, the whole equipment around the furnace is supplied by Horn. Reliability and durability are the chief criteria for all equipment whether wholly or partly manufactured in-house. Individual consultation in terms of the selection, adaptation and application of technically and economically sound solutions are Horn´s specialty. The company is also able to tailor entire plant packages that include products outside of the standard range so that Horn is, so to speak, your one-stopshop and ‘innovation factory’.
ilis
Henry F Teichmann 3009 Washington Road, McMurray, PA, Washington, 15317, United States +1-724-941-9550 info@hft.com www.hft.com Booth: GD7 Henry F. Teichmann, Inc. started servicing
Konrad-Zuse-Str. 22, Erlangen, 91052, Germany +49 (9131) 9747790 info@ilis.de www.ilis.de Booth: GC15 ilis develops, produces and distributes
software solutions, measuring systems and automated test equipment for quality assurance in the glass and optical industry. With the measuring and testing equipment of the StrainMatic and StrainScope series, the company develops imaging polarimeter systems for the automatic and objective measurement of residual stress in glass and plastics. BatchMaker and Chroma provide the glass industry standardised software solutions for simple and reliable calculation of batch recipes and glass properties, as well as for transmission and colour measurement.
company has based its development on a long-term partnership with glassmakers in the field of glass defects detection, as well as on an exceptional knowhow in innovative vision technologies. Iris was the first to develop and propose a 12 camera inspection machine. The success of Iris is due not only to the exceptional efficiency of its Evolution machines range, but also to the excellent support provided by engineers worldwide. Thanks to a network of international agents and technical service centers, Iris is able to support customers throughout Asia, Europe, the Americas, Africa and Australia.
Impianti Novopac
LWN Lufttechnik
Via dell’Automobile 41 - Nuova Zona D3, Alessandria, AL, 15121, Italy +39-0131-242111 info@novopac.it www.novopac.it Booth: GC14 Leading Italian manufacturer of shrinkwrapping equipment for the packaging of empty glass containers such as pharma bottles, juice and water bottles, jars, etc. in straight and off-set configurations. Our production ranges includes special equipment for the packaging of glass tubes, to be stacked and shrinkwrapped on the ends.
Iris Inspection Machines
14 Rue du 35eme Regiment d’Aviation, Bron, France +33 472 78 35 27 contact@iris-im.fr www.iris-im.com Booth: GB2 Iris Inspection Machines is a worldwide leader in the cold end camera inspection of glass containers for international brands with high quality standard articles, produced by global companies such as Nestlé, Coca Cola, Heineken, Carlsberg, etc. Iris Inspection Machines provides inspection solutions for glass containers of any shape or colour, including wine, beer, liquor and Champagne bottles, pharmaceuticals, perfumes and food containers. A team of dedicated Research and Development engineers has evolved a range of equipment to match the industry’s demanding requirements and satisfy the inspection needs of key international customers. The
Hühndorfer Höhe 7, Wilsdruff, Saxony, D – 01723, Germany +49 176127 08506; +49 17610353533 a.pinda@lufttechnik-lwn.de; r.giesbert@ lwn-lufttechnik.de www.lufttechnik-lwn.de Booth: GC4 LWN Lufttechnik is a worldwide market leader in cooling systems for the glass industry. The company produces not only high efficiency fans but also valves (up to 1000°C), air ducts, nozzles, electrical cabinets and automatic control systems. With its innovative cooling system for mould cooling of IS machines, it’s possible not only to save energy but also to increase production speed. It is the first complex control system of mould cooling of IS machines. Built as a combination of fans, fans automatic control and control of mould temperature, the entire system is supported by thermal calculations of the moulds. LWN cooling systems for container glass are successfully installed and used in over 50 countries all around the world including the biggest container glass producers (e.g. Ardagh, Vetropack, Can-Pack, Veralia, Ambev). LWN also produces furnace cooling systems for both container and float glass plants. Companies such as AGC, Euroglass, Saint-Gobain in float and Sorg and Horn in container, use with success our furnace cooling equipment all around the world. From 2014 LWN provides also FEM calculations of thermal distribution on moulds for IS machines, air flow and pressure losses in air ducts and cooling nozzles. We will cool your glass!
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Glassman Middle East Catalogue
7 El Tesseen St New Cairo 11774 Egypt shawi@megafzco.com Booth: GC5 Since its founding seven years ago, MEGA Enterprise is the first agency in the world to be made up of partners rather than employees. It is also the first agency in the Middle East to offer after sales services, and technical services that range from production assistance, to container forming training to furnace expertise. While it started by mainly covering the Middle East, MEGA’s customers range from Latin America to Japan. MEGA started with the idea of bringing added value to its customers and suppliers by offering after sales service and also by providing catered solutions to each customer’s needs. Thriving on bringing cost effective alternatives and solutions to its customers, MEGA continues to serve 50 customers in 15 countries, representing 15 companies all of which strive for excellence.
Messersi Packaging Via Primo Maggio 8, Barbara (AN), 60010, Italy +39 071963861 mes@messersi.com www.messersi.com Booth: GC5
Nikolaus Sorg
Stoltestrasse 23, Lohr am Main, Germany +49 9352 507-0 nsorg@sorg.de www.sorg.de Booth: GA1 The Sorg Group with their member companies can supply turnkey installations and equipment from raw material delivery through the glass gob worldwide. This includes all aspects of the furnace lifetime cycle. From sustainable designs, construction, services, repairs, through to demolition at the end of the campaign. Sorg, through EME, Nikolaus Sorg GmbH & Co. KG and SKS, delivers Made In Germany solutions to all sectors of the glass industry. Our latest products include the LoM burners and the BATCH3 system. LoM burners are Low Momentum, Low Maintenance oxy-fuel burners. BATCH3 consists of the IRD Doghouse, EME-NEND chargers and the proven Sorg batch and
cullet preheating systems. Sorg solutions provide our customers the lowest total cost of ownership over the life of the investment. Serving the glass industry since 1872, we currently have customers in more than 70 countries, and there are more than 250 Sorg designed furnaces in operation throughout the world.
four axis); ware transfers; water cooled segmented cross conveyors; dosing units; cold end sprays; under belt sprays; belt cleaning brushes; burner low emission unit (BLEU); mould oven.
