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May 2017—Vol.40 No.5
VOA VERALLIA PROFILE FURNACES RUSSIAN OVERVIEW I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
Glass International May 2017
E C N ERIE
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GI Cover May - Copy.indd 1
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Defects no longer know where to hide
Intelligent engraving inspection The Evolution 12 engraving identification and inspection module is a software innovation that allows the machine to identify engravings in a container’s body or base. Because it is very difficult to predict how an engraving will look, this module dramatically improves inspection in these areas. By calculating the position of the engraving, the machine identifies the pixels related to the engraving, as well as those that relate to a defect. This algorithm has been improved and tested over recent months on several production lines, including those devoted to beers, carbonated beverages, wine and high value spirits.
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Contents
2 Editor’s Comment
May 2017
Vol.40 No.5
WWW.GLASS-INTERNATIONAL.COM
May 2017—Vol.40 No.5
3 International news
10 Company profile: Verallia Verallia completes €46 million VOA modernisation in France.
VOA VERALLIA PROFILE FURNACES RUSSIAN OVERVIEW I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
14 Glassman South America 2017: South American container manufacturers attend in droves. Glass International May 2017
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Company profile: SteklSouz SteklSouz and Expocentre ready for Mir Stekla 2017 in Moscow
NCE
ERIE
Front cover image www.sorg.de
Furnaces 21
TECO: Making the most of your furnace
24
Richard van Breda: Putting the efficiency into container glass furnaces
26 Ametek Land: Accurate temperature measurement
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28 Falorni Tech: Focused on the environment 30 33
16 Plus find us on Linked-In and Twitter.
@Glass_Int
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Excelsius: A reliable partner to the furnace industry Durr Systems: 3-in-1 approach to dust. SOx and NOx
History: Prof. John Parker
38
Glass recycling: IGR Quality assurance in the use of recycled cullet
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Events Worlds: China Glass preview Exhibition returns to Beijing
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Coatings: Stewart Engineers Make CVD part of your future
46
Precision weighing: Zippe Advanced Load Cell Monitoring for weighing indication
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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
France remains a hub of hollow glassmaking
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Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelmartinquereda@quartzltd.com Production Executive: Martin Lawrence Managing Director: Steve Diprose Chief Executive Officer: Paul Michael
rance. Just that one evocative word conjures up a thousand picture postcard images in my mind. The sun-drenched fields of Provence, the iconic architecture of Paris, windswept beaches on its west coast, sophisticated cuisine and, of course, glorious wines to suit the most sophisticated tastes. Away from the tourist imagery, the country remains one of Europe’s main economic hubs with a GDP of approximately $2.422 trillion. The IMF states it was the world’s 20th country by GDP per capita in 2013. Its glassmaking industry is similarly industrious. The country is a global hub of container and hollow glassmaking with a glass industry stretching from Normandy in the north to Languedoc in southern France. The major players of the sector all have bases there and its products are exported and known around the world. Tableware from one of the world’s largest manufacturers, Arc International, is likely to be in your kitchen while the bottles for all those French beers and wines enjoyed by consumers around the globe are likely to have been made in France. Such is the popularity of the Made in France slogan, that Arc has adopted it on one of its quality marks for several years now.
The largest container glass manufcaturers have their headquarters in France: Verallia in Paris, while O-I has its European base in Lyon. These two companies serve the famous winemaking regions of France. The north of the country is a hotbed of hollow glassmaking, including the Bresle Valley – or Glass Valley – in Normandy and the Pas-de-Calais region where Arc, Saverglass and Stoelzle are among those located there. The Stoelzle plant in Masnières is the company’s centre of excellence in terms of high-end flacons for the perfumery and cosmetics markets. It is here that the high-end bottles for these markets are conceived and manufactured. All of which leads me to the Glassman Europe hollow glass event, which takes place in Lyon this year. Watch out for a series of forthcoming company profiles on French glassmakers, beginning this month with Verallia’s VOA Albi plant, which recently completed a €46 million investment. It is not the last investment we will hear of from these famous French glassmakers. � Greg Morris, Editor gregmorris@quartzltd.com
Directory 2016 Annual international reference source
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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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Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2016 edition: UK £206, all other countries £217. Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.
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Glass International May 2017
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International News
Cristalerías Chile is to invest in a $100 million furnace expansion of its Llay Llay plant. It will construct a third furnace, which will have a capacity of 400 tonnes a day. It is due to begin operation in the second half of 2019 and
will increase the production capacity of glass containers by 100 thousand tons per year. The company said the new technology would comply with environmental and energy efficiency standards. The plant located in the com-
mune of Llay Llay is considered to be the most modern in its field in Latin America, both in production processes and in the care of the environment. The new furnace will be the seventh in the company and will meet the needs and growing demands of sectors such as the wine, beer, liquor, beverages and food. “With this expansion we seek to create the technological conditions of quality and service that meet the growing needs of our customers, who must compete in ever more demanding markets,” said Eduardo Carvallo, General Manager of Cristalerías.
Verallia chooses Zippe batch plant for new Minas Gerais, Brazil site Zippe has been awarded the contract for a batch plant and cullet return system at Verallia’s new Brazilian plant. Zippe CEO, Dr. Philipp Zippe and its project manager, Heiko Brand, were in Sao Paulo for the official contract signing with Verallia Brazil.
The new plant in Jacutinga is in the south of Minas Gerais state, about three hours drive from Sao Paulo. The batch plant will be designed in row and supply a new furnace with a capacity of 440t per day. It can be expanded to feed
a second furnace, in a second step. The scope of delivery also includes a Cullet Return System. Zippe will supply the engineering, complete delivery, installation, cabling, commissioning and start-up, which is scheduled for the end of 2018.
IVN closes Sergipe plant Brazilian glass container manufacturer Industria Vidreira do Nordeste (IVN) has closed its plant in the city of Estância, State of Sergipe, Brazil. The owner blamed adverse economic conditions in Brazil, particularly in the northeast region, where IVN was operating with significant financial losses and without liquidity. The €70 million greenfield
site employed 195 staff and was only inaugurated on April 4, 2016 after two years of construction. It made glass containers for food and beverages. The Sergipe factory operated one furnace and was expected to produce 80,000 tonnes a year, with the containers distributed primarily to the north east region of the country. The majority partner of IVN
is Ipiaram Empreendimentos e Participações. French glass container manufacturer Verallia was a minority partner with a 27% share. Verallia said it was making every possible effort so that IVN addresses the issues arising from the suspension of its activities, in a manner satisfactory to all parties involved (employees, customers and suppliers).
Soliver set to close
Lebanese container glass manufacturer Soliver is set for closure. It blamed a loss of market share, cheaper imports from other countries and increased energy costs for the forthcoming closure. Soliver pays more than $3 million a year to generate its own electricity. It produces 140 tonnes per day of container glass in a variety of colours and sizes and employs 250 full time staff. Omar Kaddoura, Soliver General Manager, said the factory will not be sold for the time being and may re-open ‘if the situation improves’.
Emhart order boost
Order intake increased by 12% in the first quarter of this year for Bucher Emhart Glass. But it reported a sales decrease of 3% compared to the year before in its quarterly financial results. It said brisk demand for glass forming machinery and spare parts contributed to healthy business in Europe and North and South America. The market remained at a low level in China though. The restructuring of the Chinese joint venture with Sanjin progressed according to plan, it added. It anticipates demand in the project business to remain lively for the rest of the year.
Libbey downturn
Tableware manufacturer Libbey reported a decrease in sales of 5.4% compared to the previous year. In its quarterly results it said sales were $170 million, with a net los of $6.6 million, down $7.3 million versus the prior year. Chief Executive Officer, William A. Foley said the sales were a continuation of difficult end-market conditions in foodservice and retail channels. It has taken actions such as cost controls, pricing actions new product launches and accelerated the development of its e-commerce platform to improve sales performance.
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CristalChile to invest $100M in third Llay Llay furnace
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International News
Verallia invests €30 million in its largest glass furnace
including one of the world’s largest glass furnaces. The new equipment was inaugurated in the presence of Verallia’s main customers, suppliers and local authorities at a ceremony led by Jean-
Vertech’ success in China China’s Zhaoqing Tongchan Glass Technology has ordered Vertech’s SIL system on five of its production lines. The order includes for the laboratory, mould shop and SILX system displaying Key Performance Indicators. The Zhaoqing plant, located in Guangdong Province, is part of the Tongchan group, a major Chinese glass manufacturer that produces bottles
primarily for the Asian market. The order for the SIL system was placed in September 2016 and the installation was successfully completed in April this year. As a Manufacturing Execution System, SIL is set to help improve plant productivity and operational performance, by reducing defect percentages in production, decreasing reaction times on issues and
helps managers to make decisions based on real time facts. Vertech’s presence in China has grown rapidly in recent years. Two lines were equipped with SIL in 2010 while today, in 2017, 23 lines have been equipped. A second SIL installation is scheduled in Nanchong Tongchan plant soon.
ing process technology, which is adopted as an alternative to conventional blow-blow production. This equipment helps customers to increase production speeds and save energy, while also improving returns on investment via the production of lighter containers, it said. At least eight new Heye NNPB lines will be commis-
Arab Trading House has concluded a contract with the Algerian pharmaceutical glass producer Messrs. GGP for its new container and pharmacy glass production plant. Zippe is to design and deliver the Batch Plant with batch transport to the new furnace. The scope of delivery also includes the cullet return and addition system. The plant will be built on a greenfield side in Mascara, Algeria.
European Operations Director at Wall Colmonoy
Robert Davies has been appointed as Operations Director for Wall Colmonoy’s European headquarters. Mr Davies joined Wall Colmonoy in March 2015 bringing with him 14 years’ experience in strategic, operational and engineering management. He will oversee all company operations to deliver excellent product quality through measured process efficiency, whilst maintaining a safe working culture.
Mavsa’s Egypt job
Argentina’s MAVSA is installing three MPS 24-34 press lines in Egypt’s New City Glass. The lines will produce coffee and tea mugs in double gob at 60 articles a minute per line at the company’s site in 10th of Ramadan City.
Slovakian investment
Heye sees growth in Asia-Pacific Heye International has seen sales growth throughout the Asia-Pacific region. It has installed more than 40 production lines since 2012 in countries such as Australia, China, India, the Philippines, South Korea, Taiwan, Thailand and Vietnam. More than 70% of the installations feature Narrow Neck Press and Blow (NNPB) form-
Zippe batch plant for new Algerian project
sioned this year, including one that features the latest Heye Swabbing Robot. Substantial orders have also been received for Heye’s high performance HiSHIELD cold end inspection solutions. To date, for example, more than 200 Smartline check inspection machines have been sold to the region’s leading glassmakers.
€25 million has been invested in the new Centre for Functional and SurfaceFunctionalised Glasses (FunGLASS) in Trencín, Slovakia. The research centre has partner institutions in Germany, Spain, and Italy. The establishment of this European centre will help boost the momentum and importance of glass research on a global scale. The centre will conduct research on glasses with special functional properties.
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Verallia is investing €30 million on modernising its Azuqueca plant in Spain, to improve its standards of sustainable development. A new furnace and facilities were installed at the plant,
Pierre Floris, President and CEO of Verallia (pictured). This latest-generation furnace is the upgraded plant’s flagship innovation. It is the largest the company has ever installed anywhere in the world. It is also more sustainable, as it emits less CO2 per metric tonne of glass produced. With this new furnace, Verallia Azuqueca can produce two million containers a day (more than 500 jars a minute). During the event, JeanPierre Floris pointed out that “Verallia is continuing to invest with the longer-term future in mind while aiming to continuously improve quality, flexibility and productivity.”
NEWS IN BRIEF
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International News
NEWS IN BRIEF
Russian groups invest in Heye International
Heye International’s digital age technology has helped obtain great results in quality and profit for Russian container glass manufacturers. Russia’s Kransoe Echo will install the first Heye SpeedLine in the CIS region. Russian container glass producer Ruscam Glass has also trusted in Heye International technology. The Heye Servo Feeder allows the company to run different weights on one machine (assortment production).
