Glass november 2014

November 2014 | Vol. 37 No.10

SGD: NEW FRENCH SITE SCHOTT: RESEARCH CENTRE RAW MATERIALS

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Contents

November 2014 Vol.37 No.10

November 2014 | Vol. 37 No.10

SGD: NEW FRENCH SITE SCHOTT: RESEARCH CENTRE RAW MATERIALS

10

2

Editor’s Comment

3

International News

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Glass International November 2014

Company profile: SGD 10 SGD to build France’s first new glass plant in 20 years

12 Front cover image courtesy of Air Products www.airproducts.com

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Executive Interview: Schott R&D head 12 Research centre celebrates 25 years of progress

Perspectives: Klaus Wolff 17 Klaus Wolff reaps the benefits of the Thai container market

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Raw materials 20 A global soda ash outlook 23 Ceramic filters and the development of hot gas filtration 26 The use of furnace slag in glass 28 British glass

17 Plus find us on Linked-In and Twitter.

44

Furnaces 32 Old solutions to a new problem 34 Glass furnaces: Combined energy recovery and pollution abatement 37 The crucial role of industrial gases in float glass production Container glass 40 Heye delivers speedy Thai projects Events world 41 The 12th European Society of Glass conference 44 glasstec 2014 deemed a success

@Glass_Int

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30 History

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Editor’s comment

Greg Morris

www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Editorial Assistant: Sally Roberts Tel: +44 (0)1737 855154 Email: sallyroberts@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com

Optimistic air in the container industry

Sales Manager: Jeremy Fordrey Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com

(but keep it quiet...)

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W

hisper it, and keep it among yourselves, but perhaps, just perhaps, the glass container industry has an air of optimism about it.

The industry, usually regarded as conservative and traditional, seems to be relatively upbeat at the moment Plenty of suppliers have reported new contracts to supply equipment to the glass manufacturers.

Equally, a skim read of the manufacturers’ quarterly financials reveals a rise in profit for the majority of them.

The glasstec event at the cavernous Messe Dusseldorf last month highlighted this renewed positive air.

Even as early as the first day, exhibitors reported that orders had been made and contracts signed. They reported that the profile of visitors to their stands tended to be senior executives who had the power to make decisions. They had received sign-off to make the trip to Germany and as such, intended to do business.

In other words, there were no time wasters visiting the stands – the type of people who were described by one exhibitor as ‘tourists’.

Generally, these decision makers were from developing nations such as from South America, the Middle East and Africa. Perhaps it is an indication of where the glass industry is heading in the forthcoming years.

The Glass International website news

pages this month reveal signed orders for several suppliers in places as diverse as Brazil, South Africa and France.

However, such is the nature of the glass industry that suppliers and manufacturers are not getting too carried away. It only takes a political crisis in a country, a terrorist incident or even an unlikely killer disease to put investors off.

The industry is at the behest of factors far larger than itself. Orders, and optimism, can quickly evaporate should an emergency take place in a particular country or region.

An example of this is the recent conflict between Ukraine and Russia. Both countries are considered as developing nations, ripe for expansion, not just for glass, but for many industries.

However, as soon as the crisis erupted orders were shelved and confidence dropped. Technical engineers, flown in by overseas companies to install machinery, were quickly withdrawn from the country and work had to stop.

It is for this reason that the industry is unlikely to shout from the rooftops when things are going well – the good fortune hangs by a thread. So keep your fingers crossed that this period of positivity lasts for some time. Just don’t tell too many people about it.

Greg Morris Editor gregmorris@quartzltd.com

Quartz Glass Portfolio

Monthly journal for the industry worldwide

Directory 2015 Annual international reference source

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Productive Executive: Martin Lawrence Subscriptions Tel: +44 (0)1737 855023 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034.

Email: glass@quartzltd.com Website: www.glass-international.com

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Glass International (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 173180437.

Glassman specialist exhibitions rotate between America, Asia and Europe © Quartz Business Media Ltd, 2014 ISSN 0143-7838

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International News

EBRD invests €125 million in Turkey’s Sisecam Group

investment of EBRD in Turkey.

Prof. Dr. Ahmet Kırman, Vice Chairman and CEO of Sisecam Group said: “With its 79 years of experience, 20,000 employees, exports to 150 countries and sales over $3.1 billion, Sisecam is a corporation of international scale.

“As a producer located in 13

Gerresheimer youth research project

Gerresheimer is supporting a youth research project focusing on making ‘smart’ glass.

Roderich Wallrath and Fabian Marischen have been conducting research into sputter technology in a workshop at Gerresheimer Essen since August.

Sputter technology is a chemical process for coating glass. The coating gives the glass new properties, such as better light transmission, which is useful for applications such as car windscreens.

The two young researchers hope to have concluded their project by December 2014.

countries, Sisecam produces 40% of its glass abroad.

“Sisecam is Europe’s second, world’s third largest producer of glassware; Europe’s third, world’s sixth largest producer of flat glass; and Europe’s fourth, world’s fifth largest producer of glass packaging in terms of production capacity.”

SGD orders batch plant from Zippe Zippe has received the order for a batch plant for borosilicate glass from SGD in France.

The plant will be established in Saint Quentin la Motte in the North of France, only a few kilometres away from SGD’s factory in Mers- les-Bains.

Zippe will also deliver the batch and cullet transport to the furnaces, a cold top charger for the electric furnace as well as the cullet return system. The batch plant represents a part of the new and modern ‘Greenfield’ factory

that SGD is building at this site.

The plant will be completed with a control system made by Zippe. The plant is scheduled to start operation in June 2015.

A full profile of the new SGD site is on page 10.

Verallia Italia invests in Furnace 73 The new Furnace 73 is the result of a large investment made by Saint-Gobain Group for Verallia in Italy.

The new furnace, installed for the production of glass food containers, respects the environment thanks to its low Co2 emission levels and an intelligent use of energy.

The project was completed

in May 2014, with the production of the furnace’s first container. 130 companies were involved in carrying out the project with an average of 200 people a day present at the work site.

Gazzo Veronese was chosen as the location for the new installation.

It was identified as a stra-

tegic position from which to best serve those Food & Beverage clients most devoted to export, a driving sector in all of Italy’s economy today.

The furnace, working at full capacity, will be able to produce around 1,000,000 containers a day on three lines, in order to better satisfy the needs of Verallia’s clients.

Beatson Clark wins recycling contract

Beatson Clark has won the contract to manage the town of Rotherham, UK’s recycling collections.

The company’s recycling plant on Greasborough Road, which employs nine people, receives 6,240 tonnes of metal, textiles and glass from the council every year, of which 4,734 tonnes are glass.

The glass is used to make new bottles and jars at the Rotherham factory, while the textiles are sent to Bag It Up and metals are recycled at Morris & Co and Alutrade.

Ardagh wins ‘Innovation of the Year’

At the inaugural Luxury Packaging Awards in London, Ardagh won ‘Innovation of the Year’ for the development of Absolut Originality.

Judges said that “by using partial colouring for the first time on a commercial scale with a drop of cobalt blue infused into the molten glass, and completing this in three weeks, something truly remarkable has been achieved”.