Pneumofore
Nils & Abbas PO Box 26564 Al Quoz 3, Dubai - UAE, 26564 +97143390044 assistant@nilsabbas.com www.nilsabbas.com Booth: GC12 N&A has a great reputation for the best quality, prompt supplies and service; hence, our company products are being specified in various prestigious projects in the UAE and other countries by many consultants. Nils & Abbas with its complete engineering solution offers a wide range of products to satisfy our valued customer needs. As an agent of CompAir, we make sure that we provide you the best quality of service ensuring that your requirements are met. We provide components and innovative engineering solutions for compressed air, steam and industrial automation. Due to the wide-ranging nature of the products that Nils & Abbas represents, we are able to cater to a variety of industrial sectors, including but not limited to oilfield and petrochemical companies, the pharmaceutical industry, food and beverage manufacturing companies, the packaging industry, and glass manufacturing companies. Our expertise and experience allow us to supply both individual products and complete turnkey packages including design, fabrication, installation, testing and commissioning for both on- and off-shore sites.
Pennekamp Königsfelder Strasse 38-42, Ennepetal, Germany +49 2333 605 0 info@pennekamp.de www.pennekamp.de Booth: GD3 Pennekamp is a leading manufacturer of lehrs, handling systems and glass coating. This refers to container glass, float and display glass, solar glass and automotive glass processing. The scope of supply includes: container glass annealing lehrs (float, solar & display); decorating lehrs; toughening lehrs; automotive glass processing; servo lehr stackers (one to
Via N. Bruno 34, Rivoli, Italy +39 011 950 40 30 info@pneumofore.com www.pneumofore.com Booth: GB17 Founded in 1923, Pneumofore manufactures vacuum pumps and air compressors for industrial applications worldwide and supplies the hollow glass industry with centralised vacuum and compressed air systems, designed for the pneumatic requirements of the IS machines. With references such as Ardagh, O-I, Verallia, Gallo, Middle East Glass, Altajir, Gulf Glass, Sisecam and many more, Pneumofore compressors and vacuum pumps are found worldwide, whenever customers require extraordinary reliability and constant performance. A leader in rotary vane technology, Pneumofore solutions focus on efficiency, durability, minimal Life Cycle Cost, and high environmental respect. At Glassman Middle East 2016, the company presents the UV Series vacuum pumps, ranging in capacity from 250 to 6480m3/h with 0.5mbar(a) residual pressure, and its latest market entry: the A400, the world’s largest, single-stage, air-cooled, rotary vane air compressor. This unit has 250kW of nominal power for a capacity of 2560m3/h and pressures from 2.5 to 10 bar(g). As for all the compressors of the A Series, which ranges from 67 to 2560m3/h, several options are available, such as the VS drive, remote control or connection to any PLC system. Each option facilitates heat recovery and air cooling, even in harsh environments up to 50°C.
Reckmann
Werkzeugstraße 19-23, Hagen, Germany +49 2331 3501-744 ouallam@reckmann.de; info@reckmann.de www.reckmann.de
Booth: GB7 Quality made in Germany. Since 1970, Reckmann GmbH is one of the leading manufacturers of thermocouples and resistance thermometers. With more than 140 employees we produce crown, stack, bottom, spout and forehearths/feeder elements with platinum TC’s and platinum tip. We also offer recycling of old platinum and buying of your scrap of platinum and rhodium. Best quality for your satisfaction! Please test us!
Revimac Via M.Carraro, 19, Montecchio Maggiore, Vicenza, 36075, Italy +39 0444 493494 pietro.agnetti@revimac.com www.revimac.com Booth: GC5
Ruitai Materials Technology 4F Main Building China Building Material Academy, Guanzhuang Chaoyang District, Beijing, China +86-10-57987983 wxsh@bjruitai.com www.bjruitai.com Booth: GC5 Ruitai Materials Technology Co.,Ltd (Ruitai Technology) is a listed company (Stock Code:002066) with China National Buildling Materials Group Corporation (CNBM) as its holding company. Ruitai Technology is a scientific and technological enterprise that provides research, production, sales and service. It is also a comprehensive service that provides refractory technology, installation and transportation for high temperature furnaces in the glass, cement, non-ferrous, electrical and petrochemical industries. In terms of production scale, technological levels, product quality and innovation capability, Ruitai Technology takes a leading position in the industry. Ruitai Technology is the birthplace for refractory in the buidling materials industry in China. Ruitai Technology owns 16 member firms and five production systems are established. The product range covers fused cast refractory, basic refractory, alumina-silica refractory and special wearand heat-resistance material. At present, Ruitai Technology’s material is exported to over 50 countries and over a thousand glass furnaces are serviced by our material. Our customers include O-I, Saint-Gobain, Arc, Sisecam, Philips, AGC, Yamamura, Toyo Continued>>
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MEGA Enterprise
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Conveying glass around the world for over 30 years
Premium Conveyor Chain and Sprockets +44 (0) 1484 864733 sales@penninne.org www.pennine.org
Glassman Middle East Catalogue
- Maintenance at high temperature Research & Development - Other services
Sefpro Saint-Gobain
Techglass
2539, route de Sorgues – Le Pontet, F 84131, France +33 490 32 72 49 www.sefpro.com Booth: GB5 Make the difference with Sefpro. Sefpro has been providing refractories for the glass industry for more than 80 years. We invite you to come and discover how we can accompany you at each phase of your furnace lifecycle, thanks to an extended range of services. Tell us about your projects to find out how innovations and higher performing products will help you make the difference.
124 Zygmunta Starego, Kraków, Poland +48 126375862; +48 126362349 office@techglass.pl www.techglass.pl Booth: GC5 Designing and constructing glass production lines - designing and constructing glass furnaces and forehearths - manufacturing and supply of complete furnace equipment, instrumentation and control, complete forehearths - drainage and heat-up inspection, diagnostics of furnaces in operation - hot-repairs - glass technology and production assistance.
Rua Central Nº22, Garcia, Marinha Grande, 2430-017, Portugal +351 244 555 060 vidromecanica@vidromecanica.com www.vidromecanica.com Booth: GC20 Vidromecanica’s main equipments are: annealing and decorating lehrs, belt tempering lines for tableware, spindles, toughening lines for stemware, chemical tempering machines, roller annealing lehrs for flat glass, special glass thermal treatment ovens, moulds, pre-heating kilns, servo-stackers, hot-end coating hoods, cold-end coating spraying systems, scraper conveyors, cullet crushers, cullet processing plants.
Tiama
Zippe Industrieanlagen
ZA des Plattes - 1ch. des Plattes, Vourles, France + 33 437201580 Service@tiama.com www.tiama.com Booth: GC5 Tiama is a global provider of on-line process and quality control for the glass packaging industry. 50 years’ expertise for a one-stop-shop. Process monitoring solutions such as: I-Care (hot imaging); GIA (Gob weight control); the new range, ‘Tiama HOT systems’ (HOT mass, HOT move, HOT form). Traceability solutions such as: laser code engraving and readers; article quality control; vision and carrousel technologies such as MCAL4, MULTI4 and MX4. IT intelligence tools for analysis and management of plant performances: ‘Tiama IQ range’. Complete range of service activities: customer local support, multilingual on-line spare-parts catalogues, tooling, repairs, refurbishment.