GTS to deliver Glass Appreciation course
The UK’s Glass Technology Services Ltd (GTS), a leading independent provider of glass analysis, testing, consultancy and research, will deliver its introductory glass training course in a format suited to larger organisations and associations. To be delivered on behalf of British Glass on the 17th May,‘Glass Appreciation’ will introduce delegates to glass manufacture, processing, benefits, environmental and quality considerations, including practical sessions for melting and inspection. For further information, or to book, please visit the British Glass website: www.britglass. org.uk/glass-appreciation-2
Vitro Glass plant reduces water demand by 50m gallons Vitro Glass’ Wichita Falls plant has been cited as a national model for water reclamation after its use of reclaimed water reduced demand by 50 million gallons per year during a time of drought. The Wichita Falls plant in Texas is operated by Vitro Architectural Glass (formerly PPG Glass), and has been cited in a case study published by the Water Environment & Reuse Foundation (WE&RF). Vitro Glass was recognised for a $1.9 million project that diverts treated non-potable wastewater from the city’s Northside Wastewater Treatment Plant to seven glass-cooling towers operated by Vitro Glass, which has reduced potable water consumption at
the facility by more than 50 million gallons per year. The project, which was implemented during extreme drought conditions in 2014 and 2015, included construction of a 1-million-gallon reservoir to store non-potable water on-site, as well as the rerouting of rinse water for a glass coater and washer.
Vitro Architectural Glass recently announced that the Wichita Falls plant will be the site of a new $55 million jumbo magnetron sputtered vacuum deposition (MSVD) glass coater, expected to be the largest of its kind in North America. Groundbreaking is scheduled for April.
O-I Poland orders flue gas system
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ICG’s Summer School
The ICG is hosting its 9th Summer School Workshop for new researchers in glass science and technology in Montpellier, France, from the 3rd-7th July 2017. The course is designed for PhD or Masters glass science students, or those who have recently started research in the glass industry. Spaces are limited to 30 participants, and those interested in taking part should email verres2017@mycema.fr. The course is €800, reduced to €300 for students and academic staff.
O-I’s Jaroslaw, Poland plant has installed a flue gas treatment system from ATS. O-I equipped the Jaroslaw glassworks with an efficient flue gas treatment plant. The system is among the first for the Polish container
glass industry and involves lime injection inside a dry reactor upstream of an electrostatic precipitator (ESP). The lime reacts with the sulphur oxides present in the flue gases, transforming them into sulphite and sulphate that can
be collected by the ESP. O-I has two plants in Poland: Jaroslaw (pictured) and Antoniniek. It has six active furnaces in Poland that supply the global food and beverages industry.
Furnace Solutions 12 in Stoke, UK Furnace Solutions 12 has 11 presenters from the USA, Turkey, France, Italy, Germany, Czech Republic, The Netherlands and the UK. Papers will cover subjects
as designing and monitoring the condition of the furnace to extend its life, the use of electricity to melt and condition glass, heat recovery, emission control and post mortem
analysis of glass and refractory defects. For more information visit the SGT website at www.furnacesolutions.co.uk
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International News
NEWS IN BRIEF
New Technical Sales member for AGR
AGR International has employed Adam Neupert as part of its Technical Sales team, serving the North American market. Headquartered in Butler, PA (USA), AGR specialises in process control and quality testing systems for the packaging industry. Adam previously worked for Quantum Engineered Products Inc., which specialises in improving the critical process of blank side forming.
European patent granted for Ramsey RKO tool
Ramsey was recently granted a European patent (EP 2905092) for the RKO chain tool. This new patent expands on the coverage already provided by United States patent (US 9,174,269 B2). The RKO tool, or Ramsey Knock Out Tool, is designed to quickly and easily remove pins wherever a chain must be disconnected. The same tool can also be used to easily install chain connecting pins wherever chain sections are to be joined. The tool is particularly beneficial on the plant floor, where it allows chain to be easily installed, repaired or replaced.
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Coca-Cola Bulgaria breaks world record
Coca-Cola Bulgaria has broken the Guinness World Record for the largest mosaic made from glass bottles. Creating an image almost ten times larger than the previous record holder, the mosaic was made using 72,933 empty Coca-Cola, Coca-Cola Zero and Schweppes Soda glass bottles. The resulting mosaic had a total surface area of 250 square metres. The record attempt took place at the company’s annual sales conference in Kamchia, Bulgaria.
Top 10 stories in the news Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1 Verallia invests €30 million in its largest glass furnace � 2 Cristalerías Chile to construct third Llay Llay furnace � 3 Vertech success in China � 4 Venvidrio on brink of bankruptcy � 5 Verallia chooses Zippe for new Brazilian plant � 6 Vitro Glass plant reduces water demand by 50m gallons � 7 South American container industry attends Glassman event � 8 Russian groups invest in Heye’s digital age technology � 9 Asia-Pacific delivers positive sales for Heye International � 10 ATS secures O-I Poland flue gas treatment system contract
Chinese glassmaker chooses exhaust air purification system Dürr first deployed the Ecopure CCF, a new combined DeDust, DeSOx and DeNOx process, for a Chinese glassmaker. It enables the glassware manufacturer to reliably comply with low emission limits. Another strength of the space-saving technology is its suitability both for new installations and retrofits. Due to TA-Luft 2017 – the new air pollution control regulations – this technology is also of particular interest to industrial companies in Germany. The Ecopure CCF technology eliminates three pollutants
in one system, which translates into economic total cost of ownership. As DeDust, DeSOx and DeNOx processes are combined in just one unit; the setup is compact and allows space-saving installation within existing production facilities.
Venvidrio on brink of bankruptcy Venezolana del Vidrio (Venvidrio) is on the brink of bankruptcy, reports El Carabobeno, a Venezuelan newspaper. 90% of its operational capacity is paralyzed, raw material inventories are empty and nine of the 11 lines are damaged. The machinery of the plant located in Los Guayos, east of Carabobo, has deteriorated since October 2010 when the national leader ordered the
expropriation of Owens-Illinois (O-I) Venezuela. At the time of the measure the company supplied more than 60% of the national demand for glass containers for the food, pharmaceutical and cosmetic industries, with 2.1 million units per year. The expectations of the Government at the beginning of its administration were to raise those numbers up to six million.
Today they do not reach a million and only manufacture glass containers for liqueurs and mayonnaise, according to Hernán Serrano, a member of the Frente Amplios de Trabajadores of the region. Compounding the problems is a lack of soda ash, which has to be imported. 600 Venvidrio workers have been dismissed, according to the newspaper report.
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Company profile: Verrerie d’Albi
Glassman Europe takes place in Lyon in France on September 6 and 7. To mark the occasion, Glass International will focus on a number of French glassmakers in the build-up to the event.
Verallia completes €46 million VOA modernisation Since becoming a standalone company in 2015, Verallia has invested more than €46m in modernising VOA’s (Verrerie d’Albi) two furnaces as well as its cold end equipment. The investments allow the plant to offer flexible and shorter runs to its customers.
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V
OA’s furnace no.1 and its three production lines underwent a complete re-build at the end of 2015 and came into service at the beginning of 2016. It is dedicated to the production of flint and extra-flint glass. Following on from that investment, VOA’s furnace no. 2 has been fully refurbished and produces green, dead-leaf and cannelle-coloured bottles. A match lighting ceremony was recently held at the plant to celebrate the re-start of furnace number 2. Benoît Chatillon, Managing Director of VOA, stated: “The modernisation of furnace no.2 and all its manufacturing lines concludes an investment programme that is historically high for our site. “Today, our plant is newly equipped with industry-standard tools. This is a key competitive strength that will help us to grow our presence on the market, support our differentiation strategy and ensure our customers are delivered an exemplary level of performance and service.” The new installations will enable the VOA plant to extend its partnerships with customers who have expressed a preference for extra-flint glass, such as Bacardi and the Perrin family. VOA’s furnace n°1 is one of two Verallia France furnaces that specialises in producing extra-flint glass (the other is located in Cognac). Another investment was the colouration feeder, which enables certain colours to be obtained without having to colour the glass bath in the furnace, notably extra-black. The modernisation of furnace no. 1 cost €24m, took two months of construction work, and required more than a hundred subcontractors. More than 800 people were involved in the project, all in all. With improved combustion and by using special refractories, furnace n°1 now consumes less energy and emits less CO2, sulphur oxides (SOx) and nitrogen oxides (NOx).
� Pierrette Marty and Simon Duran, two VOA retirees, light the matchstick at the furnace reopening event.
For the same glass furnace pull, it generates between 5% and 10% less waste than its predecessor. According to Glass Global consulting company, both furnaces at the site have a capacity of 250 tonnes a day. Furnace n°1 feeds three production lines on which three IS machines form 350,000 bottles a day. Today two of these lines, compared to one in the past, are equipped with Flex Line technology, making it possible to produce several products simultaneously. The set-ups also contribute to this flexibility, with VOA’s team able to do up to four a day, which equates to two thirds of production. Investments were also made further down the line, with a heat recovery system installed on the annealing lehrs. The whole cold end sector has also been revamped, notably with the acquisition of two packaging robots co-developed with CRITT, a small Albibased company. These palletiser robots continuously pack the small runs of the Flex Line lines. All settings are memorised by the machine and applied instantly whenever the same bottle is made. Safety and workstation ergonomics have also been improved. In the hot end the cabins have been enlarged and acoustically insulated. Some cabins will also be installed in the cold end for the first time. The building’s lighting has been reviewed and VOA has also invested in hoists to carry moulds, thus minimising the loads lifted during set-ups. Continued>>
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Company profile: Verrerie d’Albi
VOA in figures: � 120 year history. � 300 employees. � First private company in the Albi region. � Two non-stop manufacturing furnaces and six production lines. � 4000 machines and engines in the factory. � 800,000 bottles made each day, including 350,000 bottles made of extra flint, and 350 different models each year. � 1000 customers in France and in 20 countries. � Design and engineering office. Its design centre produces 80 creations a year.
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VOA is also fully involved in its region’s environmental chain. The plant receives all the household glass collected in the Midi-Pyrenees region, where it is then sorted and reprocessed: it is totally recycled in one of the plant’s two furnaces.
VOA’s business Located in the middle of southern Europe’s major vineyards, VOA predominantly serves this wine market, which represents around 60% of its sales. It also makes bottles for spirits and non-alcoholic beverages. In 2015 it had a turnover of €105 million and is based on a 23 hectare site. Continued>>
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� The plant produces 800,000 items a day. Part of its production is dedicated to Selective Line, Verallia’s premium brand for still and sparkling wines, spirits and soft drinks. VOA mainly serves the wine regions south of the Loire River. Stretching from west to east, its geographic presence covers the following wine appellations: Bordeaux, Côtes de Gascogne, du Lot, du Gaillacois, du Languedoc, Côtes du Rhône and Coteaux Varois. It is also present in Burgundy. VOA is part of Verallia’s manufacturing base in France, which consists of seven glassmaking plants, a decorating facility and two design centres. It employs 300 staff. VOA Chairman, Emmanuel Auberger, said: Over the past few years the plant has focused on the high end market. Its design and engineering office creates tailored models and part of VOA’s production is reserved for Selective Line.” Significant projects for VOA include it partnering with the Perrin family to develop the Miraval bottle, named after Brad Pitt and Angelina Jolie’s family estate. The estate owners were won over by the design proposed by VOA and based on an old Burgundy-style bottle in extra-flint. Since then, this rosé wine is grow-ing fast, sold in a number of countries. Since 2014, VOA has produced fluorescent glass bottles. Completely transparent in daylight, they turn fluorescent blue when exposed to black light in bars or nightclubs. VOA also produced a new bottle for the Federation of Châteauneuf-du-Pape Producers’ Unions. Conserving its original 1937 shape, this embossed bottle now meets eco-value criteria. Its weight has been reduced from 650 grams to 610 grams. VOA manufactures bottles for producers of appetizers and spirits, and its long-time customers such as Ricard or Bacardi are often geographically close to Albi. Today, these historic key accounts have been joined by customers such as Moët Hennessy, which have opted for VOA’s high-end products in extra-flint or extra black glass to serve their flourishing markets. �
Waltec Maschinen GmbH Kronacher Straße 2a 96352 Wilhelmsthal / Steinberg Germany Phone +49 9260 9901-0 Fax +49 9260 9901-99 E-Mail info@waltec.de
VOA, Albi, France www.verallia.com www.voaglassbottles.com Glass International May 2017
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Events World: Glassman in Argentina
Exhibitors and visitors alike reported a successful Glassman South America show, which was held in Argentina recently. The international exhibitors met, discussed and did business with visitors who came from all over the Latin American region.