“To receive this award brings welcome recognition for the whole team,” said Ardagh’s Head of Marketing for Glass, Sharon Crayton.

VISIT: www.glass-international.com – For daily news updates and regular features

www.glass-international.com

The European Bank for Reconstruction and Development (EBRD) has become a shareholder in Pasabahçe, the glassware subsidiary of Sisecam.

EBRD has invested €125 million in the acquisition of an equity stake of 15.44% in Pasabahçe Cam. The deal is the largest equity

NEWS IN BRIEF

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International News

Ardagh creates embossed bottle

NEWS IN BRIEF

AGR launches website

American Glass Research has launched its new website, www.americanglassresearch. com.

This site replaces the previous website that has been in use for a number of years. In addition to aesthetic improvements and traditional information on services and training school schedules, the site provides an interactive experience for users with ample opportunities to communicate directly through the ‘Ask Our Expert’ feature, ‘Contact Us’ and ‘LinkedIn’ connectivity.

IGC to host Chinese glass workshop

The International Commission on Glass (ICG) is transferring the successful Montpellier concept, and hosting the first ‘workshop for new researchers in glass science and technology’ in Shenzhen, China, this December.

The workshop will run between 8th-12th December 2014. The course is designed for new PhD students or for young researchers who have recently started research in the glass industry.

For further information contact Prof Parker: j.m.parker@sheffield.ac.uk

www.glass-international.com

Glaston’s €4 million deal with Press Glass

Glaston Corporation has closed a deal for advanced glass processing machinery valued at over €4 million with Press Glass.

The deal includes three models of the Glaston FC500 toughening furnaces for processing toughening glass.

The delivery will be made during Q2 and Q3 in 2015.

“This is a win-win situation that is highly appreciated by our company”, stated Arto Metsänen, CEO & President of Glaston Corporation.

Press Glass has expanded its operations and operates four plants in Poland. The company is developing its plant in Radomsko, which the largest centre in Europe for processing glass for the construction industry.

Ardagh Group has created a bottle for Henkell & Co Vinpol’s range of Totino vermouths, which features embossing as a key feature.

The design and production teams at Ardagh’s Gostyn unit in Poland redesigned the 1L bottle, and created two new capacities: 500ml and 750ml.

“We were working at the very margins of what is technically feasible to reproduce complex embossing for a high volume bottle of this shape,” said Roman Sobecki, Senior

Product Designer at Ardagh’s Gostyn unit.

“We are absolutely delighted with the final result, which we feel meets the aesthetic requirements of the brief as well as the technical,” he added.

Dariusz Polak, Marketing and Export Director at Henkel & Co Vinpol Poland, said: “Our new Totino bottle expresses a clean, modern and very stylish look that exemplifies the quality of our product and meets raising expectations of our customers.”

Xpar Vision and Bucher Emhart Glass sign cooperation agreement Xpar Vision and Bucher Emhart Glass have signed a cooperation agreement.

The agreement will see Bucher Emhart Glass launch its BlankRadar, based on two of XPAR Vision’s products, the Gob Assist (GA) and the Blank Temperature Control (BTC).

BlankRadar is based on Xpar’s Gob Assist (GA) and the Blank Temperature Control (BTC).

Bucher Emhart Glass will provide full product support for the BlankRadar system and will also continue to sell and support the established TCS. Xpar Vision will continue to sell its GA and BTC system independently. Similar to the Gob Assist, the BlankRadar comprises a camera module with two optical cameras positioned at the blank side of the IS machine.

The acquired data enables stable gob loading and faster gob loading after an equipment and/or job change.

The BlankRadar will be available through Bucher Emhart Glass with immediate effect. This cooperation agreement will not interfere with any other agreement that either party has already.

Encirc sale commences The sales process for Encirc, the former Quinn Glass, has entered its second phase after initial bids have been received for the business.

Lazard, an international investment bank, is handling the sale of the business.

A spokesman for the company confirmed: “Encirc is currently engaged in a sales

process which is unlikely to conclude for a number of weeks.”

He declined to comment on the level of interest in the business, which employs 1,000 people at facilities in Derrylin, Ireland and Cheshire, UK. Encirc has annual revenues of more than €300 million and its plants are considered

among the best in Europe.

Existing private equity shareholders in Quinn Glass are believed to be in the running to acquire total control of the glass manufacturing business. External private equity investors are also looking at the company.

Full story: www.irishtimes.com

Be first with the news! VISIT: www.glass-international.com for daily news updates

4 Glass International November 2014

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International News

Zippe batch plant commissioned at Nampak Zippe’s batch plant has been commissioned at the Nampak Glass container plant in Johannesburg, South Africa on schedule.

The batch plant has a daily capacity of 400 tons.

As well as the silo feed and batch plant, Zippe received the order for a batch preheater, which is the first of its kind on the African continent. It will contribute to energy savings and increased efficiency in the whole plant.

Its process control system PCS7 is being deployed. The concept of ‘Plant-wide automation’ (PWA) means that several plant areas are integrated into one superior system, has been realised.

The control sectors batch house, batch preheating and furnace have

merged to one overall project. Two independent servers allow high-availability of automatic operation re an integral part of the process control system at the same time.

Zippe has been a certified, long-term Siemens

PCS7 solution partner and has already supplied more than 20 batch plants with PCS7. Apart from projecting control systems, Zippe is also able to implement the coordination of the PWA concept as system integrator.

Stölzle invests in Austrian site Stölzle has replaced its amber furnace at its Koflach, Austria plant.

It has also started to use regenerative heating technology instead of recuperative power.

The company said that

this year’s investment of €18 million is an indication of its intention to improve its environmental footprint.

The key benefit has been a 50% reduction in the amount of electricity used

to heat the furnace and also 20% in gas.

The adoption of the technology has resulted in a reduction in CO2 emissions by 4500 tons per year.

Vitro boosts its container sales Vitro’s third quarter 2014 results show consolidated sales have increased by 1.3% year-on-year, driven by positive results in the Mexican company’s glass containers business unit.

Consolidated sales were up 1.3% year-on-year to US$433 million, driven by a 6.8% increase in sales in the glass containers business unit across all segments,

except CFT (Cosmetics, Fragrance and Toiletries).

During the last quarter Vitro achieved important milestones that should secure future profitable growth for the company.

Vitro has secured a longterm contract to supply beer bottles to Constellation Brands, with an estimated sales value of US$950 million over the next seven

years.

The Vitro board has also authorised an investment for a furnace in Brazil to supply the CFT market.

In the Flat Glass business unit, a solid performance in sales to the automotive market partially compensated for the impact of lower domestic and export sales to the construction segment.

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International News

Ardagh glass sites recognised for energy performance

NEWS IN BRIEF

Dip-Tech world record

Dip-Tech has been awarded the Guinness world record for the largest digital flatbed printer, thanks to its 18 metre, Dip-Tech AR18000 digital ceramic in-glass printer.

The achievement was officially recognised by Guinness World Records under the category of ‘largest digital flatbed printer’.