Alfred-Zippe-Strasse 11, Wertheim, Germany +4993428040 zippe@zippe.de www.zippe.de Booth: GB11 Zippe has dedicated all activities to the international glass industry. Acting as a partner in the area of melting material preparation, the design, manufacturing, installation and commissioning of plants, on a turnkey basis if required, Zippe offers: - batch plants - engineering - control and automation technology - modernisation of existing plants - modernisation of electronic control and weighing systems - processing plants for factory cullet, post-consumer glass, special glass waste - batch chargers - glass level controllers batch preheating - maintenance & service. Zippe is a competent and reliable partner not only offering delivery of equipment but also consulting and engineering. In-house educated engineers and supervisors install and commission the plants.
Sipac Via Berettinazza, 25, Fontevivo (PR), Italy +39 0521 611811 sipac@sipac.pr.it www.sipac.pr.it Booth: GC21 Sipac designs and produces conveying systems, elevators, lowerators and other package transportation systems such as automatic systems for the handling of glass, PET and PVC bottles, cans jars, cartons, crates, shrink-wrapped packs and drums.
Stara Glass
Piazza Rossetti, 3A/1, Genova, 16129, Italy +39 010 576391 info@hydragroup.it www.staraglass.it Booth: GD5 Turnkey jobs - Furnace design - Materials supply - Furnace construction and demolition - Plant start-up and running
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Vidromecanica
Glass, Panasonic, Kaveh Glass, Sorg, Horn, Fives Stein, CTIEC.
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GUIDE TO EXHIBITORS & SERVICES
Glassman Middle East Catalogue
Air compressors
Control systems, cold end
Pneumofore
All Glass ilis Iris Inspection Machines Stara Glass Tiama
Annealing lehrs/kilns Antonini Pennekamp Vidromecanica
Batch chargers EME Maschinenfabrik Clasen Falorni Tech Horn Glass Industries Stara Glass Techglass Zippe Industrieanlagen
Batch plant EME Maschinenfabrik Clasen Falorni Tech Henry F. Teichmann Stara Glass Vidromecanica Zippe Industrieanlagen
Batch/cullet preheaters EME Maschinenfabrik Clasen Falorni Tech Techglass Zippe Industrieanlagen
Boosting equipment Electroglass F.I.C. (UK)
Bubblers F.I.C. (UK)
Coatings, hot/cold end Bohemi Chemicals Pennekamp Revimac Vidromecanica
Combustion equipment Falorni Tech Flammatec Horn Glass Industries LWN Lufftechnik Nikolaus Sorg Revimac Stara Glass Techglass
Container forming machinery/components Bottero LWN Lufftechnik Revimac
Control systems, forming Bottero Revimac
Control systems, hot end Bottero Falorni Tech Glass Service LWN Lufftechnik Nikolaus Sorg Revimac Techglass Tiama
Control systems, melting Falorni Tech Glass Service Horn Glass Industries Nikolaus Sorg Techglass
Cullet handling systems All Glass EME Maschinenfabrik Clasen Falorni Tech Sipac Vidromecanica Zippe Industrieanlagen
Nikolaus Sorg Stara Glass Zippe Industrieanlagen
Feeder mechanisms Bottero Forma Glas Glass Service Horn Glass Industries Nikolaus Sorg Revimac
Fire polishers Forma Glas
Forehearth assemblies Electroglass Falorni Tech Glass Service Horn Glass Industries Nikolaus Sorg Revimac Stara Glass Techglass
Flat glass production machinery Bottero LWN Lufftechnik
Handling & packaging equipment, cold end All Glass Emmeti Pennekamp
Decorating equipment, hollow
Handling equipment, hot end
Vidromecanica
LWN Lufftechnik Revimac Zippe Industrieanlagen
Decorating lehrs Antonini Pennekamp Vidromecanica
Inspection equipment, flat
Electrodes
Inspection equipment, hollow
Electroglass F.I.C. (UK)
Electric furnaces
Forma Glas ilis Iris Inspection Machines Tiama
Electroglass F.I.C. (UK)
Laboratory equipment
Engineering/plant design services
Glass Service ilis Tiama
Bottero Electroglass EME Maschinenfabrik Clasen Falorni Tech Glass Service Henry F. Teichmann Horn Glass Industries LWN Lufftechnik
ilis
Laminated glass machinery Bottero
Lehr loaders/unloaders Revimac Continued>>
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Glassman Middle East Catalogue
Sipac Vidromecanica
Melting furnace heat up/cool down Falorni Tech Glass Service Horn Glass Industries LWN Lufftechnik Nikolaus Sorg Techglass
Melting furnaces, continuous Electroglass Falorni Tech Glass Service Henry F. Teichmann Horn Glass Industries Nikolaus Sorg Techglass
Melting furnaces, day tanks Falorni Tech Glass Service Henry F. Teichmann Nikolaus Sorg
Melting furnaces, pot Falorni Tech Glass Service Henry F. Teichmann
Moulds, glass forming All Glass LWN Lufftechnik Pneumofore
Mould maintenance equipment
Oxy-fuel technology
Processing machinery, hollow
Technical assistance/training
Falorni Tech Flammatec Henry F. Teichmann Horn Glass Industries Nikolaus Sorg Stara Glass Techglass
Falorni Tech Forma Glas
Bottero EME Maschinenfabrik Clasen Falorni Tech Forma Glas Glass Service Horn Glass Industries LWN Lufftechnik Nikolaus Sorg Revimac Techglass Zippe Industrieanlagen
Project management services
All Glass Emmeti
Falorni Tech Henry F. Teichmann Horn Glass Industries LWN Lufftechnik Nikolaus Sorg Techglass Zippe Industrieanlagen
Plant utilities
Raw materials
Pneumofore
Glass Service
Pollution control systems
Refractories, glass contact
Flammatec
Forma Glas
Revimac Ruitai Materials Technology Sefpro Saint-Gobain Stara Glass
Falorni Tech Glass Service Horn Glass Industries LWN Lufftechnik Reckmann Techglass
Process control equipment
Refractories, insulating
Trade publication
Bottero EME Maschinenfabrik Clasen Falorni Tech Glass Service Horn Glass Industries ilis LWN Lufftechnik Nikolaus Sorg Reckmann Stara Glass Tiama Zippe Industrieanlagen
Revimac Ruitai Materials Technology Stara Glass
Glass International Glass Machinery Plants & Accessories/ Glass Online
Refractories, secondary
Turnkey glass plant construction
Processing machinery, flat
Tableware forming machinery
Bottero
Forma Glas
Palletisers
Presses
Revimac Ruitai Materials Technology Stara Glass
Shrinkwrapping equipment All Glass Impianti Novopac
Temperature measurement equipment
Falorni Tech Forma Glas Nikolaus Sorg Stara Glass Zippe Industrieanlagen
Vacuum pumps Pneumofore
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All Glass
Join us in 2017 for two Glassman events that will cover the entire hollow glass production process from two essential glassmaking regions. Glassman South America will take place in March in Buenos Aires, giving exhibitors access to the dynamic markets across that continent. Following on from 2015â&#x20AC;&#x2122;s successful event Glassman Europe will return to Lyon in September 2017, to once again take advantage of the glass business in this region.