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N
early 1000 visitors from South America’s glass industry attended the recent Glassman South America event. The free-to-attend exhibition and conference devoted to the container glass industry attracted visitors from throughout the continent. The majority of visitors to the Buenos Aires show were from Argentina, with domestic manufacturers Cattorini, Rigolleau, O-I, Verallia Argentina and Coop de Trabajo Cristal Avellaneda all sending delegations of staff to the show. There were also visitors from the rest of the continent. These included Verallia Chile, CristalChile and CristalToro of Chile; O-I, Heinz Glass, Envisac and Compañía Peruana de Vidrio of Peru; as well as a number of Brazilan glassmakers in attendance, such as Nadir Figueiredo tableware manufacturer of Sao Paulo and Wheaton Brazil.
Exhibitors expressed their satisfaction with the event and with the number of glassmakers they had spoken to. Several exhibitors reported that they were even asked to put together quotes for new equipment while at the exhibition. Among those who were pleased with the event was Exhibitor Luis Zertuche, Sales and Marketing Director of Mexican group Fama, who said: “It has been a very enriching experience for the entire FAMA team and we are sure very good things will happen for our business from this fair.” Fellow exhibitor, Stuart Hakes, Managing Director of FIC UK, said: “Its been important to be in Argentina and see old customers that perhaps we’ve lost touch with, such as Rigolleau, Cattorini, and CristalChile, all of whom have visited our Continued>>
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stand, plus a few new companies. “It’s been the best South American show we’ve had. All credit to the organisers.” Günther Mlynar, Managing Director of Zippe, said the main reason for exhibiting was to visit its long-time customers in Argentina, Chile and Brazil. “We have a long term relationship with many customers here and we have helped build many plants in South America. “South America has been an important market for us for some time. We have a strong position here but you have to maintain the contact with your customers. “Generally speaking I’m really satisfied with the show, it has been even better than expected.” Marc Meersschaut, Sales Manager for South America for futronic, said it was important to see
its customers in a region where the company has several of its systems in place. “It’s important to see our clients and the people who work with the systems, in order to know how it is going; if they are satisfied with the project; is there something we can do to improve it... We have met those people so I am satisfied. “We’ve met a lot of people and not always the same people I meet when I visit the plants and that has been really interesting. We also met people from a number of smaller glass companies, so I was surprised. That is interesting for us for the future.” The free-to-attend conference featured 14 presentations from a variety of suppliers, consultants and glass associations. Several of these papers are available to download for free from www.glassmanevents.com/south-america �
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Events World: Glassman in Argentina
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Company profile: StekloSouz CEO
StekloSouz and Expocentre ready for Mir Stekla 2017 in Moscow Glass International spoke to Viktor Osipov*, CEO of StekloSouz Russia and the Chairman of the Organising Committee of the Mir Stekla Trade Fair, ahead of the event which will take place between the 5th and 8th June in Moscow. Glass International is a media partner of Mir Stekla and publishes an annual Russian language issue for this event.
www.glass-international.com
How are preparations for the Mir Stekla 2017 exhibition? StekloSouz, the Russian National United Council of Glass Industry Enterprises, together with ZAO Expocentre is the co-organiser of Mir Stekla in Moscow, Russia. Mir Stekla is the largest exhibition in Eastern Europe and Central Asia that covers the production of glass products, technologies, equipment, raw materials, refractory materials and engineering. Exhibitors include about 200 companies from 25 countries with national pavilions from Germany, Italy and China. Last year the number of visitors from 37 countries exceeded 8000, mainly specialists who had come to the exhibition with specific business demands. The motto of our exhibition is ‘Everything from glass. Everything for glass.’ This year we expect an increase in the number of exhibitors from Russia and countries of the Eurasian Economic Union (EAEU). The domestic glass market from last year has grown due to the influence of the development import substitution under current sanctions. This year many Russian companies will take part in the exhibition for the first time, and we expect the participation of more than 100 manufacturing plants from Russia and the EAEU countries. The current economic and political aspects have not affected the number of exhibitors. Businesses want to work in Russia, and the country offers new technological opportunities. Foreign companies will be represented by manufacturers of equipment, refractories and innovative glass products. Russian participants along with raw materials, refractories, machinery and equipment will show the whole range of glass products for various sectors of the national economy. About 80% of the exhibitors are regular participants at Mir Stekla, which indicates the
� Viktor Osipov, CEO of the StekloSouz Russia.
Continued>>
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FIVES TECH + FIVES TEAM DÜZCE CAM CHOSE FIVES AGAIN TO GET PERFORMANCE AND RELIABILITY FIVES PROPRIETARY FURNACE TECHNOLOGY WITH ULTRA-LOW ENERGY CONSUMPTION PRIUM® MELT FLOAT L.E.M.® (LOW ENERGY MELTER) ENABLES GLASS MANUFACTURERS TO SAVE UP TO 20% ENERGY COMPARED WITH CONVENTIONAL SOLUTIONS. In order to comply with quality, output and energy performance objectives, Turkish glassmaker Düzce Cam has renewed its confidence in Fives’ Glass teams for the design and supply of its second manufacturing line. This new 800t/day float glass line will feature Fives’ latest technologies such as the float furnace, the tin bath and the annealing lehr. It will be dedicated to the production of both residential and automotive glasses.
www.fivesgroup.com
Company profile: StekloSouz CEO
success of our annual exhibition, which this year will be its 19th edition.
production growth may reach 4-5%, according to estimates by experts.
How are the Mir Stekla conference preparations proceeding?
Have there been any major investments in the hollow Russian glass industry recently?
An interesting business programme will reflect the state of the world and Russia’s glass industry, as well as new trends in the use of glass products. We divided the programme of the Glass and Modern Technologies Forum into four main sessions in accordance with the general structure of the glass sector. We would like to invite Glass International’s global readers to participate in the Forum as speakers. Representatives from various sectors, such as builders, hothouse, furniture, transport, food, and other industries, will highlight the modern requirements for glass and its products. Our Forum is a platform to present scientific achievements and developments of international industry players, and is a springboard for Russian and international companies that decide to enter Russia and the CIS glass market.
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How many hollow glass plants are there in Russia? Russia has about 100 glass container plants with a total capacity of 12.5 billion items per year. Today in Russia there are about 20 glass container producers equipped with modern NNPB technology. During the crisis and a decrease in alcohol consumption, glass containers collided with the problem of overproduction. In 2014, in the structure of the StekloSouz of Russia, the AntiCrisis Headquarters was set up to find opportunities to increase exports of glass products from Russia. Some flat glass Russian factories export some 80 to 100% of their float glass. Glass containers and medical glass are also exported. Glass containers have become more widely used for milk packaging, fruits, vegetables, coffee, oil, and other segments of the food industry, including bottles and wide-necked glass containers. After a three-year continuous decline in glass container production, the Russian glass industry’s output grew by an average of 2.0% in 2016. In 2017
In 2016, several furnaces were built or modernised by Russian glass container producers, including at the Ekran, Light and Fakel plants. For example, RATM Holding’s Plant, Ekran, fully modernised three glass melting furnaces in 2015 and in 2016. In September 2016, it launched another new line for the production of lightweight glassware using NNPB technology at its Furnace No. 5. This reduced the weight of its glassware by 20-25% to 280 grams. In November 2016, a line with the option of producing colour bottles was installed on Furnace No. 2. The daily capacity of the plant, which has three furnaces, is 525 tonnes of glass melt or 1.37 million units of glass containers. The Alexinsky glass container plant (JSC Strategya) located near Tula can manufacture up to 700 million pieces of various glass containers per year. In 2017, it plans to modernise two glass melting furnaces with a capacity of 360 tonnes of glass per day. Today, under pressure from new Russia environmental laws, many investors have shown an interest in building facilities for the production of raw materials from cullet for glassmaking factories. StekloSouz of Russia develops the industry’s GOST technical standards for this specific production. There is an organisation for the foundation of the centralised supply of cullet and raw materials. Of course, we are also preparing for two global football events: the Confederations Cup in 2017 and the World Cup in 2018. We expect these events to increase the consumption of flat glass for construction, as well as more glass containers and then a rise in the supply of empty glass containers for recycling. There is a cooperation agreement with the organisers of these two events. Mutual economic policies and the strong Ruble current exchange rate play a positive role in the development of the domestic glass industry. According to experts’ estimates, by 2020 the growth of production of sheet glass will increase to 31.0 million sq. m, while the number of glass containers produced will rise to 16.2 billion units. The growth of medical, quartz, artistic and other kinds of glass is also expected. �
*CEO of StekloSouz Russia and Chairman of the Organising committee of the Mir Stekla Exhibition in Moscow. www.steklosouz.ru Glass International’s Russian language issue 2017 will be distributed to exhibitors and visitors via its booth and reception table as well as at all business related events.
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WE ARE GLASS PEOPLE
MAXIMISE YOUR PROFIT
COMBINE SPEED AND FLEXIBILITY WITH SUPERIOR LIFETIME High production speed Fast job changes Reduced downtimes Robot option Clean design
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Furnaces
� Fig 1. Encirc furnace installation.
Making the most of your furnace
T
he TECO Group began as Toledo Engineering Co. Inc. (TECO) in 1927 with its roots in the glass container industry. Some 90 years later TECO supports all sectors of glass manufacturing: float, fibre, tableware, solar and speciality, while continuing to support the container industry. Focused on the long-term financial performance of glass melting systems, TECO is proud to say that there are hundreds of TECOdesigned furnaces operating in these various glass manufacturing industries worldwide. The group has amassed expertise that brings vast industry knowhow to the forefront of its designs and engineering. TECO knows not only how to build furnaces, but uses the latest Computation Fluid Dynamics (CFD) modeling and has more than 600 years of collective industry experience to assure design and operational excellence. The TECO Group includes forehearth design and operation from Zedtec, electric
boosting equipment from KTG Systems, and more recently, custom control systems from EAE Tech. These capabilities provide support to glass companies with a complete spectrum of value-added services that optimise their operations through offerings that complement the process. At the same time these capabilities provide training opportunities to improve energy and productivity metrics.
Encirc In 2003 Tecoglas, as part of the TECO group, was approached by Encirc to assist it in evaluating the design and installation of two large furnaces with capabilities to produce multiple colours of glass for the industry (Fig. 1). It was at this time that TECO took the opportunity to adapt the group’s knowledge and modeling capability of high tonnage production into the design and construction of these large side port
natural gas-fired furnaces. TECO used its technology and know-how to bring to life the largest side port furnaces designed for use in the glass container industry. These machine configuration was designed to provide a stable platform, which allowed the furnace to achieve pulls well above industry norms. The benefits resulted in increased furnace life, increased furnace pull, stable melting with improved quality, energy efficiency per tonne pulled, minimal disruption during job changes, and efficient tonnes/square metre over the life of the furnace. The first furnace was commissioned in mid 2005 and is being prepared for a repair in 2018, at which time it will have pulled in excess of 16,000 tonnes/square metre over the campaign (a key metric of capital efficiency).
Continued>>
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The glass industry is challenged with high capital requirements for furnace repairs towards and at the end of the campaign life. Furnace repairs are costly, not only in capital expenditure but in downtime. Lost sales and lack of fixed cost absorption during idle repair periods reduces the overall profitability for glass manufacturers. James Uhlik* discusses how engineers at the TECO Group provide their experience for high quality engineering and design for quick repairs. TECO aims to supply its customers with furnaces and technology that will exceed their expectations for quality, performance and life.
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Furnaces
100
% Refining
90 80 70 60 50 40 30
TECO Group Endport Convective Flow Technology Other Endport Technology
20 10 Residence time
� Fig 4. Park Cam facility. � Fig 3. Diagram showing TECO data for optimum furnace conditions.
� Fig 2. An example of a CFD modeling diagram. Adrian Curry, Managing Director of Encirc, said: “Encirc has built its reputation on providing customers with a quality product. We make more than 2.5 billion glass containers a year for some of the world’s leading brands, so having welldesigned and efficient furnaces has been crucial. I am pleased to say that to date our furnaces have given us the flexibility, the quality and most importantly of all the reliability that we require as a business to be successful.” Encirc continued with its second TECO furnace and today enjoys these same performance standards. The furnace staff at the facility have done an excellent job of continually inspecting, applying proper maintenance and operating the furnaces with care. The preplanning, engineering, machine configuration and diligence of the Encirc team have resulted in a high utilisation of the assets without compromising glass quality and the life of the furnaces, resulting in extended life and maximum use of the capital investments.