Solvay to invest in Bulgarian plant

Solvay will bolster the competitiveness of its soda ash factory in Devnya, Bulgaria, by improving its energy efficiency.

The measure is part of the competitiveness breakthrough plan that Solvay’s Global Business Unit Soda Ash & Derivatives launched last year, and which is on track to deliver its €100 million cost-improvement target by the end of 2015.

The Devnya plant, Solvay’s biggest synthetic soda ash production plant in Europe, will be equipped with a new high-tech steam boiler, whose energy efficiency will reduce CO2 emissions and bolster the site’s environmental performance.

www.glass-international.com

Corning receives automotive award

Corning Incorporated has received the BMW Supplier Innovation Award in the lightweight construction category for the development of its Gorilla Glass for automotive use.

Gorilla Glass is used in the BMW i8 as an acoustic glass partition to shield sound from the rear engine.

“For Corning to be recognised by an innovative design leader like BMW, it is quite an honour,” said Dr. David Morse executive vice president and chief technology officer for Corning Incorporated.

“Our technical glass, along with other lightweight materials, enabled BMW to maximise performance and control rear-engine sound for the i8.”

Ardagh Group has been awarded five Energy Star plant certifications from the Environmental Protection Agency (EPA) in the USA for its energy performance.

As a result of certifying five facilities in 2014, Ardagh has also received recognition as a Member of the EPA’s Certifi-

cation Nation. The five Ardagh sites in Burlington, Wis.; Dunkirk, Ind.; Madera, Calif.; Milford, Mass.; and Sapulpa, Okla., were the only glass container facilities in the USA to earn the recognition.

It places them within the top 25% of similar facilities nationwide for energy effi-

ciency performance levels set by the EPA. The five facilities have improved energy performance by upgrading and optimising furnaces, using recycled glass, installing energy-efficient lighting fixtures and repairing air compressor leaks, among several other initiatives.

Nampak Glass opens furnace Nampak’s energy-efficient glass furnace was officially opened in Roodekop, Gauteng by South Africa’s Minister of Trade and Industry, Dr Rob Davies, and Nampak’s Chief Executive Officer, André de Ruyter.

The R1.2 billion ($187.5 million) furnace is the third

at Nampak Glass and will increase the plant’s capacity to 295, 000 tons per year and create about 140 direct jobs.

Nampak has already secured long-term contracts to supply customers with a mix of glass bottles and jars.

“Of the R1.2 billion invested in the third furnace, 50%

was spent on developing the building in South Africa and the balance was used to buy the furnace equipment in Europe,” said Mr de Ruyter.

Nampak Glass is considering both greenfield and brownfield growth opportunities in the regions of West and East Africa.

Furnace Solutions call for speakers Breaking with the tradition of invite-only, the organiser of Furnace Solutions has made a call for speakers to increase the variety of topics.

It requires a 20 to 30 minute presentation with PowerPoint slides that will be made available to attendees later.

Anyone interested should provide a short abstract by the end of 1 December to Christine christine@sgt.org or neil-

simpsonfsgt@btinternet.com.

All presenters, who are not part of the Melting Technical Committee (MTC), will be eligible for The Michael Garvey Award - for the day’s best presentation. The recipient of the award is decided by members of the MTC present on the day.

The 2014 FS9 Garvey Award went to Erik Muijsenberg for his presentation titled ‘Complete model-based control of

glass production.’ (Pictured below). Part of the success of the events is due to its sponsors. In 2014 these included Tecoglas, Eclipse Combustion Systems, Guardian Industries, Calumite, Parkinson Spencer Refractories, Global Combustion System Ltd, IRE, Lucideon, BOC, IOM3, DSF Refractories and Fives Stein.

Further information at www.furnacesolutions.co.uk/

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Company profile: SGD  Artist’s impression of the new site at St.Quentin Lamotte

SGD to build France’s first new glass plant in 20 years French glass manufacturer SGD is constructing a plant that will be dedicated to the pharmaceutical industry. It is the first new glassmaking site to be built in France in 20 years. Ahead of Glassman Europe in Lyon next year, Greg Morris spoke to SGD’s Laurent Zuber, President of the Moulded Products group within the pharmacy division, about the group’s expansion.

www.glass-international.com

Congratulations on laying the foundation stone of the St. Quentin Lamotte plant. Why did you decide to construct a new plant?

SGD group decided last year to split its activities – glass for perfumery/cosmetic and pharmacy – as each business has very specific industrial needs and constraints. Separating the activities to better serve its customers also means having plants and teams entirely dedicated to each activity.

Within this strategic plan, a new plant dedicated to the pharmaceutical industry was needed in France to allow the current one, based in the Somme region at Mers les Bains, to fully focus on the glass for the cosmetic and perfumery industry.

The new plant at St Quentin really marks a major step for our company’s new strategy.

Why did you decide to construct the plant in this particular region?

The Bresles Valley, which is at the border between Picardy and Normandy is an area that has developed a very important know-how in the glassmaking industry for centuries. To give

We are very “ proud at SGD to build a new glass plant, the first one in France in the glass industry for the past 20 years

”

you an idea, the SGD plant at Mers les Bains is the biggest plant in the world and provides glass bottles for the luxury perfume industry and the most important pharmaceutical laboratories.

In order to keep all the very precious internal know-how, it was a logical solution for SGD to build a plant in the same area allowing some synergy with the Mers plant and an easy transfer for the employees already working for the pharmaceutical division in Mers.

How will the plant be structured and how many employees will it have?

The plant will cover 28,000 square metres out of which more than a third (11,000) will be dedicated to manufacturing.

The site will employ around 300 people producing 130 tonnes of glass a day.

Can you tell us more about SGD’s pharmaceutical profile?

SGD Pharma has unique know-how in the Continued>>

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Company profile: SGD

the world. The emerging markets represent the source of our future growth.

The plant will use the latest state of the art equipment. What ‘green’ technologies are in place at the plant and how important is the environment to SGD’s manufacturing practices?

pharmaceutical moulded glass industry but is also able to offer packaging tailor-made solutions to very specific pharmaceutical needs, the quality and patients’ safety always being our first priority.

SGD Pharma has the largest industrial footprint and broader agents network.

 SGD CEO Ashok Sudan lays the foundation stone at the new site.

SGD has mentioned there were some significant human and technical challenges. What were these challenges and how did it overcome them?

What products do you make?

SGD Pharma offers a range of glass vials. It goes from injectable, lyophilisation, all sorts of nasal, syrups and pill jars to glass baby bottles.

Parenteral packaging, though, represents 60% of our sales.

The challenges that SGD faces are indeed multiple: To have a plant of such dimensions built within a year, i.e. in a very short time, is the first challenge to achieve both technically and financially since €50 million is invested in the plant.

The other challenge SGD needs to address is the gradual manufacturing transfer, as well as 300 employees being relocated to the plant.

All the employees are regularly informed about the new plant’s developments and the 2015 calendar involving their transfer.

We are very proud at SGD to build a new glass plant, the first one in France in the glass industry for the past 20 years, and everybody is excited and is looking forward to seeing it in a year’s time. r

How has the pharmaceutical market performed in recent years, especially in light of the recent global recession?