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Electrical melting in perfection Engineering and modeling for boosting systems Water-cooling systems for electrode holders etc. Electrode holder for bottom / side / top Power regulation / Transformers Special service in hot-drilling and change of electrode holders
Bock Energietechnik GmbH Gรถsen 15 92685 Floss Germany IBDU 1.pdf 1 08/02/2016 09:24:32
Tel: + 49 9603 / 1295 Fax: + 49 9603 / 2995
info@bock-energietec.de www.bock-energietec.de
INDEPENDENT TRANSFER AND DRIVE UNIT WITH INTERMEDIATE BELT SYSTEM System is designed to: Enhance container stability throughout the transferring stage. Reduce the frequency of replacing the traditional transfer dead plate. Reduce friction on the base of containers being transferred.
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Visit our stand at China Glass Room W1, Booth 435 Halifax Way, Elvington, York, YO41 4AU, UK T: 0044 1904 608999 E: sales@sheppee.com W: www.sheppee.com
Packaging
Packaging group has it wrapped up Close collaboration with a number of UK glass manufacturing companies has helped elevate Marpack’s position in the packaging market. Jamie Gibson* describes a shrink foil, which reduces down gauges to 70mu.
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UK
polythene manufacturing company Marpak has nine extrusion lines and approximately 40% of its customers are from the glass container market. Marpak works with companies such as Allied Glass, Beatson Clark, Stolzle Flaconnage, Ardagh Group, Rondot Group and Metaglobal to name a few. It has invested more than £1,000,000 in machinery over the past year and has recently moved into new offices as it expands. It has two manufacturing plants with a production capacity of around 20,000 tonnes a year. Marpak has developed a strong position in the shrink wrap market, particularly in the glass container market, where a strong working relationship with Ardagh among others has led to it developing films with a clear knowledge and focus on how the product should perform. While many of Marpak’s competitors have the ability to use products on the market such as metallocene, many of them do not have the knowledge to reduce the film without it having an adverse effect on the overall quality of the product. It is due to the collaborations between Marpak, its suppliers and customers that has led to it being at the forefront of shrink foil for glass containers. This knowledge, developed since the mid-1980s through Marpak’s founder Richard Gibson, continues to be nurtured. Its expertise and contacts within the glass industry led to developments outside film production. Marpak became involved in the production of a transport simulator as data became more important due to the importance of cost savings among the larger container manufacturers, not to mention the added awareness of environmental responsibilities and the impact on companies’ carbon footprint. Marpak has a new product which it states will enable the down gauging of shrink foil to as low as 70mu while maintaining the same mechanical
properties as many of the thicker films on the market.
Company growth Marpak’s sister company Talos was born in 2013 and the business slowly grew organically. However further demands and developments within the business, coupled with the ambition of its founder Jamie Gibson, led to the appointment of Tony Pawinski to the management team. Tony, who worked at Allied Glass for more than 30 years joined the team in the second half of 2015 with the idea of strengthening the product portfolio, bringing with him 35 years of experience within the glass industry.
z The Marpack production process. Talos produces bespoke solutions not only for the glass container market but also other industries such as the food and beverage and general manufacturing sectors. Around 80% of its customers are linked to the use of various film products manufactured by Marpak, while the remaining 20% are independent customers. Talos has designed, manufactured and installed equipment for most of the large glass manufacturing companies such as Allied Glass, Beatson Clark and Stoelzle Flaconnage.
Symmetry Talos’ early success was based on its
ability to understand the symmetry between the machines and film. Due to this understanding of both, it made Talos unique. It has been able to take the same philosophy into other areas of the glass industry, in particular the coldend. The characteristics of speed, shape and interaction with each other as well as machinery are all key to designing the correct bottle handling equipment. Talos uses professional 3D modeling on all its projects, which gives the customer a feel of how the final project will look prior to production. It is conversant with all major PLC types, including Siemens and Allen Bradley. Its panels are Sistema compliant and it works to the Machinery Directive 2006/42/EC. As well as bespoke products such as those listed in the case studies below, Talos also produces core products such as the TX002 Transport Simulator, which is a fully CE compliant system for simulating the effect of transporting a product over a pre-planned journey. In summary, the operator can plan a series of events such as speed bumps, roundabout’s, corners, etc. all at varying speed and then run a simulation based on this plan. Each event, such as speed bumps, have all been pre- programmed to recreate the g forces from a real life test. Talos also makes a simple stretch hood system for applying stretch film to white goods such as washing machines etc. However, with relatively minor modifications it can be adapted to apply stretch film to practically any product. This machine doesn’t require any electrical, pneumatic or hydraulic connection and can be used virtually anywhere. Talos still supplies and installs new or second hand stretch equipment as per its origins. Talos’ recent bespoke glass related projects are summarised overleaf in short case studies. Continued>>
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system that had ensured less than 2mm of gap at any stage throughout the divert system. Talos modified the existing line and palletiser control as well as conveyor, guide rail and motor modifications to give the customer a turnkey solution. Due to the preparation work between Talos and our customer, the installation was achieved within an extended mould change.
Case study 2 z A transport simulator.
Case study 1 A major UK glass manufacturer approached us with a problem bottle, a square bottle with only 4mm between axes. This caused the bottles to spin at cross overs and in particular, its palletiserdivert system; from one lane divided into two lanes. Every time this bottle was produced, personnel were required at the divert system to orientate the bottles prior to the palletiser. To solve the problem, Talos designed and manufactured a bespoke divert
One of our customers had two problems regarding the lehr offload of flask-shaped containers. Problem one: Every time the cold-end line stopped due to an issue, the line would back up and jam the un-loader. Problem two: Two flasks would stick together due to the heat, consequently they would not be in single line format by the time it came to the first line conveyor. Both issues caused a number of bottles to be lost and required full time personnel to work at the un-loader. Talos designed, manufactured and installed a new three-piece conveyor and control system. This allowed for stoppages in the
z An unloader for bottles. line of more than ten minutes without the intervention of an operator. It was designed and controlled in such a way to speed up when it was full of bottles, in a controlled manner so the line didn’t become flooded, and then slowed when back in normal production. It also had further control that recognised if two bottles were sticking together and changed the speed of two conveyors to ensure the second bottle was guided into single line format.