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From art to science The TECO Group respects the need for proper auditing, maintenance and ongoing performance monitoring to assure the long life of a furnace. Itspredictive modeling uses multiple furnace modeling software programmes and has become a value added service for not only design, but also troubleshooting (Fig. 2). The art of glassmaking is becoming more of a science as we refine the use of these tools in our interactions with customers. “Modeling has allowed us
to investigate the inner workings of what has been a closed box in the past,” stated Chris Hoyle, Vice President – Technical Director, TECO Group. “The science of modeling along with our industry know-how and experience has shown us through operational data that in most modern furnaces fining is the bottleneck to meeting operational flexibility or production requirements, whether it is increased pull or glass quality”, he said. The resulting optimised design incorporates a flat bottom with a submerged throat. TECO data shows that fining is both improved and more predictable (Fig. 3) and the collateral benefits are improved operational flexibility and glass consistency, reduced energy consumption and longer campaign life. This is the design being recommended for the glass container industry on new projects.
Park Cam Greenfield construction has come along infrequently over the last few decades, so TECO is proud to have been selected to participate in the most recent greenfield installations at Park Cam in Turkey. TECO used its experience to design, engineer, build and commission the largest endport furnaces in its history. TECO engineers used their extensive experience in container, float and other glass industries, in conjunction with CFD modeling, to produce a highly efficient design. This project has been a success, rapidly exceeding the guaranteed pack to melt ratio and continuing to maintain that standard. In operation,
both energy efficiency and glass quality have also proved to be consistently above expectations. Park Cam has continued to grow its business, completing the second phase of its long-term plan with the installation and commissioning of a second furnace in 2016. This furnace has the same design as the original with the exception of some minor design enhancements focused on additional energy savings, improved access for future maintenance and life extension (Fig. 4). The glass industry has a long history and the TECO Group is honoured to be such a large part of it. Proper deployment and maximisation of capital is our job. TECO works hard with our customers to ensure a product that exceeds their expectations and continues to invest in the latest technologies available to improve our ability to design accurately from the beginning. Also, investing in people allows TECO to stay up to date with shop floor needs for auditing and operational excellence. It is the firm belief of the company that designing a furnace or a plant correctly from the start; employing a rigorous audit programme; employing appropriate upgrades and keeping up on preventive maintenance; and training of key personnel are critical to the long life of these capital intensive assets, and assist in the preservation of life and optimisation of the investments. �
*Director of Technical Services, Toledo Engineering Co, Inc. Toledo, Ohio, USA.
sales@teco.com www.teco.com
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ENDTOEND Full-Process Excellence
Furnaces
Putting the efficiency into container glass furnaces
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T
he heart of a container glassmaking plant is the furnace. It is where glass is created and is where the magical transformation happens where silica sand is converted into glass through the addition of vast quantities of heat energy. In the world of container glass, the furnace is the area where a large part of the costs of making glass bottles is concentrated. Firstly, there is the large capital cost of the furnace complex, which is the single most expensive part of a container glass plant. Secondly there are the running costs. Energy is a major cost driver in container glass and most of the energy is used in the furnace. It appears certain that energy costs are going to rise. Forbes reports that “The International Energy Agency (IEA) projects a 75% increase in oil prices by 2020”. This is a commonly held view among the energy commenters and forecasters. So what does this mean for operators of container glass furnaces fuelled with traditional oil and gas derivative fuels? When one examines the cost drivers in container glass, energy quickly appears near the top of the list, commanding between 12 to 20% of the cost structure. In some very high energy cost regions this amount can reach the 25% mark. The cost of glass containers is heavily linked to energy costs and prices. Glass containers will always be regarded as the premium packaging medium, and as a result at the high-end market level there will always be a demand for a fancy glass bottle for a premium product. However, in the mass market where there is significant price sensitivity and price pressure, glass has to compete with other lower cost packaging solutions such as PET and cans. While both of these products also have cost structures linked to energy, they come under less pressure from increased energy costs when compared with glass.
Energy price pressure Glassmakers are very conscious of the energy price trends and it is a subject that keeps them up at night. The focus quickly moves on to how to control energy costs, as this is a major driver of the overall cost structure of glass containers. There are three obvious solutions: the first is controlling the costs through financial hedging; the second is to simply reduce the amount of energy used per tonne of glass produced; and the third is to find an alternative source of energy which is not expected to rise.
Energy hedging Financial energy hedging is a well-used methodology that has been used for many years by both the glassmakers and the large glass container buyers to set and lock the price of energy. This methodology provides the ability to fix the price of energy for a fixed period of time – but this privilege comes at a cost. From time to time the hedge may beat the market. When this happens it is usually more luck than skill. Over the long-run a well-executed hedging programme is likely to follow the market rather than beat it. Therefore, hedging should be seen as a methodology of providing price certainty, stability and predictability for a period into the future. This makes setting pricing and achieving budgets possible. It would be reckless to view hedging energy costs in the glass industry as a way to make money. Hedging smooths out the long-term price change trends, but does not mitigate the overall price trends in the long run.
Improved furnace efficiency The second option of using less energy per tonne of glass produced appears to be obvious. Furnace designers and builders have invested significant efforts in designing furnaces that are more
fuel efficient. This has been achieved by improved heat recycling through regenerators or recouperators. The quality of the furnace refractories and insulation has improved over time, however as the quality improves generally so too does the capital cost increase. The size and the scale has increased, which has made the furnaces more efficient. Today large furnaces of around 400 to 450 MT of glass per day offer some of the most efficient sizes. Larger furnaces means more efficient glass melting and hence lower production costs, but it can mean reduced flexibility. Think of a scenario where a glass plant installs three 450 MT per day furnaces, one for amber, one for flint and another for green glass. The resulting output is in the region of 440 kMT per annum of good glass. There are not many regions in the world that can economically support glass installations of that scale. So, while the desire for energy efficiency calls for larger furnaces, the demand flexibility insists on smaller for flexible furnaces – and herein lies the paradox.
Alternative energy sources Decades ago when there were still pockets in the world where electricity was available in abundant supply and at cheap rates, it was common to find electrical glass furnaces in place for large scale production. South Africa was a good example. Electrical furnaces are still seen, but mainly for small installations. Electricity has become expensive and its use has been substituted by furnace oil and natural gas, which offer lower cost primary fuel solutions, although it is also true that the use of electrical boosting is commonplace to optimise the gas and oil fired furnaces.
Continued>>
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Furnaces
Oxy fuel furnaces have made their debut in some regions with high cost energy costs such as Italy. But their application is limited and requires complex and expensive oxygen processing plants. These furnaces also have the additional advantage of lower emissions. With the advent of renewable electricity generation, solar and wind, combined with the improvement in energy storage and battery technology, could we see the return of electrical furnaces?
Inefficient Container glass furnaces are fundamentally inefficient. In the container glass industry it is accepted that to make glass bottles it requires between 6 and 7 GJ of energy per metric tonne of glass produced. Of this, only half of this energy is actually used for a useful outcome and the remaining energy is lost and wasted. However, when one looks at the real useful energy that is used in the process, one realises how inefficient a glass furnace really is. Chemistry dictates that about 2.6 GJ. of energy is required to melt batch and create glass. We also know that about 0.35 GJ is required for the forehearths and lehrs respectively. A further 1.2 GJ is lost as heat from the furnace. Approximately 2.5 GJ of energy
� Typical energy flows in a container
Fuel source (6.5 to 7 GJ) Heat air 1.4 to 1.5 GJ Energy input (4.8 to 5.0 GJ)
glass furnace.
Lehrs 0.35 GJ Forehearts 0.35 GJ
Furnace (6.2 to 6.5 GJ)
Compressors, Fans etc 1.2 to 1.3 GJ
Hot waste gas (2.5 to 2.7 GJ)
Stack 1.1 to 1.3 GJ
Furnace losses 1.2 to 1.3 GJ Regeneration Melting glass 2.5 GJ
is then pumped out of the furnace as hot exhaust gas. Fortunately, just over half of this heat (1.4 GJ) is recaptured in the regenerator or recouperator and sent back into the furnace. The other 1.1 GJ of energy is pumped into the atmosphere via the stack. Therefore, of the 4.5 to 5 GJ of energy that is supplied to the furnace, less than half is used to melt glass. The remaining energy is lost and wasted. Given the high energy cost and the fact that the majority of the energy is wasted, surely there needs to be a focus on optimising this?
Possibilities for improved furnace performance The obvious place to start is to use the low grade heat expelled through the stack to generate steam, electricity generation and even desalination of water. However, this comes with substantial capital investment. The use of new techniques such as submerged combustion may hold some opportunity to optimise the combustion and the amount of energy required for the processes. Fundamentally, is it possible to reduce the amount of lost heat?
Furnace life Apart from the high energy costs associated with the furnace, the furnace is also an expensive piece of capital equipment. A new large container glass furnace can cost upwards of $10 million. The life of the furnace is limited and companies are glad if they get 10 to 12 years life out of the furnace. This leads to a large depreciation charge. The glass markets are calling for more bespoke bottles, with a wider range of colours and more complexity. All this calls for smaller and more agile furnaces that can support short runs and faster colour changes.
Innovations such as forehearth colouring, and post process firing and conditioning go some way to achieving increased flexibility. However, the associated costs constantly inhibit their wider commercialisation. The industry has focused on making larger furnaces, chasing the increased efficiency of larger furnaces. But the market is calling for smaller and flexible furnaces. Many markets in the world simply cannot support the large furnace configuration. In pretty much every country in the world there is a market for beverage or food production requiring the use of glass bottles. However, there are many countries where the glass market simply cannot support the scale of the new modern day efficient glass furnaces – a 450 MT per day furnace produces more than 100 kMT of glass per year. Therefore, it is little wonder that many countries in the world simply do not have local container glass manufacturing. Surely there is a need to develop a more agile, smaller scale efficient glass furnaces, that will allow for the proliferation of glassmaking facilities locally. This will have the effect of creating more flexibility, lower cost glass, and importantly more accessibility. This will ensure that glass remains relevant in the mass market as the packing solution of choice. �
Richard van Breda has extensive experience in the container glass world, manufacturing, recycling and buying container glass. He operates as an independent consultant to the packaging industry and is based in Switzerland. Richard van Breda, Independent Consultant, Switzerland Email: richard@richardvanbreda.com Tel: +41 78 858 0488
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Container glass furnaces are fundamentally inefficient, believes Richard van Breda*, with half of the energy supplied to a furnace being wasted. Here he discusses how there needs to be a focus on optimising energy, with the answer being smaller, more agile and efficient furnaces rather than the huge furnaces currently in fashion with the industry.
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Furnaces
Accurate temperature measurement improves Holophane furnace French glass lighting solutions provider Holophane has implemented Ametek Land’s Near Infrared Borescope (NIR-B) Glass, a thermal imager, at its plant in northern France. It is reaping the benefits by accurately measuring the temperature within its glass melt tank, reports Mark Bennett*.
H
olophane has produced and transformed glass for technical applications, specifically glass optical components for automotive lighting since 1921. When the company rebuilt the 33m², 85-tonne, end-fired regenerative furnace in 2014 at its Les Andelys plant in northern France, Holophane wanted to replace its existing visual camera system with new thermal imaging technology to provide continuous on-line temperature measurement. Ametek Land recommended its Near Infrared Borescope (NIR-B) Glass with an auto retraction system, which can operate at extremely high ambient temperatures adjacent to the glass melt tank, while providing real-time thermal images and temperature data from inside the tank (Figs. 1 and 2).
Demanding environment
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The NIR-B Glass was developed specifically to operate in the demanding environment of a glass melt furnace. It features an integral cooling system as well as a specially designed air purge that keeps the 90° lens clear of contaminants to provide 24/7 data to the plant.
Even at high furnace temperatures, it delivers high-definition (656 x 494 pixel) thermal images to generate accurate, traceable temperature measurements in the 1000 to 1800°C (1832 to 3272°F) range. This solution is suitable for float, container, borosilicate, fibre and speciality glass furnaces. At the Les Andelys plant, the NIR-B Glass was installed above the throat of the tank in a location with a high ambient temperature of more than 60°C. Ametek Land recommended a heat shield below the borescope for this installation to reduce the heat coming directly from the throat.