SGD Pharma has known a steady progression of its sales over the past years. + 2.2 % in 2013 versus 2012, and + 6% in 2012 versus 2011. This is based on our global presence, and on the acceleration of sales, particularly in emerging markets.

What markets will the new plant serve? Will it just be domestic based or will it export as well? Approximately what percentage will be exported?

We made sure to conform to the latest environmental rules and requirements. SGD Pharma was the first to have all its sites certified ISO 15378: 2011 and is now implementing a programme of certification for ISO 14001 (environmental management and OHSAS 18001 (management of health and safety in the workplace) for all its sites.

Our Kipfenberg facility in Germany is already certified OHSAS 18001 (management of health and safety in the workplace), ISO 9001 (Quality Management), ISO 15378, ISO 14001 (Environmental Management) and ISO 50001 (Energy Management).

Furthermore, part of our energy in the future plant of Saint Quentin will be produced by the local wind field.

 An SGD transparent glass filling line.

SGD Group, France www.sgdgroup.com

www.glass-international.com

The new plant will be dedicated to the production of type I moulded glass exclusively. This specific type of glass is not only sold on the domestic market but all over the world.

In fact, 80% of SGD Pharma’s global production is dedicated to the export market. It is true for type I too. Our customer portfolio is diversified and we serve most of the international pharmaceuticals laboratories.

How important is the French market to SGD, and is this market is set to grow?

The French market represents 15% of SGD Pharma’s sales, but it is a mature market. Unfortunately the prospects of the French pharmaceutical industry are not favourable. That is why our strategy of growth is oriented towards Europe and the rest of

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Interview

x The Otto Schott Research Center, where workers generate a steady flow of ideas that become Schott innovations.

Research centre celebrates 25 years of progress The Otto Schott Research Center has been pursuing application-oriented glass development for 25 years. Christine Fuhr* describes how its multifunctional service centre functions as a ‘think tank’ for the company by driving new products and technologies and bringing them to market together with the operative Business Units.

www.glass-international.com

I

n quoting the British novelist John Galsworthy, the former Schott Speaker of the Board of Management Dr. Heinrich J. Klein, once said, “If you don’t think about the future, you cannot have one,” on the occasion of laying the cornerstone for the Otto Schott Research Center in June 1987.

Schott management had thought about its future – and taken action.

At that time, the company invested approximately 50 million deutschmarks (€25 million) in a future-oriented project: A research and development centre that opened its doors in the autumn of 1989 and was called the ‘Otto Schott Research Center’ in honour of the glass scientist and company founder.

1989: Starting out on a new scale The Schott Group has been committed to achieving top scientific and technological performances since the company was founded 130 years ago. “Research was never an end in itself, but rather always directed at industrial practice in close cooperation with the operative units with respect to results and findings,” explains the Schott Board Member responsible for R&D, Dr. Hans-Joachim Konz.

Here, the new building added a different dimension with respect to the infrastructure for the employees in R&D, who had been working in a laboratory building and at 14 other branch offices.

The Research Center with 43,000ft2 of space housed modern laboratories

and analytical devices, affiliated workshops, clean rooms and an 8600ft2 experimentation hall. This created the ideal environment for the 100 researchers, engineers and application experts who initially worked there.

2014: Multifunctional service Today, in its 25th anniversary year, the Otto Schott Research Center is a multifunctional innovation and technology service site. Under its roof there is an analytical and measurement technology service that has a command of more than 300 measurement methods and problem-solving techniques for external clients, as well as Schott Pharma Continued>>

12 Glass International November 2014

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Interview

Global R&D network mass spectrometer to measure the surface properties of various types of glass.

Highlights from 25 years of the ‘glass laboratory’ Services with analytical laboratory services specifically for pharmaceutical customers.

The development of computer technology over the past 25 years has substantially changed how glass developers work. Nearly all relevant manufacturing processes can now be simulated accurately on a computer and material properties can be calculated precisely in advance. This helps researchers to perform development processes more quickly and cost effectively and thus maintain and extend their development lead in competing internationally.

“As a results-oriented innovation partner to the Schott Business Units, we open up new business opportunities and defend our position with respect to our current businesses by developing new materials and technologies,” explains Dr. Martin Heming, head of Schott Research & Development.

Megatrends such as conserving energy and resources will rank among the main drivers of innovation in the decade to come: “Our research on materials is in great demand,” notes Schott materials expert Dr. Matthias Bockmeyer. The company is developing opportunities in strategic fields such as thin, high-strength glasses; storage of energy for electric mobility; as well as resource efficiency in the area of melting technology; ‘green’ glasses; and enabling technologies for the development of new and improved existing products and functionalities.

Over the past quarter of a century, the cooperation between researchers at the ‘glass laboratory’ and developers from the Schott Business Units has resulted in numerous innovations in the materials sector, applicationoriented solutions for products, and new production technologies. Some of the developments are now only history; however, many of them are still relevant and successful in the market today: r The PICVD process (Plasma Impulse Chemical Vapour Deposition) r Floatable glass-ceramic r Technologies for manufacturing

glass substrates for flat panel displays r Fibre-optic glasses r High-temperature refining processes r Lead- and barium-free crystal glass r Lead-free optical glasses r Coloured and transparent glass- ceramics r Sidelight fibres r Special glass tubes for backlights r Lead-free, eco-friendly glass

fibres (PURAVIS) r Glass-ceramics for electronic applications r Boron-free glass that offers high

physical and chemical resistance r High-strength glass for touchscreens

The appropriate investments form the basis for successful research.

Schott’s share of R&D expenditures in relation to sales was 4.3% in fiscal year 2012/13, which was slightly higher than in previous years. The global R&D network with its approximately 600 highly qualified employees also contributes to the company’s power of innovation. It covers everything from the field of applied research to product development. The network stretches from Mainz and its R&D branch that was founded in Duryea, USA in 1969, to the Business Units’ R&D units, as well as to application centres in China, South Korea and Japan.

The external network is also large and now includes more than 120 partners around the world. Cooperation with universities and institutes and extensive support for young professionals by hosting doctorate theses and diplomas are but two key aspects of this. The Otto Schott Research Award that has been awarded since 1991, many joint research projects, and regular expert panels are further examples of global networking at Schott. “Immense development potential for innovations lies within our research center,” notes Schott Research Fellow, Dr. Roland Langfeld. “We want to leverage this potential to continue to ensure a high new product rate of 30%”, he adds. r

*Marketing and Communication, Schott AG www.schott.com

z ­Experts use nanoprint technology to apply sophisticated surface structures to glass.

Continued>>

www.glass-international.com

 Schott uses equipment such as the TOF-SIMS

13 Glass International November 2014

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Interview

“Innovations are our biggest drivers of growth .”

Growth through innovations Dr. Hans-Joachim Konz* discusses how research is the driving force behind Schott, and the benefits of being a ‘connected company’.

What challenges does Schott research face today?

Innovations are our biggest drivers of growth. In light of the fierce competition we face, it is now more than ever the job of research to creatively speed up innovation processes and improve our market position and thus growth opportunities by developing new products and technologies.

www.glass-international.com

How does this work at Schott?