*Commercial Director, Marpak Extrusions, Leeds, UK www.marpak.co.uk
Lubricating and Coating Solutions for the Glass Container Industry
Fixed Drop Guides Greater gob stability equating to better loading Increases the lifetime of the shear mechanisms moving parts due to the weight reduction Optimisation of the Shear sprays reducing oil and water consumption No internal wear parts Shear blade cooling and lubrication achieved by fine atomisation
See us at China Glass Hall W1 Booth 435 Graphoidal Developments Ltd, Broombank Road, Chesterfield S41 9QJ, England Tel: +44 (0) 1246 266000 Email: sales@graphoidal.com Fax: +44 (0) 1246 269269 Website: www.graphoidal.com Marpack.indd 2
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Modelling
Simulation models provide solutions to manufacturers Dominique Lochegnies*, Fabien Bechet** and Norbert Siedow*** highlight how a simulation model is able to solve the radiative transfer equation in glass, and consequently can consider the internal radiation contribution. This allows for accurate simulation results.
N
umerical simulation is now well implemented in glass research. It is used to predict the final shape resulting from glass forming as well as to predict the residual stresses created by glass toughening and annealing. In both cases, prediction is based on historical temperatures inside the glass and their impact on the shape or stress distribution of the glass. In these situations, since the glass is hot, radiation effects are important. Different methods are proposed to compute the temperatures, the easiest way being to ignore radiation effects. A second method involves considering that radiation is limited to the surface, such as for metal parts. These methods are not well adapted since glass is a semi-transparent medium and, for this reason, internal radiation must be considered to generate simulation results that are as close as possible to real results.
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2D models The Modeling of Glass Forming and Tempering (MGFT) group of the Laboratory of Industrial and Human Automation Control, Mechanical Engineering and Computer Science (LAMIH) and the Transport Processes Department of the Fraunhofer Institute for Industrial Mathematics (ITWN) have developed simulation models that consider internal radiation in glass. In these new models, the Radiative Transfer Equation (RTE) has been solved, and as a consequence the internal radiation contribution can be considered in the heat transfer equation. For 2D cases based on the differences in temperatures, shapes and stresses between simulations that only take surface radiation into account and those that consider surface as well as internal radiation, it has been shown
b
a
z Fig 1: (a) The corner of the glass sheet (xOz and yOz are symmetry planes) on the support structure (in grey). (b) Upper view of the 3D finite element mesh. that even for thin glass, internal radiation cannot be ignored[1-3]. It has also been shown that Rosselandâ&#x20AC;&#x2122;s approximation is not adapted to the toughening process of thin glass[2].
Application In this paper, a 3D simulation of the annealing of a square glass sheet on a metal support structure is considered. Due to symmetry conditions, only one corner of the glass sheet (300mm x 300mm square and 1mm thick) is analysed (Fig. 1a). The external dimensions of the support structure are 340mm x 340mm while the inner dimensions are 280mm x 280mm. For the computations, the finite element mesh is refined in the glass/support areas (Fig. 1b) to generate an accurate evaluation of the temperature and stress gradients. At the beginning of the simulation, time t = 0 s and the temperature of the glass sheet is uniform at 923K. The initial temperature of the support structure is 293K. Natural air convection is modeled with a convection coefficient equal to 15 W/m2/K and an air temperature equal to 923K. The thermomechanical properties of the glass and the support structure are given in[3]. Traditionally, when annealing
occurs through natural cooling, small compressive stress values, and not tensile stress values, are expected throughout the surface of the glass sheet. Initial results are on the upper surface of the glass sheet. Fig. 2 presents the maps of the residual stresses when only surface radiation is considered (Fig. 2a) and for the new model with RTE resolution developed by LAMIH and ITWM (Fig. 2b). In both figures, a tensile area appears around the corner of the glass sheet. However, when only surface radiation is considered, this area is limited, represented by a yellow area corresponding to +5 MPa; when internal radiation is considered, not only is the zone larger (yellow, orange and red), but it also has the highest tensile stresses (red means +25 MPa). The next results pertain to the lower surface of the glass sheet in contact with the support structure. Once again, the tensile area is larger when internal radiation is considered. Only orange appears in Fig. 3a while red and dark orange are present in Fig. 3b. This also means that the area with higher tensile stresses (stresses equal to +25MPa in the Continued>>
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red colour area) is larger. Considering the breakage risk (e.g. in the areas where the tensile stress values are observed) and using new models, where internal radiation is taken into account we can identify: r When using surface simulation models only, it is not evident that there are critical zones inside the annealed sheet since the tension zone is limited in size and tensile stresses are low. r When using the models, it is proven that there is a sensitive zone around the corner of the sheet for the surface not in contact with the support structure; there is also a sensitive zone in the middle of the sheet widthwise for the surface in contact with the support structure. r
a
b
z Fig 2. Residual Stresses σ_yy on the upper surface of the glass sheet: (a) when surface radiation only is introduced (b) when radiation is considered inside the glass.
a
b
References 1
Lochegnies, D., Béchet, F., Siedow, N. &
Moreau, P. (2014). Radiation impact on the two-
z Fig 3. Residual Stresses σ_yy on the bottom surface of the glass sheet (in contact with the support structure): (a) when surface radiation only is introduced (b) when radiation is considered inside the glass.
dimensional modeling of glass sheet sagging and tempering. In S.K. Sundaram (Eds). Ceramic
in Analysis and Design, 94, 16-23. ISSN: 0168-874X.
Engineering
3
and
Science
Proceedings,74th
Siedow, N. Béchet, F., & Lochegnies, D.,
Moreau, P., Wakatsuki, H. & Inoue, N. (2015).
Wiley. ISBN: 978-1-118-93293-3.
Axisymmetric modeling of the thermal cooling,
2
Béchet, F., Siedow, N. & Lochegnies, D.
including radiation, of a circular glass disk. J. of
(2015). 2-D finite element modeling of glass
Heat and Mass Transfer, 89, 414-424. ISSN: 0017-
forming and tempering processes. Finite Element
9310.
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Conference on Glass Problems, 35, 1 (pp. 109-115).