� Figs. 1 and 2: The Ametek Land NIR-B Glass, installed on Holophane’s 85 tonne furnace for speciality glass.
The solution also incorporated an autoretract mechanism that provides the instrument with additional protection with instantaneous automatic retraction from the furnace wall in the event of a failure of air purge, water cooling and mains power or if there is an overtemperature condition detected at the borescope tip. Among the borescope’s major benefits to Holophane is its ability to provide a 90-degree wide-angle thermal image with clear visual definition, combined with a continuous temperature readout. This helps the operators maintain furnace control and therefore optimise productivity. The NIR-B Glass has been used to continuously monitor the optical profile (temperature profile) along the furnace walls to optimise the location of hotspots and to monitor areas of the crown for high temperature with alarms to prevent overheating. Ametek Land’s Cyclops optical pyrometer was used as the basis for the technology incorporated into the NIR-B Glass – hence the reliability of the temperature measurement. Continued>>
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Furnaces
ANNEALING LEHRS � Fig 3. The NIR-B equipment allows operators to ‘see’ problems from data displayed in the operating room.
With more than 324,000 available temperature measurement points in the field of view, the borescope can also be used to monitor for drift in crown roof thermocouples by assigning emissivity values for a specific or range of data points. The wide-angle thermal image provided by the NIR-B Glass has helped operators at Holophane to monitor glass batch line and batch flow from the charging end up to the throat. With configurable outputs, it is possible to create an alarm if the batch crosses the desired melt line. By using an area function in the Land Image Processing Software (LIPS) Holophane can monitor foam.
HOT-END COATING
Alerts The NIR-B Glass also alerts the operator to any air leakage or ratholes/cracks in the melt tank as well as corrosion areas near the chargers or burners. The instrument gives an operator the option to see the difference in temperature gradients when the burners do not operate correctly, which may be an indication that the burner needs to be cleaned, re-aligned or air-to-gas ratio adjusted. Emmanuel Declerck, Industrial Director at Holophane said: “The borescope helps greatly to maintain the right quality flames with good turbulence and shape, therefore optimising the quality of our end products along with our energy usage. The images provided by the instrument are particularly important at the exit, near the throat, where temperature profiles are routinely monitored by operators.” Combing video images with continuous real-time temperature data, has allowed the NIR-B Glass to replace Holophane’s traditional CCTV cameras and provide a full optical profile. The NIR-B Glass solution offers Holophane’s plant operators the ability to see cold spots from air leaks in the structural refractory, making it easier to detect cracks and enable prompt repair. Its operators can also visualise flames to optimise the flame patterns and thermal efficiency and overlay thermal profiles across the crown and along the melt for more accurate batch line control, production throughput optimisation and batch transit time recording (Fig. 3). “We are confident that as a direct result of implementing Ametek Land’s solution, we are achieving significant savings in energy usage,” added Mr Declerck. �
*Glass Sector Manager, Ametek Land, Dronfield, UK www.landinst.com Glass International May 2017
COLD-END COATING
SCRAPER CONVEYOR • Belt and spindles tempering lines • Decorating lehrs • Chemical tempering ovens • Roller annealing lehrs • Mold pre-heating kilns • Stackers + cross conveyors • Scraper conveyors • Cullet crushers • Thermal shock test systems Contact us: vidromecanica@vidromecanica.com
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Furnaces
Focused on the environment An Eco Glass Innovation policy from Falorni Tech has helped several glassmakers around the world achive their environmental targets while maintaining flexibility for the production of multiple colours, reports Ing. Andrea Zucconi*
S
www.glass-international.com
ince it was formed, Falorni Tech has focused its activity in the research of new solutions to improve the efficiency and performance of glass manufacturing industrial plants. The aim is to increase energy efficiency, minimise the environmental impact and improve safety standards for workers. Within the frame of its Eco Glass Innovation policy, Falorni Tech has developed projects and produced plants that aim to achieve such important targets. At the beginning of 2017 the company completed the construction of a new concept of production facility for the fabrication of high quality coloured glass within the premises of an established and well-known Italian glass company that specialises in hand made and semiautomatic manufacturing of tableware glass. The production of glass will be based on two identical melting furnaces of a small capacity each provided with an oxy-gas heating system and tilting basement.
ďż˝ Fig 1. Furnace overview.
The glass gathering will be effected either manually or by a fully automatic ballgathering robot, which will serve both furnaces without need of dislocation. This feature will permit the factory to manage both furnaces and production lines under the maximum flexible conditions with regard to change of colour, pull fluctuations and job change keeping the overall operating cost at a low level. The tilting basement feature is also a key element of flexibility as it allows the
furnace to work either as continuous tank with a constant glass level all the time and to extract the coloured glass until the very last drop before making the colour change. As the present global market competition can be won only by investing in technology and improving quality, the companies are capable of maximizing flexibility, hence minimising production losses and energy consumption. The oxygen-gas heating technology in small plants is no longer a taboo. In fact
Furnace Data Type of furnace
Oxy-gas fired tank with a variable level and tilting basement.
Melting capacity
From 2 up to 3 ton/day.
Type of glass
Soda-lime glass flint and coloured.
Production
Hand-made and semi-automatic with robot gathering.
Nominal consumption
Max 3.100 kcal/kg depending on glass colour and operating conditions.
Oxygen supply
Industrial oxygen min 93% purity.
Max Melting temperature
1550°C
ďż˝ Fig 2. Oxy/Gas combustion skid.
Continued>>
28 Glass International May 2017
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Furnaces
it not only allows them to attain a low specific consumption, high quality of glass and production flexibility, but is also reduces NOx emissions sharply, compared with any alternative conventional heating technique. With this plant Falorni Tech aims to lessen the specific fuel consumption by up to 30% and to cut NOx emissions by up to 50% compared with the customer’s previous furnaces, but without considering the advantages gained in higher flexibility and pull. The plant, which will be put into operation in the middle of 2017, will be accurately monitored by Falorni Tech technical staff from the start of its operation in order to collect all working data and verify the actual operating parameters. All this activity is part of the Eco Glass Innovation policy which aims to build, through field experience, the database of information on which all future projects will be based. This new application is the latest from Falorni Tech in the past two years. The most relevant application was a full oxygen/gas plant in Turkey for the production of 90 tonnes/day of glasswool. This furnace, which has been in operation since the end of 2015, is equipped with the latest oxy-fuel technique in combination with a VPSA plant for the on-site production of oxygen. The furnace has replaced an existing conventional recuperative furnace. In terms of consumption the new oxygas tank confirmed the target of expected consumption (below 1000 kcal/kg of glass) and the expected level of emission (less than 50% NOx). As further proof of Falorni Tech’s engagement in Low NOx applications for environmentally friendly purposes, another important achievement in 2017 will be the supply of a new updated oxy-gas furnace for Mexican company Grupo Pavisa at its Naucalpan, Mexico DF site. The furnace, which is currently under development, will be designed using updated software for mathematical modeling, merging the results of this predictive study with Falorni Tech’s long experience in the field of furnaces for glass making. The furnace is expected to be put into operation at the beginning of 2018. �
ELECTROGLASS TIME FOR A CHANGE TO
ALL-ELECTRIC FOREHEARTHS
*Commercial Director, Falorni Tech, Empoli, Italy www.falornitech.com
PROVEN TECHNOLOGIES REDUCE OPERATING ENERGY COST BY UP TO 85%
� Fig 3. High efficiency oxy/gas burner.
The Specialists in Electric Glass Melting and Conditioning
www.electroglass.co.uk Glass International May 2017 BENFLEET, ENGLAND
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Company profile: Excelsius
Excelsius describes itself as the global option for services to the glass industry. From its head office in Lohr-amMain in Germany it provides furnace services to the float, container/hollow, specialist and fibre glass sectors. Its Managing Director, Frank Schwarzenau, spoke to Greg Morris.
www.glass-international.com
T
he furnace is at the heart of the glassmaking process and without it a glassworks would be unable to operate. Furnaces proliferate throughout the glass industry and each one has to be heated up at the beginning of its life and then drained at the end of its life after many years of operation. This is where Excelsius steps in. Furnaces operate at extremely high temperatures. Refractory materials are used to line the inside of the furnace and its components. These linings require heating at controlled rates in order to ensure optimal performance and extend the potential lifetime of the furnace. At the end of the campaign life of the furnace, or upon need of a repair, there is a need for furnace draining, which can reduce the level of or empty the contents of the furnace. The Excelsius role in the glass industry is to resolve these issues for its clients on time and to their requirements. It serves all sectors of the glass industry such as float, container/hollow, specialist and fibreglass. As would be expected, 70% of its glass-related projects are within the container sector due to the fact that (discounting float) the size of this type of furnace is much larger than the others.
Company formation The company was formed by Mr Schwarzenau and a business partner in 2003. Mr Schwarzenau began working in the glass industry in 1989 as a service technician. After 14 years and gaining plenty of experience, he decided to form his own business and hence Excelsius was born.
A reliable p
ďż˝ Managing Director, Frank Schwarzenau.
When Excelsius first started he was part of a partnership with a former sales manager of the UK-based Hotwork Europe Ltd, which was closing down at the time. At the end of 2005 his partner left the business. Working with the company’s Operations Manager, Kevin Crowley, and the company’s operations team, the company has implemented systems from day one and has a support facility that ensures the reliability and continuity of its site-based activities. Between 2003 and 2011 it made major investments each year to increase its burner quantities from 50 to 150 burner sets. In the five years since 2011, these numbers have increased to 250 sets. By 2008 it had also developed its furnace drain equipment and constructed two full sets of equipment required for the recycling of water drain sets with cooling towers capable of cooling the water. The services it offers range from the beginning of a furnace lifetime to the end. This includes heating up, draining of the furnace contents, controlled cooling, expansion control of the superstructure, crown rise measurement, cullet filling and regenerator filling. These are parts of the overall package it can offer to the glass industry. Its two core services are furnace draining and heat up services. These make up approximately 60% of the business, with other refractory-related services in the glass and other process industries Continued>>
30 Glass International May 2017
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Company profile: Excelsius
e partner to the furnace industry making up the balance. It also has a separate company, Excelsius Rental Services, which deals with the rental of its equipment. About 40% of its business comes from Europe, 30% in Asia with the balance made up of projects in Africa, Scandinavia and Russian regions. It averages between 110 to 120 projects a year.
Reliable
� Glass furnace draining.
we cannot plan ahead. It makes it more difficult for us because we are usually already busy when a last minute project comes in, so it is sometimes not easy,” stated Mr Schwarzenau.
Maintaining standards
� The company is involved in several sectors of the industry.
To maintain standards the company provides regular training related to its services and in ancillary. “The depth of the training has evolved to beyond regular job training such as how to light a burner. It now encompasses extra training such as how staff
www.glass-international.com
The company works in a competitive sector and prides itself on its reliability, based upon its full time staff it has in its workshop who work hard to maintain the condition of the Excelsius equipment. Mr Schwarzenau said: “We are a service company, we do the service in the glass industry based on the equipment we send to the site. “So it is not just manpower but also the equipment that we send on site to a glassworks. “The return for our clients is that we believe the equipment we send out is the most reliable in the glass industry. This is based on us having a full team of staff back in our headquarters who look after the equipment. This equipment will return from a glassworks and is then fully refurbished, tested and made ready for the next plant.” In terms of innovations and reliability of equipment, the group has regular meetings. Recommendations from its staff who have worked on site with the equipment at a glassworks are taken on board. It also has an annual meeting with technicians to discuss progress and development through the year. “Our workshop staff have a regular development meeting to ensure that new equipment is developed. They can also see any small faults and equipment failures, or if there had been any incidents that happened which need to be taken into account, anything that may effect the longevity of the equipment. If there’s a fault they will have a brainstorm with a whiteboard to solve it. “New innovation comes around thanks to constant communication between our personnel and the workshop, both during and after projects with customers.” Reliability has become more apparent since the financial downturn of recent years. Customers increasingly want a reliable and stable partner when it comes to the type of services Excelsius provides. In furnace draining customers want to use water recycling systems to avoid over use of water or loss of water during draining. There are also more shorter notice contracts. “The long planning of projects has gone, a lot of clients run the furnace until the last moment and shorter notice repairs come into creation. It means
31 Glass International May 2017
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Company profile: Excelsius
� Equipment despatch.