Our researchers do not sit isolated inside a think tank, but rather they are networkers and business partners of the operative units – in the sense of a ‘connected company’. This means that researchers and Business Units (BUs) constantly engage in intensive, critical exchanges on market trends, technology roadmaps, recommendations and evaluation of further developments.

Our aim is to involve the BUs as early as possible, and recognise and execute on particularly promising ideas. This means we must be close to the market and do research locally where the users are.

For this reason, we are also planning to engage in R&D activities in Asia in the medium term.

that have a considerably higher electrical storage density, as well as glass-aluminium seals for permanent insulation of high power lithium-ion batteries for electric vehicles. Huge potential lies in transparent and translucent ceramics that offer interesting options for imaging systems as new optical materials, as well as high-power LED and LD light sources.

We are currently further developing our Xensation Cover glass for use in mobile devices. We want to make it even more scratch resistant and improve the legibility of the display in the future.

Innovative laminates made of Xensation Cover and plastic foils allow for fire-

resistant, thin, light and scratch-resistant internal panes for use in passenger aircraft.

The main focus of our development activity is on continuously improving our melting technology, particularly when it comes to conserving energy and resources. Furthermore, we conduct applied fundamental research in areas where we are in a position to offer our customers genuine added value due to our scientific understanding of materials and processes. r

*Schott Board Member responsible for research, Schott, www.schott.com

 Data is recorded at the measurement technology laboratory in order to develop more advanced optical materials.

What innovations are you able to share with us today?

Glass-ceramics as dielectrics for capacitors

14 Glass International November 2014

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The 3rd generation of EME-NEND® chargers

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Company profile

Klaus Wolff reaps the benefits of the Thai container market Ahead of the Glassman Asia event in Thailand next year Greg Morris speaks to a glass industry veteran who, having spotted the potential of the Thai container market, set up a business in Bangkok.

B

z PGM’s partner factory in Bangkok.  Mr Klaus Wolff.

“affinity to glass.

I have a strong

I have spent more than half my life working with glass...

I am infected by the glass virus and it will stay with me for the rest of my life.

”

Glass affinity Mr Wolff’s love of glass stems from his father, who worked at an Ardagh plant in Germany. Mr Wolff used to join his father at work during his student summer holidays and also studied glass as a technician. His love of glass and the industry remains as strong as ever.

“I have a strong affinity to glass. I have spent more than half my life working with glass. The contacts I have made over all these years are like family to me. The glass business is like a big family.

I am infected by the glass virus and it will stay with me for the rest of my life.”

Mr Wolff still uses his contacts back in his German homeland and has a partnership with DPM Glasstechnic, which is based in southern Germany. DPM is a supplier of forming equipment to the Saint-Gobain Oberland/Verallia group.

DPM provides equipment for any work that PGM cannot do.

Continued>>

www.glass-international.com

ack in 2010 Klaus Wolff spotted a gap in the market. The glass industry veteran, who has spent 30 years working in the container glass industry, could see that Thailand was an up and coming market with plenty of potential for the glass industry.

As the South-East Asian country’s GPD grew, its citizens had an increased disposable income. This meant they had more money to spend on items including glass, such as drinks bottles. The country is a strong consumer of drinks, particularly energy drinks. The country of 67 million people also has a huge tourist industry, which would also increase the number of drinks bottles sold.

After doing his own market research, Mr Wolff left his role at German company Hartmann and Bender and set up a business, PGM Technic Co Ltd, based in Thailand’s capital, Bangkok.

“I had travelled to Thailand for my job since 2004 but it was nothing compared to living here and setting up a business.

“Being a foreigner in Thailand and running a successful business is a challenge. Every domestic customer asks the question: ‘What can this foreigner do that is better, when he is more expensive than our compatriots?’

“I had to prove and convince the customer with exceptional service and quality. I had to accept that the lifestyle is different here compared to Europe.

The more direct way of conducting business in Europe is different to how it is conducted in Thailand. I had to adapt.” Using his experience his company PGM-Technic grew.

The engineering company now has three staff, including Mr Wolff’s co-owner Chuda Thaneekul, and also contracts workers out. It provides a number of solutions to the glass industry including spare parts and variables for glass forming machines, mould holder inserts, take out assemblies, and replacement parts for mechanisms. The company can also make customised parts. Since PGM – which stands for Parts for Glass Making - formed in 2010 it has sold more than 400 items. Using Mr Wolff’s 30 years industry experience, it also provides consultation services.

17 Glass International November 2014

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Company profile

“Cambodia and Myanmar are beginning to open up their markets and Mr. Wolff believes that Thai glassmakers, as well as PGM, are in a good position to grow their businesses in these countries in future

”

years .

Most of PGM’s business is based in Thailand but Mr Wolff can see potential in other parts of the region. The South East Asian region has a population of approximately 600 million consumers. Countries in the region, such as Cambodia and Myanmar, are beginning to open up their markets and Mr Wolff believes that Thai glassmakers, as well as PGM, are in a good position to grow their businesses in these countries in future years.

In the years since his arrival he has seen much change in Thailand’s container glass industry, including the opening of five glass plants in four years.

Mr Wolff said that as well as the energy drinks business, beer has become a burgeoning market even though it remains an expensive drink.

As noted in the Thailand overview in the October issue of Glass International, Thailand currently has 17 container glass plants. The largest companies are Bangkok Glass, Thai Glass and Siam Glass but there are also a number of smaller companies including Wellgrow, Asia Pacific Glass and Lucky Glass. The majority of plants are all within striking distance of the capital, Bangkok, so are therefore fairly easily accessible.

According to Mr Wolff, the infrastructure in Thailand is particularly good to other countries in the region, which is important for setting up and running a business.

z MOC mould opening and closing mechanism.

The company is a member of the GermanThai Chamber of Commerce and has formed a partnership with its Thai partner, JEP, to train local people in the container glass industry. The plan is for apprentices to spend 40% of time at college and the remaining time with the company in order to improve their knowledge of the industry.

The aim is to run the scheme as close to the German education/apprentice system as possible.

It will be for two years, with each apprentice spending a certain amount of time in different segments of the industry. Ideally, each Thai apprentice will be trained up to German standards.

Future

z Inside the factory.

 Assembling of take out equipment.

In the past four years the company has established itself in the Thai market and now the company has secured a Malaysian partner.

Mr Wolff believes the time is right to expand further afield, and is interested in expanding into Indonesia and Taiwan.

He also hopes to have successfully set-up the apprentice scheme which, in five years time, will have educated many Thai youngsters about the wonderful possibilities of glass. r

PGM-Technic, Bangkok, Thailand www.pgm-technic.com

www.glass-international.com

Strengths PGM’s strength is its proximity to its customers.

When compared to its competitors, PGM is practically on the doorstep of its customers and sees them every month, compared to sales agents from competitor companies who have to fly in from overseas.

Mr Wolff said: “To run a successful business you have to see your customers regularly. We can enter as a Thai company much easier than a foreign company. We are flexible and close to our customers. If customers come to me today I can be there by the afternoon. We are also an independent company so can switch our plans quickly.”