*Pres Université Lille Nord de France, Lille, France, ** UVHC, Valenciennes, France *** Fraunhofer ITWM, Kaiserslautern, Germany Corresponding author: dominique. lochegnies@univ-valenciennes.fr
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calumite.co.uk
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Events world: Furnace Solutions
Fired up for Furnace Solutions 2016 Neil Simpson* reports that the programme for the Furnace Solutions training day and conference in June has been completed. reduced energy usage and positive publicity. Reference will be made to how ISO50001 is used as a compliance route for mandatory energy audit schemes related to the EU Energy Efficiency Directive (EED) in some EU countries. The process of certification will be broken down into bite sized portions and some real-life anecdotes will be used to illustrate best practice and avoid common pitfalls. The session will conclude with perspectives from an international glass manufacturer on the ISO5001 standard and the practical issues around implementation and certification and the drivers for having the system.
Abstracts ISO5001 – A must have for the glass industry, by Shaun Bainbridge, Lucideon ISO50001 is the latest international management system and is based around managing energy usage. The glass industry is a natural early adopter of the standard due to its focus on energy efficiency to ensure profitability. The paper will examine the content and structure of the ISO50001 standard and the benefits it brings to organisations in terms of improved systems of operation,
Experience with Auxiliary Combustion for NOx Reduction, by R S Pont, Global Combustion Systems Auxiliary Combustion is a patented technique for reducing NOx in end -fired and cross-fired regenerative furnaces. Modelling, pilot furnace and full scale furnace testing have been used to develop the method assisted by a grant from the EU under the FP7 programme. The technique has been shown to be
capable of reducing NOx in typical glass melting furnaces to 500mg/m3 (at 8% O2) equivalent to reductions of 60%. This paper will describe the development and the results of application to end-fired and cross-fired furnaces in the container and float glass industry. Application of slags and alternative batch compounds in glass batches, by Hans van Limpt, Bart Wilms and Petri Mast of Sibelco Europe The glass industry is more interested into possibilities for further improvement of the yield, quality and energy efficiency of the glassmaking process. The focus has shifted to research on improved batch compositions with low-melting batch compounds. To support these goals Sibelco has investigated the applicability of alternative batch compounds and slags. A slag is an amorphous by-product from e.g. the metallurgic industry with limited industrial applications. Slags are silicate compounds with high levels of CaO, MgO, Al2O3 and/or Fe2O3 not seldom with contaminants such as heavy metals, sulphuric compounds and chloride species. One of the advantages of the slags will be to be able to reduce the use of traditional raw materials such as limestone (CaCO3), dolomite (CaCO3.MgCO3), feldspar/ nepheline (Al2O3 source) or iron minerals and additionally less reaction energy will be required for the batch melting process. Calcined batch compounds such as MgO and calcium-silicates such as wollastonite will also reduce the energy consumption of a glass furnace and reduce the release of CO2. This paper will show the advantages of iron-silicate slags as a colouring agent for amber glass and coloured flat glass as well as the applicability of slags for E-glass production. The advantages of alternative minerals such as MgO and wollastonite will be demonstrated.
Continued>>
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I
n this the Centenary of the Society of Glass Technology (SGT), on behalf of the Melting Technical Committee (MTC) of the SGT it gives me great pleasure to announce our Furnace Solutions 11 (FS11) programme for 9th June at Lucideon, Stoke on (TD4). With expected implementation of the BREF environmental regulations we approached several previous Training Day attendees before deciding on Energy and the Environment as the topic of the Training Day on 8th June. Also celebrating its Centenary, we are delighted to welcome one of the Registered Trainers from the Energy Institute – Chris Burgess, Alpha Management Solutions. Other speakers include regular participants from previous Furnace Solutions events - Geoff Evans FSGT (GlasRef Consulting), Mark Pudner (GTS), Matthew Demmon FSGT (MKD23) and Neil Simpson FSGT (Simpson Combustion and Energy). The cost to attend is £120 per person per day plus VAT and 50% discount for SGT members. For those attending both days the discount covers the cost of SGT membership! Places will be limited to a maximum of 100 so please book early to avoid disappointment. To coincide with the Centenary of the SGT we are planning a special gift to commemorate the event. We are delighted that our conference hosts, Lucideon, will present a paper this year.
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Events world: Furnace Solutions
Fuel Efficient Forehearth And Distributor Systems, by Simon Parkinson, ParkinsonSpencer Refractories (PSR) Although the glass melting furnace is by far the single largest consumer of energy in a glass plant and naturally the focus for energy efficiency monitoring and improvements, a correct forehearth and distributor system design can provide energy and cost reductions by reducing the actual fuel consumption required as well as by increasing the forming efficiency. The furnace supplies the glass to the distributor and forehearths, which are then responsible for cooling the glass from melting temperatures to forming temperatures while achieving a high degree of thermal homogeneity and temperature stability throughout the glass delivered to the forming process. This process of glass thermal conditioning normally involves controlled cooling of the glass as it passes along the distributor and forehearth channels from typical furnace exit (throat riser) temperatures of 1350°C to typical gob temperatures of 1150°C with a consequent approximate three-fold increase in the glass viscosity. Although a substantial amount of heat needs to be removed, more controlled and targeted heat input is also required to ensure that a high degree of temperature uniformity is achieved throughout the body of the glass at the feeder spout. The fuel consumption of a particular glass melting furnace depends on the glass throughput but the fuel consumption of a forehearth and distributor depends on many other factors covering design, operation and maintenance aspects. This paper reviews the influence that the design, operation and maintenance of forehearth and distributor systems can have on their ultimate fuel consumption and illustrates the fuel and cost savings that can be made.
an accurate way, but they also present the furnace behaviour in a much broader operational window. Therefore rMPC (control based on dynamic computer models) enables control functionalities over the complete operational area and enhances the controllability of the furnace. CFD models of furnaces and forehearth systems used for process improvement projects are now used in the engineering phase of rMPC control systems and therefore are re-capitalised upon during In this presentation, detailed dynamic modelling results of a furnace are discussed and examples are given on the application of a CFD model in a control system.
CFD-based glass furnace control system based on time transient computer model by A.F.J.A. Habraken, J.P. van der Dennen and P.J. van Santen, of CelSian Glass & Solar Conventional Model based predictive controllers (MPC) use a process model derived from experiments on a furnace. Such a control system is limited to the tested operational area. Instead of using field data the empirically derived process model can be exchanged by validated CFD simulations. Dynamic computer models do not only describe the furnace time transient dynamics and important correlations in
Solutions to Practical Problems, affecting Melting & Life, in Glass Furnaces, by Stuart Hakes, FIC UK The presentation will cover high wear areas such as doghouse corners, throat, weir walls, sidewall electrode blocks, floor area around bubblers and flux line. It will offer new approaches to these problems. In addition, it will look at other common problems in glass furnaces such as electrode wear and breakage and glass conditioning in the forehearth.