Excelsius Global Services GmbH Bgm.-Dr.-Nebel-Straße 14 D-97816 Lohr am Main Germany Telefon +49 (0)9352 6044-0 Telefax +49 (0)9352 6044-19
www.excelsius-global.com EXCELSIUS - number 2.indd 3
should manage themselves and how they should communicate with customers, how to handle company cars when abroad, what to do if you have an accident abroad, embassy information and where the medical facilities are, for example.” The training programme was formed many years ago when Mr Schwarzenau and Mr Crowley initially discussed what the 10 things were that could go wrong with a furnace drain. There were no college courses available for this type of procedure, so they decided to form training courses. “We think it’s important that we’re the best of what we do. Reliability comes from good men and good equipment and you have to support them both when they’re at your front end. You cannot offer reliability if either of them fails,” Mr Schwarzenau stated. The company has embraced social media and the internet. It has adopted apps for control of the maintenance systems and plans to create bespoke apps for more interaction between its workshop and glassworks sites. For the next few years the company plans to evolve by taking small, steady steps. Mr Schwarzenau said: “You can never remain stable, you have to remain vigilant. For example, if you have a glass of water that is full, the only direction the water can go is to empty. If you don’t always work on maintaining your presence you will lose your customers. So we need to fill the gaps all the time. “We are always looking to maintain what we’ve got, improve on it and ensure our standards don’t drop. We plan to make steady steps with steady growth.” Finally, the company is based in Lohr-am-Main, which is home to other companies in the glassmaking sector. The town is surrounded by forests, which were used to fire furnaces centuries ago. The town was famous in the 17th century for its mirror manufacturing, and its mirrors were regarded as the clearest in Europe. “The talk of high society was that Lohr’s mirrors always spoke the truth, hence the talking mirror in the Grimm fairy tale, Snow White. “That is why people believe Snow White is from Lohr, because the mirrors from Lohr always spoke the truth,” Mr Schwarzenau concluded. �
Excelsius Global Services, Lohr, Germany www.excelsius-global.com Glass International May 2017
03/05/2017 12:44:28
Furnaces
3-in-1 approach to dust, SOx and NOx
D
ürr first deployed the Ecopure CCF technology for a Chinese glassware manufacturer. It enables the company to comply with low emission limits. Another strength of this spacesaving technology is its suitability for both new installations and retrofits. Due to TA-Luft 2017 – the new air pollution control regulations – this technology is also of particular interest to industrial companies in Germany. The draft bill of the new air pollution control regulations (Technische Anleitung zur Reinhaltung der Luft, or TA-Luft) is currently under discussion in Germany, and new emission limits are being formulated as recommendations. It may seem that these are only marginal changes to the systems, but for many industries the new limit values represent the starting point for considering acquiring additional equipment or implementing completely new exhaust air purification processes. The glass industry, among other industries, now needs to review the longterm suitability of existing technologies such as electrostatic precipitators. Industrial growth in China continues to outpace that of Germany. Many firms, including those in the West, are investing in new production sites. Although GDP is no longer heading skyward at astronomical speed, the rate of growth is still three times higher than in Germany. Pollution control in China cannot always keep up with such a fast paced GDP growth – and it has not been able to do so yet, which is evident when one takes a closer look at the current
practices of many permit authorities in China. These days it is difficult to operate production facilities without an exhaust gas treatment system, especially in highly industrialised regions. This was the case for one glassware manufacturer, which was threatened with closure in the greater Beijing area. Consequently, it was forced to install a suitable exhaust air purification system within a short period of time.
furnaces are heated by burners, which, despite a high level of energy recovery, still need large amounts of fuel (oil or gas). Because of the high temperatures in the glass tank, the exhaust gas flow contains high levels of nitrogen oxides (NOx), sulfur oxides (SOx), and dust. When planning the system, it was important to reliably comply with current limit values and preferably take future tightening of limits into account as well. Firstly, a solution using conventional technology was considered. This consists of an electrostatic precipitator followed by a catalytic NOx abatement system employing a selective catalytic reduction (SCR) catalyst. While this SCR process would meet current limits, it would not meet future stricter dust emission limits. As an alternative, Dürr looked at using a filter with fabric hoses in combination with an Ecopure SCR. Since this type of filter can only be operated at a maximum temperature of 220°C due to the filter media used, the raw gas, which is hotter than 350°C, has to be cooled. For the subsequent DeNOx process however, the optimal temperature is around 350°C, which means the gas has to be heated again. The high investment and operating costs of a heat displacement system, that is the cooling/ heating option, represented an excessive overall additional cost, so this technology was rejected.
Technology selection
Solution
In glass manufacturing, furnaces are used when the glass, made from various raw materials including cullet, is melted. These
Dürr’s Ecopure Catalytic Candle Filter
� Fig 1. Ceramic candle filter, 2m long.
Continued>>
www.glass-international.com
Matthias Hagen* discusses how the Ecopure CCF, a new combined DeDust, DeSOx and DeNOx process, has been used by a Chinese glassware manufacturer to combat excess emissions from its furnace. The technology means the glass manufacturer can confidently face today’s emission targets, as well as stricter goals that will be introduced in the future.
33 Glass International May 2017
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Furnaces
� Fig 4. Ecopure CCF Furnace off gas
NOx
NH2
NOx
NH2
H2O NOx NOx
NOx
for a glass manufacturer.
N2 DeNOx
NH2
H 2O N2
Clean air
H 2O
Catalytic filter (CCF)
� Fig 2. NOx conversion principle. CaSO4/CaSO3 H2O
SOx SOx Furnace off gas
DeSOx
SOx SOx
H 2O
Clean air
H 2O
SOx Catalytic filter (CCF)
� Fig 3. Separation principle for acidic constituents in the gas, using SOx as an example. (CCF) technology makes it possible not only to comply with emission limits without additional cooling or heating processes, but it actually keeps emissions at less than 50% below limit values. As a result, the Chinese manufacturer now considers itself well equipped for future tighter limits. With this technology from Dürr, three pollutants are eliminated simultaneously in one system, which translates into economic operating costs savings.
www.glass-international.com
DeDust Filtering exhaust gases at high temperatures was already an available option for many years. Ceramic candle filters were used ten years ago in an exhaust air purification system at a hazardous waste incineration plant. These candles are made from ceramic fibres that can withstand temperatures of up to 900°C (Fig. 1). Since the filter wall is much thicker in comparison to fabrics, these filters are rigid. This results in a long service life, as the deformation during cleaning, via a burst of compressed air which causes wear in fabric filters, does not occur. The filter’s rigidity means that a permanent filter cake forms on its surface. This contributes to better filter performance and much lower cleaned gas values, especially for superfine particulates.
DeNOx In the established SCR process, nitrogen oxides are removed via a reaction between injected urea or aqueous ammonia with
NOx. Because of the catalyst, this reaction takes place at a relatively low temperature of 350°C. Ecopure CCF filters are coated with this catalyst material. The candles therefore perform the same function as the coated ceramic honeycomb in an Ecopure SCR, another Dürr exhaust air purification system. The doping of the fibres with catalytically active centres on their surface proves to be advantageous in this case. Unlike in conventional catalyst honeycombs, the omission of the gas phase helps to improve the filter’s performance (Fig. 2). The catalyst thereby is located on the inside of the filter wall where it is dustprotected. The usual aging due to the clogging of pores and reduction of active surface area doesn’t happen.
DeSOx Sulphur in many processes exists mainly as SO2, which may be separated using wet or dry processes. With low pollutant concentrations, dry processes have become the preferred choice over highly efficient wet processes, due to their lower life-cycle costs. This technology is based on the reactivity of a sorbent such as calcium hydroxide (Ca(OH)2) with acidic constituents in the exhaust gas such as SO2, HCl and HF. In many applications, the technology described above has proven effective both with electrostatic precipitators and with fabric filters. For the desulphurisation process to achieve good separation
efficiency, a temperature of up to 180°C and sufficient moisture are required (Fig. 3). At higher temperatures, however, the reactivity of the calcium hydroxide decreases at first, before rising sharply again from about 300°C upwards. This selective temperaturedependent behaviour makes the use of calcium hydroxide particularly suitable for separating acidic constituents from exhaust gas in a temperature range that is favourable for the Ecopure SCR DeNOx process mentioned earlier.
3-in-1 technology As all three processes are combined in one unit, the setup is compact and allows space-saving installation within existing production facilities (Fig. 4). The high efficiency of the individual processes delivers maximum separation efficiencies for all types of pollutants, meeting the latest requirements of the forthcoming TA-Luft 2017 regulations particularly in respect of dust and nitrogen oxides. Integrating the three individual processes into the Ecopure CCF system means lower maintenance costs and reduced space requirements, which results in lower operating costs. The 3-in-1 technology has been well received, particularly in overseas markets, and now it has been included in the official draft of the VDI 2578 standard in Germany. �
*Global Customer Director, Dürr Systems, Germany www.durr-cleantechnology.com
34 Glass International May 2017
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Tooth Chain
Conveyor Tooth Chains Made in Germany Uwe Gillert, Industry Management for the glass industry, has established close contact with the customer in field service and has a great understanding for the “hot topics� in the glass industry.
Excellent guiding characteristics, a long service life, reliable delivery: our laser-welded inverted tooth conveyor chains are convincing in any production setting. They offer a wide variety of application options: from hot bottles to entire vehicles, they carry the product precisely to the right location. Reliable, safe, efficient and always tailored to the specific application.
Renold GmbH Zur Dessel 14 31028 Gronau (Leine), Germany Phone +49 5182 58724 toothchain@renold.com www.renoldtoothchain.com
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History
Prof. John Parker
The sands of time Glass hourglasses that used to define the time were widespread in Europe by the 14th century, reports Prof. John Parker. He discusses the use of glass in telling the time.
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S
ociety’s early appreciation of time was based on tracking the sun’s motion across the sky, perhaps using the shadow of a stick in the ground or by building monuments such as Stonehenge. Sundials appeared around 1500BC and as annual variations in the earth’s orbit were better understood, seasonal recording errors could be minimised. Eventually they were installed on church towers for all to use. But sundials required sunshine and didn’t work at night or indoors. Clocks based on flowing water are almost as old. In the 11th century AD a Chinese engineer built a tower housing a water clock able to mark the passing of each quarter hour. Nevertheless evaporation, condensation, spillage and freezing all reduced their accuracy. Similarly the shrinking of a burning candle was the basis for a primitive timepiece. The consumption of oil in a lamp (18th c) was an improvement because the glass chimney lessened the influence of drafts. Sand glasses (hourglasses) offered greater reliability in defining a time interval, typically one hour. Some suggest they date back to Greek and Roman times but certainly by the early 14th century they were widespread in Italy and subsequently spread throughout Europe. Early hourglasses had two separate blown bulbs between which the sand passed via a flexible linkage made from leather or waxed paper. A wooden frame gave support, facilitated turning possibly using a pivot and counter, and provided decoration. Accuracy was affected by absorbed moisture, the angularity and the size distribution of the grains. Sieved, rounded grains between a half and a twelfth of the neck diameter were preferred and often limestone or shells were major components. One early version of Mrs Beeton’s Guide to Good Housekeeping had recipes for sand
preparation. Washing nine times in wine was vital to remove traces of grease! Hourglasses were made by overfilling the top bulb, stopping the flow after the required time and discarding the excess. Not until the 18th century were the two bulbs made from a single length of glass tubing. Today, a glassmaker’s lathe would be used and a glass ballotini, which can be coloured to match the décor of a room, makes the perfect decorative sand.
Sea Early hourglass references link them to the sea. In 1345 Thomas de Stetsham, a ship’s clerk, ordered 16 while an inventory of King Charles V of France’s possessions (1380) lists a large sea clock. A ship’s speed was measured using a rope tied to a log that was thrown into the sea. Knots in the rope were counted as they ran through the seaman’s hand during a time interval defined using a sand glass. Since the advent of compasses and charts for navigation at the turn of the millennium, ships needed to measure time to find their longitude. By the 1300s they were using banks of sand glasses to mark the hours, halves and quarters with a boy to turn them. Hourglasses were relatively unaffected by the ship’s motion and temperature; nevertheless, in one incident, after nine stormy days without sight of the sun, an 11 hour error had accrued when the sun finally reappeared. Others were also using hourglasses: for timing parliamentary divisions, university lectures and sermons. There were even ‘short’ and ‘long’ hourglasses for congregations that preferred brevity or speakers who valued eloquence. In one play, a preacher offers his parishioners the turn of a glass with the double meaning of taking a drink or delivering a two- hour sermon. Medics used 30 second glasses for measuring pulse rates until the 19th century. Even now we buy sand glasses to define the 3 minutes required to boil an egg.