18 Glass International November 2014

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Raw materials

A global soda ash outlook Marguerite Morrin* analyses the global soda ash market and reports on how China has become both the largest producer and the largest consumer of soda ash in recent years.

A

ccording to IHS Chemical, prior to the recent recession global soda ash demand had been increasing at a strong rate, averaging 4% to 5% a year.

At the same time, global operating rates had elevated and peaked at almost 90%, which is close to the industry maximum.

Meanwhile, a combination of weak demand coupled with a net increase in capacity in 2009 caused global soda ash operating rates to drop below 80%, likely the lowest rate the industry has ever seen.

Soda ash demand is dominated by glass production, which accounts for half of the world total. Flat glass is the single biggest application and has driven soda ash demand during the last 10 years.

Historically, container glass was the biggest end use of soda ash.

In 2014, according to IHS Chemical forecasts, flat glass will represent about a quarter of world soda ash demand and container glass will follow with 19% of demand, suggesting that flat glass will continue to drive demand during the next decade (Fig 1).

www.glass-international.com

Cash cost comparison According to the 2014 IHS Chemical Soda Ash World Analysis, the global operating rate for soda ash production is not likely to return to the 2008 prerecession production levels over the next five years.

The main driver keeping global production rates low is China’s ongoing capacity growth, which persists despite an existing capacity surplus in the country.

Most importantly, China is a high-cost location for soda ash production, and much of the excess capacity is, in effect, stranded.

If you consider global operating rates that exclude Chinese production, it yields a much different picture. During the forecast period, the world operating rates (excluding China) are forecast to be higher than previous peak levels. In fact, going forward, markets could be quite tight depending on the strength of

economic growth, as well as the timing of the large expansions in Turkey.

World production imbalances Prior to 2003 the USA used to be the single largest soda ash producing country in the world. Today, China is not only the biggest producer, but also the largest consumer in the world. Since 2000, soda ash demand in China has grown 9% annually. According to IHS Chemical, in 2000, China accounted for 19% of global soda ash demand, and this year, it is expected to reach 43% of global demand.

Like China, India has a population of more than a billion people. The soda ash market in India is undeveloped and the per capita demand extremely low.

India represents only 5% of world soda ash demand, highlighting the longterm growth potential for the country.

According to IHS Chemical forecasts, positive soda ash demand growth in India is expected, but not on the same scale as in China. IHS Chemical also expects that, due to high production costs in India and its geographical constraints, India is likely to be more reliant on imports than China, which is mostly self-sufficient.

Both the USA and Western Europe are mature soda ash markets that share some similarities, but also differences dictated by different economies. For US producers’ exports are the engine of growth, while Alumina & metals/mining 6%

Western Europe is becoming increasingly reliant on imports. Therefore, while US production has continued to grow in recent years, production in Western Europe has declined.

Largest producers Solvay is the largest soda ash producer in the world and has production in the USA, Western Europe, Central Europe and Africa. Tata Chemicals is the secondlargest soda ash producer globally. Tata is one of the largest producers in India and also has capacities in the USA, Western Europe and Africa.

FMC, which is currently for sale, is the largest producer in the USA and number three globally.

Chinese producers also feature in the global ranking and include Shandong Haihua and Sanyou Chemical. The Ciner group, with its natural soda ash reserves in Turkey, is expected to join the global top-10 ranking by 2019, if its projects come on stream as scheduled.

Capacity developments According to 2014 IHS Chemical World Soda Ash Analysis, during 2009 to 2014, there was a net increase of 8.5 million metric tons (MMT) (expansions minus closures) in world soda ash capacity.

Despite the net capacity additions in soda ash capacity, a substantial amount Continued>> Pulp & paper 1%

Alumina & metals/mining STPP & soaps/detergents

STPP & soaps/detergents 16%

Others 19%

Other glass Chemicals 8%

Container glass

Other glass 6%

Flat glass Flat glass 25%

Container glass 19%

Chemicals

Demand=55.4 million metric tonnes.

î Ł Fig 1. 2014 world soda ash

Source IHS

demand.

Others

20 Glass International November 2014

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Raw materials

z Fig 2. Curt E. Siverling, President Specialty Products Division, Church & Dwight, presents a paper at the recent IHS World Soda Ash Conference held in Shanghai.

Capacity closures However, despite the capacity closures, according to IHS Chemical, an additional 12MMT of new capacity is scheduled to be built during 2014 to 2019. Most of the new capacity is expected to be added in China, followed by an additional 3.0MMT in Turkey, and just 180,000 metric tons in the USA – the lowest-cost producer in the world.

Historically, the US was the prime location for capacity investments. This changed during the late 1990s, when the focus moved to China. According to IHS Chemical, since 1999, China has added more than 24MMT of capacity, primarily to support domestic demand. During the same period, US total capacity declined by more than 1.3MMT. China’s efforts to become self-sufficient in soda ash supply resulted in the country becoming the world’s largest producer in 2003.

Interest in capital investments in the USA has resurfaced in recent years.

However, while idled capacity was brought back into production in 2007 and 2008, the recession subsequently undermined these initiatives, and any capacity that was restarted was once again idled in 2009. The largest US producer, FMC, did re-launch idled capacity in Granger, Wyoming, in mid-2011, and was hoping for board approval to bring back the rest of the idled capacity.

However, in September 2014, FMC said it planned to sell its alkali business, which is mainly comprised of soda ash.

Thus, any plans regarding Granger will be in the hands of the facility’s new owner.

Solvay is debottlenecking capacity in Wyoming to offset the closure of capacity in Portugal in 2014. According to IHS, other future expansions in the USA are likely.

Technological production Soda ash can be produced by two different methods: Synthetically or from natural mineral resources. In 2014, synthetic capacity accounted for 75% of the world total and natural capacity the remaining 25%. Trona is the primary mineral mined to produce natural soda ash, and the largest source of natural reserves is located in the US state of Wyoming.

However, the most recent natural soda ash development is in Beypazari, Turkey.

In 2009, a 1MMT per year trona-based plant came onstream at this location, the first trona-based unit in the Middle East.

Another 3MMT of trona-based capacity is expected to come on-stream in Turkey in the coming years.

The most common synthetic process is the Solvay (ammonia soda) process.

Synthetic technology, including both the Solvay and Hou processes, dominate in China. The Hou process was developed in China, but a few other plants operate elsewhere that use this process.

Ammonium chloride, a by-product of the Hou process, has a key application as a nitrogenous fertiliser.

A key difference between natural and synthetic soda ash production is the production costs. Natural soda ash production is considerably cheaper than synthetic production. The extent of the natural soda ash’s cost advantage renders synthetic soda ash production uncompetitive if suitable natural ash

deposits are in close proximity to major soda ash markets.

However, the world’s major commercial deposits of natural soda ash tend to be located in remote regions. Transportation, therefore, is a major component of the overall production costs. The sharp increase in crude oil prices since 2005 caused the difference between natural and synthetic soda ash production costs to widen. This change has increased the relative competitiveness of natural over synthetic production.