Oxygen Injection with a Linde difference, by Alessandro Curti and Neil Simpson When a premature regenerator failure reduced glass production on an end-fired container furnace in Italy a solution was successfully implemented. The presentation will review the options considered, the solution with results and potential other applications of this technology. Centauro, a solution for glass furnace advanced heat recovery, including a SNCR plant by Giampaolo Bruno, Ernesto Cattaneo, Giorgio Minestrini, Alessandro Mola, Francesco Prosperi Centauro is a hybrid ceramic/metallic system for heat recovery in glass furnaces. It is a cost-effective solution to solve the most frequent problems related to a conversion from unit melter to end port, the optimum solution to increase plant efficiency beyond the performance of the best regenerative furnace by taking advantage of the highest quota of waste gas heat and it includes a robust, easy to manage and cost effective SNCR system for NOx abatement.
Primary NOx Reduction On Regenerative Glass Furnaces by Gary Laird, Elster
A two-part paper, that first reviews the newest ‘Eclipse’ Brightfire 200 gas burner with a focus on its ability to reduce NOx levels in regenerative glass furnaces. Secondly, it will introduce the ‘Eclipse’ staged combustion system, a trusted technique of running furnace burners in reduced conditions, while injecting an additional source of oxygen later in the combustion process. It thus minimises NOx emissions while still maintaining normal levels of CO. How fused-cast AZS Properties influence glass contact behaviour, by Dr Michel Gaubil and Bruno Malphettes of Sefpro AZS fused-cast products properties have a direct impact on glass contact behaviour that influence lasting life and glass quality level. The internal structure of Fused Cast AZS soldier block is discussed at a macroscopic and microscopic level, and the relation with corrosion resistance and glass defect ability.
Award All presenters who are not members of the MTC are eligible for entry to The Michael Garvey Award for the day’s best paper, courtesy of Guardian Industries. The recipient of the award is decided by members of the MTC present on the day and remembers the untimely loss of Michael Garvey, who was killed in a climbing accident. We have managed to keep costs to attend these events as low as possible due to the generosity of the many sponsors. Sponsors so far this year are Calumite, CelSian, DSF, Elster/Honeywell, FIC, Fives, Fosbel, Glass Technology Services, Global Combustion, Harbison Walker International, IRE, Praxair, PSR and Tecoglass/Zedtec in addition to IOM3 and Glass International with, of course, the hosts Lucideon. We have one new sponsor so far for 2016, Sibelco and have two spaces for anyone wanting to sponsor. Please contact Christine Brown Christine@sgt. org if you would like to support us. This year an additional Furnace Solutions Centenary on 8th September will be held as part of the ESG and SGT Conference in Sheffield and the launch of a second Compendium. More details to follow. r
*Chair of Melting Technical Committee, Furnace Solutions 11, June 8th and 9th, Lucideon, Stoke-on-Trent, UK http://www.furnacesolutions.co.uk
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Events world: Glass Technology Course
Techology course has the glassmaking process covered Celsian’s latest glass technology course was held in Sheffield, UK to coincide with the SGT’s centenary celebrations. Course tutor Mathieu Hubert spoke to Greg Morris about the event.
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rofessionals from a variety of glassmaking sectors participated in a technology training course that focused on industrial glass production. Attendees from the hollow, flat, and glass fibre sectors were represented at the Celsian-NCNG International Glass Technology Course for the Glass Industry in the UK. They were joined by refractory, oxygen, raw material and furnace suppliers at the event in Sheffield, UK. The course is now in its 25th year and was held for the first time in the UK, coorganised with Neil Simpson as part of the Society of Glass Technology’s (SGT) centenary celebrations and hosted at the SGT and British Glass building. A total of 24 people attended, the majority of whom were from the UK glass industry. Three people from Italy, two from Germany and a sole delegate from the USA also attended. Attendees had a range of experience: some had more than 30 years experience in the glass industry while others had only been in the industry for a matter of months. Celsian’s Mathieu Hubert and Neil Simpson, a consultant from Simpson Combustion and Energy, taught the fiveday course. Mr Hubert said: “It was a really good group from different backgrounds and different visions of the glassmaking process. There was a range of experience, with some new to the industry, while one or two had only joined the industry a month before the course! “You cannot teach the guys with 30
plus years experience how to do their job – they know more than I do! They have the practical knowledge. But it is an opportunity for them to refresh their knowledge and get an overview of what happens in other places in the plant.” The course provides an overview of the entire glassmaking process. For attendees with plenty of years of experience it gives them an opportunity to see the consequences of actions in areas of the glassmaking process they are not familiar with. Mr Hubert added: “For the experienced guys, they learn that if they take one action they learn of the consequences further down the process. It gives them a complete picture and they get a different point of view of their actions if they change something.” The variety of different perspectives means attendees new to the industry
learn from the course tutor as well as the experienced attendees. The course is taught in an informal atmosphere and there is plenty of time to comment and network with fellow delegates. Mr Hubert commented: “When you talk about a specific topic, someone with practical experience will say what they see day to day. Often someone will ask a question and another attendant will reply with their experience and the consequences of certain actions. This correlates with the content of the course and adds an interactive element to the course. It’s one of the course’s strengths.” A popular topic from participants in recent tutorials has revolved around energy emissions. While many companies already have advanced energy and environmental policies Mr Hubert warns that new regulations will force companies to examine their environmental policies even more deeply.
Background Celsian’s (then TNO) first course was in 1991 and was for Dutch glass industry professionals only. People were worried about knowledge transfer in the industry with the amount of industry professionals that had retired. The course was formed to retain this vital knowledge. In 1997 the course was translated into English for the first time and since then has been organised several times a year in
zTopics covered on the course include recycling.
Continued>>
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z A total of 24 people attended the course, which also included a trip to the DSF refractory site.