Early mechanical clocks used weights to drive them and were installed in churches from the 13th century. Bells could be incorporated to mark the passing hours hence the phrase ‘telling (counting) the time’; outside the astronomical community the term ‘minute’ meant little. But increasingly reliable and accurate mechanical clocks were devised during the 16th and 17th centuries gradually displacing the hourglass, and culminating in the prestigious prize awarded to Harrison in 1773 for his nautical clock accurate to seconds over a month. Shakespeare’s audiences would have known all these means of time measurement, although only the rich would have owned a pocketwatch, and that primarily for ostentation. His plays include allusions to their various characteristics. Prospero in the Tempest gives the time as ‘at least two glasses past the midseason (noon)’. The motion of sand in an hourglass offered a visual image of passing time in the way that a sundial did not. Shakespeare refers to an hourglass as the glass of time. Consequently it became a symbol for the grim reaper and was widely used in art and on gravestones. Today computers use it to signify a (forever) running programme while an hourglass figure alludes to fashion and the shapeliness of the female form. �
Bibliography Tiffany Stern, Time for Shakespeare: Hourglasses, sundials, clocks, and early modern theatre in http://www.britac.ac.uk/sites/default/files/01%20 Stern%201817.pdf https://en.wikipedia.org/wiki/Hourglass https://en.wikipedia.org/wiki/Marine_sandglass
*Curator of the Turner Museum of Glass, The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk
36 Glass International May 2017
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GLASS HAS A GREAT PAST.
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Recycling
Quality assurance in recycled cullet Heiko Hartung* discusses the Institut fur Glas und Rohstofftechnologie’s (IGR) research on how glass recyclers and manufacturers can obtain a homogenous sampling of the cullet used in glassmaking, using quality assessments. It means the entire supply chain can be assured of the quality of the end product.
I
t is not easy to get a common definition of recycling (for any product) between recycling companies, production companies and end-user, particularly regarding the recycling of glass. What can be agreed is that glass is one of only a few products that can be reused infinitely without any loss of quality. Systematic collecting and reusing of End-of-Waste (EoW) glass in the production of bottled glass by the use of a nationwide collection of containers was established in Austria and Germany, for example, in the early 1970s. Today, cullet rates of up to 95% for a green bottle batch are possible. Float glass production using a lot of external cullet, however, is rare.
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Why use End of Waste glass? The European Waste Framework Directive[1] defines waste, its re-use and its recycling steps, but prior to this directive there were separate rules for different countries. In Germany, for example, the packaging rule ‘Verpackungsverordnung (VerpackV)’ of 1998 defined a recycling target of glass packaging of 60% until 2008, and since then an annual average of 75%.[2] The use of EoW glass has ecological and economical benefits. Some of the raw materials used in glass production are limited resources, which leads to an increased price. As EoW glass already contains the majority of these raw materials, its use leads to a direct economical benefit. An indirect benefit can also be made, as a batch with about 50% of cullet will reduce its melting loss by 50kg/t. Cullet may reduce the required energy of the furnace, which results in reduced heating costs. A cullet use of, for example, 10% reduces the required energy of a glass bottle furnace by 3%. The energy consumption of Germany’s glass production was reduced by 20% from 1970 to 2001 thanks to EOW glass recycling.[3] Both effects lead to savings in
� Fig 1. Aftermath of impurities. (left and right)
CO2-emissions by reducing the required energy and by reducing the weight loss due to the reduced amount of carbon raw material. The use of one tonne of EoW glass means a saving of more than 300kg CO2[4]. Cullet also increases the melting capacity of an existing furnace, as the use of cullet allows more throughput per unit (metre and time). The IGR has developed the following example in the field: An existing furnace of 35m² achieved a throughput of 130t/ day by using 60% cullet. The same furnace had to reduce the cullet use to 10%, which resulted in a throughput of only 90t/day with the same glass quality. However, the economic benefits are fading as the price of cullet reaches €100/tonne. The use of raw material is becoming economically more interesting. The use of EoW cullet can be of high risk to the glass industry as reliability is key to effective automated production. It is important that all used materials are of a reliable, consistent composition. This composition can be checked in advance and throughout production, so as to regulate additives and achieve a stable production. Regarding EoW cullet, this is the most important reason that prevents a higher usage and, even more critically, may lead to a reduction of cullet use. The major problem with cullet composition is its impurities. To lose its waste status and to be accepted as a
secondary raw material for use at all, the European Commission Regulation 1179/2012 (Appendix A, Section 1.2 “Content of non-glass components”) allows EoW glass to contain less than 50ppm ferrous metals, less than 60ppm non-ferrous metals, less than 100ppm ceramics, stones and porcelain (CSP) in the >1mm fraction, and less than 2.000ppm organics.[5] CSP and metals leads to inclusions in the produced glass due to their higher melting point. This has to be compensated by reducing the throughput or increasing the sorting capacity at the cold end. But a high amount of organics and/or offcolours may result in a uselessness of the complete melt. The chemical composition of the cullet is also important. Thresholds are valid, for example, for heavy metals in the end product, and therefore indirectly for the cullet. The German VerpackV, for example, limits the amount of lead, mercury, cadmium and chromium to a cumulative 100ppm for selling packages in Germany. Only when the excess of this value is directly related to the usage of EoW cullets, up to 250ppm is allowed[2]. This value is valid throughout Europe, whereas some US states only accept 100ppm. Fig. 1 shows the aftermath of several impurities.
Continued>>
38 Glass International May 2017
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Recycling
CSP at glass recycling (25 g/t = 0,0025%)
� Fig 2. Calculation basis for sample weight [7]
Total weight of the sample (kg)
10.000 Impurities in recycled building materials (0,1%, 1%, 10%)
1.000
100 Impurities in substitute fuels (3%)
10
1 Off-colour at glass recycling (22%)
0 0,0010
0,0100
0,1000
0,10000
10,000
100,000
Contents %
Quality is crucial for the use of cullet in glass production and there are a lot of technical possibilities for a cullet recycler. Manual sorting is outdated, at least for the majority of impurities and sorting machines have taken over most of it. A large reduction of organics can be made quite simple, as only time and water are needed. The longer the EoW glass is stored outside in weather conditions, the fewer organics are left in the resulting cullet. It is also standard to sort non-ferrous metals with a magnet field, for example in an eddy current separator, plastics in an air classifier and CSP with light transmission. That technique is simple, as nontransparent parts were recognised by a camera and sorted out using compressed air. Once installed, such a system is also used for off-colour sorting, thanks to powerful computers that are not limited to the three major colours any more, as even special colour sorting is possible. There is a general restriction, valid for all sorting techniques based on optical recognition, which is the grain size of the cullet. Not long ago only cullet of at least 6-8mm was sortable. It is a development to sort out cullet of up to 2 or even 1mm. The glass industry’s quality demands regarding cullet has increased in parallel to the sorting development. In Germany, for example, a CSP threshold of 60g/t was common in 1991, but in 1994 had reduced to 25g/t. In other European countries a value of more than 100g/t was usual until 2010. Since 2009 the first sorting machines were able to detect and sort glass ceramics and leaded glass with UV- or X-ray fluorescence detection on an industrial scale.
Another challenge of cullet treatment, the volatile humidity level of the cullet, was met in 2013. Dirt on the cullet, responsible for the detection rate, varies due to its humidity. This was solved using a drying system, with the effect that the cullet is cleaned, and therefore the detection rate was not only more stable but also better. Only the resulting dust was problematic, as it was added to the melting process heterogeneously. Concentrated dust leads to a redox reaction, as with coke. This may result in an unwanted colour change from white to amber. As a consequence, most glass producers only use cullet of >2mm.
Quality assurance IGR’s experience shows that, even in a country like Germany, where glass recycling has been in use for 50 years, cullet quality varies. The reason for this is related to processing, but geographical reasons are also important. For that last reason it is important for the glass producer to separate the EoW 18 16 14
� Fig 3. Cullet sieving and the outcome.
12 Number of relics
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Sorting techniques
cullet recyclers. The quality assurance (QA) for the glass producer starts with the cullet of their production, for example by monthly analyses of a cullet sample and additional random cullet samples. Some food producers are aware of this and demand a QA concept from their packaging producers, including their cullet supplier. A mass of cullet such as a lot/pile is much better to calculate regarding its composition than a single cullet or even a tonne, due to mathematical reasons. This means that the sampling itself is the most important step to effective QA. The homogeneity principle says that a sample of a mass of cullet is most accurate when it is divided into halves or quarters over and over again. This is of course not practical, neither at a pile, nor in a lorry full of cullet. Most of the glass producers ‘solved’ this by sampling from the top of the lorry. However, the so called ‘Brazil-nuteffect’[6], a phenomena of physics, states that smaller parts always go down in a mass when it is moving, which results in contaminants not being visible (and thus un-sampleable) from the top of the pile, as they are smaller than most of the cullet. For that reason the IGR developed, based on investigations and calculations of the Bauhaus University in Weimar, Germany, a process to sample a pile directly at the recycler’s plant. To get an almost homogenous sample, up to 100 single samples of the pile were required from different locations, including the surface and the core. These single samples were then put together and divided following a defined procedure, so that a common pile of more than 1000 tonnes ends up in a sample of about 1-2 tonnes (Fig. 2).
10 8
Start of using sieved EoW cullets
6 4 2 0
Raw materials
EoW cullets
Refractory material
40 Glass International May 2017
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Recycling
Analysing possibilities In our experience, the mass of 1-2 tonnes currently appears to obtain the best result. Others have named less than this weight as being OK to use, but we believe the resulting values have too high a variance. Another important thing is the grain size, as the examination reason defines the size. If gravity separation is used to find corundum, small grains are sufficient, whereas off-colour examination does not make sense if the cullet is <8mm. However, sieving can also make sense for other examinations, such as for CSP (Fig. 3). A sample was once examined at the IGR, completely mixed regarding its grain size. 10 pieces per ton resp. 15 grams per tonne were found. Afterwards, the same sample was put together and then sieved. The grains were then examined separately, and 100 pieces per ton resp. 30 grams per tonne were found. Another quality check may be an investigation regarding the cullet’s COD or the loss on ignition. Both can be an indication of organics in the cullet that may lead to redox reactions in the furnace. The influence of organics in the produced glass can be examined with a method developed by the IGR to measure the iron (II) content. These iron oxides are one of the ingredients relevant to colour glass. Furnaces in glass factories have produced flint glass that has changed colour to a dirty green and contains bubbles due to the amount of organics stuck to EoW cullet. IGR’s experience shows a disparity between the two redox states of iron (iron(II) and iron(III)) responsible for this phenomenon. One is coloured green-blue, the other yellowbrown. In the end, only a few grams or less is required for a complete chemical analysis. However, to get there the QA must have a clearly structured and defined method. It is not possible without some effort, and that starts with the recycler. Part of that is homogeneous sampling, dividing and processing, but only structured, defined ways ensure that the values measured with ICP-OES (or comparable) are representative of the complete cullet pile. This helps the food producers, container producers and therefore also the cullet recyclers to sell their product continuously and reliably. �
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Sources 1 Directive [2008/98/EC] of the European Parliament on waste 2 Packaging Ordinance = (Verpackungsverordnung - VerpackV)”, 21 August 1998, last change 17 July 2014. 3 Deutsche Umwelthilfe, (German Environmental Aid Association) Informationsblatt 9730-050. 4 Federal Association of the German Glass Industry),http://www.was5 Commission Regulation (EU) No 1179/2012, 10 December 2012 establishing criteria determining when glass cullet ceases to be waste under Directive 2008/98/EC of the European Parliament. 6 A. Rosato, K. J. Strandberg, F. Prinz and R. H. Swendson, Phys. Rev. Lett 58 (10), (1987). 7 Source: Müller, A: Probenahme aus heterogenen Haufwerken.