Tradeflow shifts The huge cost differences between natural and synthetic soda ash production have caused regional imbalances between supply and demand. As a result, large volumes of soda ash are shipped around the world. According to IHS Chemical, total trade in 2014, including what is moved intra-regionally, is forecast to reach approximately 13.7MMT, which accounts for nearly one-quarter of the soda ash to be consumed in another location.

Among all countries, the USA is the largest exporter in the world, followed

by China, Bulgaria and Turkey. Turkey’s aggressive capacity growth exceeds the demands of its domestic market and will continue to be a competitive element in the international market.

IHS Chemical has just published its 2015 World Soda Ash Analysis.

The new study provides clients with a detailed world, regional and countryby-country soda ash supply/demand outlook, strategic issues and emerging trends over a 16-year period (five-year history, base year, ten-year forecast). For information on the study please contact Marguerite Morrin. r

*Senior Director, IHS Chemical marguerite.morrin@ihs.com

www.glass-international.com

of capacity was closed. In 2009, the new low-cost capacity added in Turkey came on stream at a time when global demand collapsed, and had a direct impact on the European market. According to IHS Chemical, in 2009, approximately 1.1MMT of capacity was closed in Europe, and additional plant closures continued outside of Europe as well. IHS Chemical forecasts that during 2013 to 2015, an additional 1.7MMT of capacity is set to be taken out of the market.

21 Glass International November 2014

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Raw materials

Ceramic filters and the development of hot gas filtration Brightcross (a Unifrax company since 2010) has been supplying ceramic filter candles for hot gas filtration applications for nearly 20 years. Jason Weir* describes a recent case study and outlines how the company has developed three-metre filter candles.

 Unifrax ceramic filter candles.

www.glass-international.com

I

n 2013, emissions monitoring was undertaken on a gasification system processing municipal solid waste (MSW). Gasification is a well-established process dating from the early 1800s when it was first used to produce town gas from coal. The gasification system here is integrated with a high temperature ceramic air filter, using 1.25 metre long (60mm OD) Brightcross ceramic filter candles with a sodium bicarbonate (NaHCO3) dry sorbent injection system.

The gasification of the MSW produces a combustible synthetic gas (‘syngas’ – typically containing a mix of CO, CO2, H2, CH4 & H2O) which is subsequently combusted in a combustion chamber.

The hot exhaust gases from the process are extracted via an induced draft (ID) fan. These are cooled from ≈900oC to >400oC at the filter inlet. By maintaining the temperature at above 400oC, the de-novo synthesis of dioxins/furans is prevented.

The de-novo synthesis mechanism is the main one by which dioxins form in the flue gases and involves the formation of dioxins from organic and inorganic compounds (known as ‘precursors’) at temperatures between 200-400oC (known as the de-novo temperature ‘window’). The filter operates at temperatures above 400oC and by removing these precursors (such as carbon in fly ash and metal chlorides) as particulate at such temperatures, the Continued>>

23 Glass International November 2014

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Raw materials

MSW Gasification & syngas combustion

Filter to ID fan ducting - clean gas

Process to filter ducting - combustion gas >400°C Filter

Fan to stack ducting Fan

SB injection system Filter residue discharge

Stack

www.glass-international.com

z Fig 1: Process diagram of a syngas filtration system.

main mechanism by which dioxins are formed is prevented. Dioxins and furans are poly-chlorinated compounds and it has been shown that major reduction of dioxin/furan formation can be brought about with upstream sorbent injection for hydrogen chloride (HCl). The filter incorporates sodium bicarbonate injection to neutralise acid gases such as HCl, HF & SO2.

Fig 1 provides a representation of the process. It shows that the combustion gases are cooled through simple radiant heat loss through a suitable length of ducting to achieve the required temperature loss from ≈900oC to >400oC at the filter inlet. However, at other facilities operating the same gasification and Unifrax filtration technology principle, this temperature loss is achieved by passing the gases through a waste heat boiler. This generates steam that is fed to a steam turbine in order to generate electricity, or the steam is passed through a heat exchanger to heat water which can then be pumped to any available district heating networks.

a fully reactive coating on the surface of the filter candles, thus maximising contact time between the acid gases and the sorbent particles due to the necessity of the incoming gases to pass through the filter cake that contains the sorbent reagent. The injection of the sorbent as a ‘secondary dust’ also aids this filtration as it enables the particulate to agglomerate.

This allows sub-micron particulate to be more easily filtered.

Unifrax ceramic filters are almost 100% efficient and allow particulate down to 0.1 micron dia. to be filtered.

Typically, through waste composition analysis (i.e. through knowledge of waste chlorine%, fluorine% and sulphur%) estimates of the HCl, HF and SO2 concentrations can be calculated, and when coupled with the required emission limit values (ELVs) the required sodium bicarbonate additions can be determined. This is further enhanced through pre-abatement flue gas sampling for HCl, HF & SO2. Addition rates are based on the following reactions given below (and a stoichiometric of 1 – 1.5):

Combined heat and power

NaHCO3 + HCl -> NaCl + H2O + CO2 2NaHCO3 + SO2 + 1/2 O2 -> Na2SO4 + 2CO2 + H2O NaHCO3 + HF -----> NaF + H2O + CO2

Typically, a tapping on the steam turbine generator is made to provide steam at a suitable pressure for such a purpose – these systems are known as CHP (combined heat and power) systems. The interest and development of these systems in the UK is increasing substantially, particularly as gasification technologies can receive government support under the Renewables Obligation Directive through the receipt of Renewable Obligation Credits.

To maximise the energy recovery in such systems, the combustion gases are cooled to lower temperatures (≈200oC) and as such will have passed through the de-novo temperature ‘window’ as described above. As such, powdered activated carbon (PAC) is added along with the sodium bicarbonate (SB) to adsorb dioxins/furans. By injecting directly into the filter, the sorbents create

Addition rates Furthermore, on many systems the addition rates are linked to continuous emission monitors (CEMs) that measure the acid gas concentrations and control the addition rates accordingly, thus maximising efficient use of the sorbent (and enabling a financial saving benefit) and optimising the ability of the system to meet the required ELVs. For example, the system mentioned here has the sorbent injection system coupled controlled to an HCl analyser located in the stack.

Recent emissions testing from the above facility showed that the ELVs for all pollutants regulated under the Industrial Emissions Directive (Chapter

IV and Annex VI) were being met and therefore demonstrated the efficiency of the filtration system employing Unifrax filtration technology.

Unifrax is now involved in the development of filtration systems incorporating the ceramic filter candles to filter the syngas rather than the combustion gases as is the case above.

The syngas can be cleaned using wet/ chemical scrubbers to remove particulate, HCl, HF, H2S and NH3. However, wastewater treatment from the scrubbers can be expensive – especially with regards to the removal of metals. By installing a ceramic filter prior to the wet scrubber, particulate (and thus metals in particulate form) can be removed beforehand thus reducing this expense. Acid gases such as HCl and HF can also be removed using a dry sorbent system as described above.