Mr Hubert has been a course tutor for 2.5 years after joining Celsian three and a half years ago. Before then he worked in a glass science/academic background for 10 years. He has always had a love of glass. “Glass is a fascinating material. It is not something that is fixed, always in perpetual motion, there are always new applications, always things that you can improve, and
that’s what makes it fascinating. It starts from sand and is heated up and you end up with beautiful material that can be highly transparent and made into different shapes. “There’s always something to improve and is a material that is not regarded as highly as it should be, it is taken for granted. People appreciate what’s inside the beer bottle but they don’t realise how complex it is to get the right glass for the bottle.”
z Modules covered on the course included sessions devoted to furnaces.
different regions. It now takes place every year in Eindhoven, The Netherlands in the autumn and in Toledo, USA in the summer. There is also an option of a company-dedicated course where tutors travel and teach the course on site and tailor it to the company’s requirements. So far about 1300 people have attended it since its inception. The five-day course covers a huge spectrum of the glassmaking process and includes modules on glass structure and properties, raw materials and batch preparation, glass furnaces, melting and fining processes, energy and emissions, recycling and glass defects. The organiser usually arranges an industrial trip to a nearby location and in this case it was a trip to the DSF refractory plant in Newhaven, Derbyshire. Mr Hubert said: “The trip to DSF was
really beneficial. It was interesting to visit a refractory plant because, while a lot of people know what a glass plant is like, a refractory plant is more unknown so everybody really enjoyed it. “DSF gave us a warm welcome and gave a great tour on how they make refractories and the various shapes they make so it was very interesting. We covered refractories in the early part of the course so the tour was a good complement to that. “GTS also kindly opened the doors of their lab and measuring van for a tour, complementing some of the parts covered in the course and allowing participants to see facilities used for different aspects of the glassmaking and process characterisation.” The course was held in the SGT headquarters that it shares with the
Participant comments Nick Hilton said: “The course provided a blend of classroom training, e-learning and a visit to a refractory supplier. The course offered further training opportunity, by providing a comprehensive glass production textbook and networking development. A variety of glass production subjects were covered on the five-day course, including raw materials, glass properties, melting, refining and forming. “I found the course of great value to my own personal development and would recommend to similar minded people wishing to learn more about a complex and interesting subject.” Sibelco Sibelco was pleased to participate in the first International Glass Technology course run by CelSian & NCNG in the UK as part of Sibelco’s ongoing materials solutions development programme aimed at resolving some of the challenges faced by the glass industry today as well as tomorrow.
British Glass association. British Glass President, Dave Dalton, gave a welcome speech to the participants where he spoke about the advantages of the association and the need for collaboration within the industry.
Future The next course is in Toledo, USA between June 20 and 24. Celsian is also exploring the possibility of starting a course in another region of the world. Current glass manufacturing hotspots include the Middle East and South America, and Celsian can organise a dedicated course specific to the region. r
Celsian, Eindhoven, The Netherlands www.celsian.nl/
www.glass-international.com
Course tutor background
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Events world: DGG 90th anniversary
Celebrating 90 years of Germany’s DGG group
T
he conference programme comprises 104 papers to be presented at the Prof. Frischat Memorial Colloquium as well as further sessions addressing the topics: Glass: Nature; Structure and Properties, Hot Forming, Refinement, Quality Control, Energy and Environment, Modeling and Sensor Technology, Glass Furnaces and Advanced Glass Melting. The sessions will run side by side in German and English. The technological programme will be organised in cooperation with Glass Trend. A poster session with 25 posters will also be held. The Student Workshop ‘Clear as Glass 2016 – glass technical calculation’ will attract the next generation of glass scientists. An exhibition of suppliers to the glass industry will also be staged separately. At the beginning of this year’s conference, participants are invited to join in a selection of trips to four industrial plants in and around Goslar: Rheinkalk
based in Herzberg; Auer Lighting in Bad Gandersheim; EuropTec of Goslar; VW-Motorenwerk in Salzgitter; or can participate in a tour to the TU Clausthal, Clausthal-Zellerfeld site. There will also be a variety of social events, including a reception, opening ceremony and banquet. At the opening ceremony, Professor Friedrich H. Balck, of Clausthal-Zellerfeld will give the invited keynote lecture on the technical challenge of mining in the Harz Mountains. The DGG Awards Adolf-Dietzel-Industriepreis and Goldener Gehlhoff-Ring will be presented during this ceremony.
Heritage site Goslar is a World Cultural and Natural Heritage Site and is situated in the Harz region of Lower Saxony. It has a population of 51,000 people and a 1000year history. Global companies operate from the city. The discovery of silver and copper ore deposits induced the Saxon and Salic emperors to establish their
largest and most secure palatinate there in the 11th century. The view of the townscape with the steeples of the five large parish churches is impressive when viewed from the knoll upon which the Romanesque Imperial Palace stands. The crooked, narrow, cobble-stoned streets in the Old Town are an adventure of their own, where each house tells its own story and secret nooks and crannies await discovery. The DGG looks forward to welcoming 300 to 350 members of the German and international glass communities to its Goslar event. More information: Deutsche Glastechnische Gesellschaft, 63071 Offenbach, Germany. r
Conference website: https://express2.converia.de/?sub=86 Tel: +49 69 97 58 61 0 Email: info@hvg-dgg.de Web: www.hvg-dgg.de
www.glass-international.com
The 90th Annual Meeting of the German Glass Society (DGG) takes place from 6 to 8 June 2016 in Goslar. The event is a valuable meeting place for academia, technologists, glassmakers and their suppliers as well as friends of glass.
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Events world
Glassman Middle East 2016 The Glassman exhibition and conference returns to the Middle East for the first time since 2009. May 10th - 11th 2016 Abu Dhabi National Exhibition Centre, UAE. CONTACT: jeremyfordrey@quartzltd.com kenclark@quartzltd.com www.glassmanevents.com Glass Focus 2016 This day-long event is organised by the British Glass association. May 12th 2016 Dynamic Earth, Edinburgh, UK. CONTACT: glassfocus@britglass.co.uk www.britglass.org.uk/glassfocus2016 Glass Stress Summer School 2016 An intensive two-day course containing lectures, demonstrations, practical stress measurements and informal discusions. May 27th - 28th 2016 Nordic Hotel Forum, Tallinn, Estonia. CONTACT: www.glasstress.com 90th Annual Meeting of the DGG The Deutsche Glastechnische Gesellschaft (DGG) annual two day conference event. June 6th - 8th 2016 Goslar, Germany CONTACT: express2.converia.de/frontend/ index.php?folder_id=543 Mir Stekla 2016 Annual Russian exhibition. June 6th - 9th 2016 Moscow Expo Centre, Pavilion Number 2, Russia. CONTACT:re@expocentr.ru www.mirstekla-expo.ru/ Furnace Solutions The Furnace Solutions training day and conference. June 8th - 9th 2016 Lucideon, Stoke on Trent. CONTACT: www.furnacesolutions.co.uk ESG 2016/SGT 100 conference 2016 marks the SGT’s centenary year. September 5th - 9th 2016 University of Sheffield, UK. CONTACT: www.esg2016.eu glasstec 2016 Biennial exhibition and conference devoted to all sectors of the glass industry. September 20th - 23rd 2016 Messe Duesseldorf, Germany. CONTACT: www.glasstec.de
74 Glass International April 2016
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