*Subject to technical specification, terms and conditions System 500 forehearths and distributors are offered with guarantees covering temperature stability, thermal homogeneity and fuel consumption.
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passt-ins-altglas.de/warum-glas-recyceln.html, state 14.02.2017
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*Phys Analytics & IT, Institut fur Glas-und Rohstofftechnologie (IGR), Gottingen, Germany h.hartung@igrgmbh.de www.igrgmbh.de
Holmfield, Halifax, West Yorkshire, UK. HX3 6SX Tel: (44) (0) 1422 254472 • Fax: (44) (0) 1422 254473 Email: admin@parkinson-spencer.co.uk • www.parkinson-spencer.co.uk
41 Glass International May 2017
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M-Glass Factory Services es una compañía dedicada a ofrecer asistencia a la Industria Vidriera. Junto a nuestras representadas estamos en capacidad ofrecer los siguientes servicios: • Supervisión de construcciones de hornos (Estructura metálica y refractario) • Supervisión de reparaciones en caliente • Supervisión y reparación de hornos • Mantenimiento y construcción de plantas de mezclas • Operación de hornos y asistencia técnica • Asistencia en la selección de refractarios • Asistencia en pre-montajes de material electrofundido • Auditoria de hornos, refinadores y forehearth.
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Events world
China Glass returns to Beijing China Glass will take place at the China International Exhibition Center in Beijing on May 24 - 27, 2017.
Exhibitors from Russia, Mexico and Saudi Arabia will make their debut at the show. There are three state pavilions: Italian, American and German, with 75 exhibitors confirmed at the event. The exhibition is expected to attract more than 40,000 visitors from over 70 countries.
What’s on display This year, the China Building Materials Academy will display its new products in the fields of flame proof glass, quartz glass and night-vision equipment. China Triumph will display its new 0.15mm thick and mass-produced 0.22mm thick ultra-thin float glass. Land Glass will display its toughened glass equipment with independent intellectual property rights and its V-Glass series product, while Austria’s LiSEC will exhibit its logistic system and aeroflat tempering equipment. Corning will exhibit its laser cutting solution for glass cutting, drilling, structuring and welding and Bystronic Glass will have its new B’COMFORT solution for insulating glass manufacturing. Finland’s Glaston will bring its highquality heat treatment machines and services for architectural, solar, appliance and automotive applications; Grenzebach
will showcase its new cutting tool with integrated force sensor combined with cutting force controller CFC-250mag; and China Liaoning North Glass will showcase its new autoclave and complete set of laminated glass production line products. In addition, products and solutions in sectors such as industrial robot, intelligent photovoltaic glass and new energy efficiency glass will be on display.
Forums and seminars Over the course of the show, senior experts will give lectures concerning architectural glass, glass design creativity and processing technology at the ‘Forum on Building and Architectural Glass’. There will also be several technical seminars on topics covering Industry 4.0; heat insulation energy-saving technology; full tempering vacuum glass production; oxy-fuel tableware furnace technology; trends in artistic glass decoration; and laser cutting technology for glass processing. �
China Glass, May 24th - 27th, China International Exhibition Center, Tian Zhu Area, Shun Yi District, Beijing. www.chinaglass-expo.com/
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T
he exhibition will showcase the development of the global glass industry and provide a professional platform that covers the whole glass industrial chain. Following long-term rapid development, China’s glass industry is now facing serious industrial situations such as excess production capacity, an imbalance between supply and demand, slow-paced structural adjustment and upgrading, and lack of creativity for new demand. 2017 is therefore a year to deepen the supply-side of structural reform to the building materials industry in China. Innovative achievements of the glass industry, including ultra-clear glass and ultra-thin glass, have continuously been sourced. Meanwhile, the supply-demand gap is shrinking, and the glass industry showed a growth trend in the first half of 2016. China Glasss 2017 will cover an exhibition area of over 100,000m2 in eight halls of the China International Exhibition Center (New Venue). Altogether, 995 exhibitors have confirmed their booths, including 230 international groups. The exhibition area and the exhibitor quantity increased by 32% and 12% respectively compared with the last event.
43 Glass International May 2017
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Coatings
Make CVD part of your future Christopher Cording* and Ron Hunt** discuss the history of Chemical Vapour Deposition and why now is the time to make it part of a glassmaker’s future.
L
arge glass manufacturers such as NSG Group (NSG) and Asahi Glass (AGC) use chemical vapour deposition (CVD) to give themselves an edge over their competitors. CVD technology has only recently been available to smaller manufacturers. To understand why CVD hasn’t been available, this article explores the history of the process and why now is the perfect time to make it part of a company’s future.
History Among the first uses for CVD was refining metals such as nickel. Ludwig Mond developed a method that purified nickel using CVD. The company that Mond founded, Mond Nickel Company, merged into the International Nickel Company, which was ultimately acquired by Vale (the largest nickel refiner in the world). Glass manufacturers began to use CVD for online coatings in the 1960’s. Pilkington was the first to develop a marketable product, Reflectafloat. Over the lifetime of the product it was made in both the tin bath and the lehr. Reflectafloat
is a reflective product that doesn’t have Low-E properties and is still used in developing glass markets. Pilkington licensed Reflectafloat technology to some of its float bath licensees, but never made it widely available. Pilkington acquired Libbey-OwensFord Glass (LOF) in 1986. LOF had coating experience dating back at least to 1942, when it filed a patent for a process to deposit conductive tin coatings on aircraft cockpit windows for de-icing. The next breakthrough in CVD came around 1989 when Pilkington and AFG Industries, Inc. (AFG) independently developed online conductive Low-E coatings. Pilkington’s K Glass (one of these online conductive Low-E coatings) is still used today. Shortly after AFG’s triumph, it was acquired in 1992 by AGC. During the remainder of the 1990’s, AGC and Pilkington continued to develop new CVD products although none of the next generation technology was offered for sale. During this time period Saint-Gobain and PPG also made some attempts at developing the technology. A Saint-
� A CVD chemical
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pump station.
Gobain patent registered in 1992 shows a CVD coater, although the patent makes no mention of CVD and instead only refers to pyrolysis. Saint-Gobain’s SGG Antelio Plus and BioClean are both CVD products and are both currently on the market. PPG developed CVD in the 1990’s and until recently offered these products in its portfolio. It is not clear if Vitro acquired PPG’s CVD technology when it bought PPG’s float business in 2016.
CVD development Moving into the 2000’s an exciting development took place in that Stewart Engineers committed to developing CVD so independent glass manufacturers could have access to the technology. With a concerted effort from the entire engineering staff, Stewart Engineers commissioned its first CVD system in 2005. Pilkington and AGC continued development of new CVD coatings. In 2006 Pilkington was acquired by Nippon Sheet Glass (later known as NSG). Stewart Engineers, NSG and AGC all continued with CVD development in the 2000’s with Stewart having the largest gains by percentage and the others by scale. Stewart Engineers continues to develop cutting edge technology and offers a comparable product to that offered by NSG and AGC in every category. A breakthrough in CVD is being developed at Stewart Engineers and is expected to be launched within 18 months. About half of the 10 largest float glass manufacturers use CVD; the reason is clear, it is profitable. Since Stewart Engineers has made CVD available to independent float glass producers, it makes sense for the independent float glass producers to embrace CVD technology which has been profitable for half a century.�
*Technical Director, **Process Engineer. Stewart Engineers, Wake Forest, North Carolina, USA info@stewartengineers.com www.stewartengineers.com
44 Glass International May 2017
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GLASSMATE® The Industry Standard for Advanced Hot End Processing Photo credit: Quais de Saône - Lyon - Marie Perrin
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Contact us and learn how POCO can help reduce defects and increase pack rates in your hot end processes. www.poco.com ISO 9001:2008 & AS9100:2009 POCO® and GLASSMATE® are registered trademarks of Poco Graphite, Inc. ©2017 Poco Graphite, Inc., All rights reserved.
WHERE THE HOLLOW GLASS INDUSTRY MEETS TO DO BUSINESS
After the success of 2015, Glassman Europe is returning to Lyon, 6-7 September at the CCC Lyon. Over 600 senior-level executives attended and with a packed conference theatre, Glassman Europe is expected to be popular once again this year. Glassman Lyon will be the ideal opportunity to network with industry professionals from all around the world whilst learning about the latest products and services on the market. The exhibition and conference are free-to-attend so make sure you don’t miss out.
PUT THE DATES IN YOUR DIARY NOW Stay in touch:
Official media partner:
Join the Glassman Events Group Organised by:
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01/02/2017 16:12:24 18/01/2017 12:59
Precision weighing
Advanced Load Cell Monitoring for weighing indication Dipl.-Ing. Joachim Ullrich*, reports on the latest development in weighing technology: Zippe Advanced Load Cell Monitoring.
www.glass-international.com
N
early 45 of Zippe’s 200 employees focus on control technology as a key part of the optimal operation of a batch plant. The automation and control technology of Zippe’s batch plants is an essential component for efficient, reliable and reproducible operation of a plant. For this reason, the development of efficient software and hardware systems has a particular function in the company. Zippe is a specialist in weighing system solutions. Due to its years of experience in the development and integration of precision weighing technology, it can serve special requirements in a competent and reliable manner. Weighing electronics designed for the bulk material industry provide customers with maximum flexibility. The customer decides between weighing indicators and weighing modules that can also control dosing processes independently. A weighing application usually consists of various components: as well as the weighing container, the load cells, junction box and evaluation electronics are the decisive components. The weighing container is located in the centre of the batch plant, underneath the silos. It is equipped with load sensors, called load cells. Their signals are collected in a Load Cell Junction Box (Z-LC-JB), from where one common signal is sent to the weighing electronic, which is usually installed in a control panel located in the electrical control room. This entire combination is called container scale. The weighing itself is controlled by means of an automation system (PLC) or an intelligent weighing electronic, processing the weighing signals. There are different parameters in an automation system that can be defined to reach a high weighing accuracy. Some parameters are
speed settings of a dosing feeder or the exact point of time to stop it. From the electrical side it is essential that all weighing cells are correctly wired and evenly loaded. In practice, it appears from time to time that slight failures in installation are determined during the start up. The difference between usual
consumers or sensors and load cells is that the feedback signal of a load cell is very small (Millivolts) and has to be shielded against disturbances. All load cell cables are to be checked and measured separately by an electrician, in order to correct issues. Continued>>
� Schematic diagram of load cell - Advanced Load Cell Monitoring by means of Zippe’s Load Cell Junction Box - weighing indicator.
� Electrical control room panels with installed weighing indicators (right part of the panels).
46 Glass International May 2017
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Precision weighing
This work is time-consuming and arduous. The Zippe Advanced Load Cell Monitoring (Z-ALCM) allows electronic monitoring of up to four load cells and voids manual measurements of the electrical signals. Therefore, each load cell can be monitored individually to detect failures, malfunctions and uneven load conditions. The Z-ALCM replaces the conventional terminal boxes in which the individual load cell cables are linked together. Also existing terminal boxes can be exchanged by the Z-ALCM, if requested. In connection with the weighing electronic system Z-WI-102 (weighing indicator) and Z-WM-102 (weighing module), which is developed particularly for the glass industry, no additional voltage supply of load cell monitoring is necessary. Error states of the load cells can be signalised by means of a volt-free contact. This can be used to generate an alarm message in the SCADA system or to switch on a warning light. The integrated graphic display shows the individual mVsignal of the load cell and therefore supports the commissioning and maintenance staff during their regular inspection. As there is also a bar graph available on the Load Cell Monitoring that shows the individual load of a load cell, a basic check could also be done by a non-electrician during production. �
From Concept to Completion • Glass Furnaces • Batch Plants • Turnkey Projects
*Head of Electrical and Process Automation Department Zippe, Wertheim, Germany www.zippe.de
HFT provides engineering, procurement and construction services, as well as, turnkey projects for the glass industry. Our leadership, abilities and attention to details have given HFT a highly respected reputation worldwide.
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Engineers and Contractors to the Glass Industry 3009 Washington Road • McMurray, PA 15317-3202 • USA
www.hft.com +1 724 941 9550 Fax: +1 724 941 3479
� Zippe Load Cell Junction Box in operation.
dchen@hft.com
cyoest@hft.com
47 Glass International May 2017
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