This also reduces the expense of having to remove these at the wet scrubber which can now be used to scrub H2S and NH3. By producing a clean syngas, the syngas can be fed to a gas engine or a gas turbine, increasing the efficiency of electricity production when compared to the waste heat boiler utilising combustion gases and the steam turbine route as described previously.

These systems are being developed with Unifrax’s three-metre candles in mind.

Space constraints are often a real concern for such developments, particularly because of the size and amount of equipment involved.

Therefore, filtration systems employing three-metre candles can reduce the required footprint when compared to systems employing the shorter/ smaller diameter candles. Reducing the number of candles in a three-metre filter compared to a filter employing smaller candles but with the equivalent surface area also enables the cleaning systems to be simplified by reducing the number of reverse jet ‘blast’ valves.

Unifrax has been at the forefront of hot gas filtration for nearly 20 years and its success has enabled the company to help customers achieve their objectives – not just in terms of being able to meet their environmental responsibilities, but also in terms of providing them with equipment capable of allowing them to develop their own technologies to achieve greater financial reward. r

*Hot Gas Filter Product Manager, Unifrax, St. Helens, UK. www.unifrax.com

24 Glass International November 2014

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Raw materials

The use of furnace slag in glass Frank Lesters* discusses handling techniques for blast furnace slag, and how this material can be used as a glass melting and conditioning aid.

T

www.glass-international.com

he history of slag goes back to the days of the Romans when they melted minerals to make metal armament. A mix of mineral impurities floated to the top of the melted ores that became known as slag.

The first use of slag, other than stockpiling as a waste, was to use it as an aggregate between the quartz blocks that make up the Appian Way in Italy. It remains there until today, doing its job of maintaining stability to the road.

As years passed and a more sophisticated world evolved, slag became a material of choice for road building, concrete and asphalt aggregate, insulation raw material, brick paver base and eventually a raw material ingredient for cement and glass.

A number of manufacturing techniques became available that changed the structure of the slag for its different uses when flowing from the blast furnace where iron is made, to supply the steelmaking process in an integrated steel mill.

Handling techniques For years, the handling technique for blast furnace slag was to have it flow as a liquid at 2500 degrees into a walled pit where it was later cooled with water sprays and catalogued as blast furnace air cooled slag.

Another technique was to take the liquid flow and have it pass over a water cooled drum that mechanically spun, causing the liquid splash to cool in the air and create a light weight pellet catalogued as blast furnace pelletised slag.

Another technique was to granulate slag by having it pass into a blow box in which water at 10 times the slag volume instantly crystallises the slag into a sandlike material (Fig. 1).

This instant quenching stabilises the sulphur and functions to agglomerate alumina and other contaminants with iron particles, thus making it a more stable product from which to assist in its removal by magnetic separation when

z Fig 1. Slag in a form to be introduced into the glass furnace.

used as a glass conditioning aid. This method of handling slag is categorised as blast furnace granulated slag.

The techniques of slag granulation and dewatering provide a material best utilised throughout the world for its cementitious properties, categorised as blast furnace ground granulated cement.

Glass melting In most of the developed world all blast furnace slag is committed to cement. In North America there are only five blast furnaces equipped to make granulated slag: Two in Canada, and three in the USA. For the past 40 plus years this same blast furnace granulated slag material has been used in England, Luxembourg, Czech Republic, Italy, Spain and Japan as a glass melting and conditioning aid.

At this time only one blast furnace in the USA uses a patented process to make Continued>>

z Fig 2. Technologically advanced rare earth magnets.

26 Glass International November 2014

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Raw materials

CaO

(36-42%) Sio2

(34-40%)

AL 203

(6-10%)

(9-13%)

MgO

Suphur (0.8-1.5%)

z Table 1 Manufactured blast furnace granulated slag composition range. the glass additive. Attempts at using air cooled slag for the same purpose in North America have created a number of issues with contaminants in the slag, in many cases making it a material not of choice for glassmakers.

The blast furnace granulated slag requires further processing before it can be utilised as a glass conditioning aid. The slag is tested as manufactured and only casts that meet stringent raw material specifications are stockpiled.

This is then introduced into a processing plant in which the slag is sized, dried, magnetically separated, resized, crushed and magnetically separated again with heat resistant technologically-advanced rare earth magnets (Fig. 2).

These magnets remove magnetic and semi-magnetic contaminants, controlling the iron and other contaminants to a consistent and acceptable level. The final product is sized specifically to minimise dust, without a flammable dust suppressant spray, to a US #25 X #150 mesh gradation.

A technique of testing the final product is unique and requires a fully equipped laboratory to provide a consistent approach to minimising contaminants in the final product.

Statistical Process Control (SPC) methods play a key role in identifying and eliminating sources of unacceptable variations in the manufacturing and all other phases of production.

Emissions reduction The main purpose of using manufactured blast furnace granulated slag in a glass furnace is for production and quality issues which can be addressed through its use as a raw material in the manufacture of soda lime glass.

These issues include improvements in both melting and refining. Reductions in furnace emissions and energy consumption levels below those of standard soda lime glass batch formulation may also be realised.

Slag is recognised as a melting and conditioning aid in soda lime glass as it is more effective than a carbon/sulphate system, especially at high cullet levels or high furnace pull rates. Salt cake levels can be reduced, thus SO2 air emissions can be lessened by formulating equivalent redox batches using manufactured blast furnace granulated slag.

Decreased energy consumption results from improved melting and fining times, which has a positive improvement in the reduction of NOx and CO2 particulate air emissions due to the pre-calcined manufactured blast furnace granulated slag.

As well as this, manufactured blast furnace granulated slag used as a glass melting and conditioning aid can qualify as a recycled material, thus allowing for application for Leeds Credits.

This not only allows the glass industry to reduce furnace emissions, but also promotes recycling and the reduction of virgin raw materials required to produce glass (Table 1). r

*Mineral Recycling Consultant, FeHog LLC, Chicago, USA flesters@fehogllc.com www.fehogllc.com Glass International November 2014

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British Glass

Jenni Staves British Glass

Can the glass industry capitalise on recovered heat?

Jenni Staves* discusses the issue of recovering waste heat in the UK and how this could benefit the glass industry. British Glass proposes solutions to ensure industry capitalises on the opportunity of utilising waste heat.

A

round half of the waste heat generated in the glass manufacturing process is not being recovered. Recovering it would cut costs for the industry, reduce carbon emissions and could be used to generate electricity or provide district heating. Currently the process is not economically viable, but classifying the waste heat as renewable would enable this to happen under existing incentives.

As we know, the large heat exchangers, through which the exhaust gases from the furnace pass, can recover and reuse 50% of the heat from these gases. However, it is not possible to recover all the heat with this technology, therefore, exhaust gases are being unavoidably emitted into the atmosphere without being utilised.

There are ways to recover this remaining heat and use it for heating factories and homes or local businesses via heat networks; heating and melting raw materials ; and generating electricity

www.glass-international.com

Recovered heat in numbers A number of glass manufacturers and companies in the supply chain are currently working on projects to recover heat. It is an energy-intensive sector and they want to further improve energy efficiency in order to reduce their fuel bills – here are some pertinent statistics: r Large glass sites could save more than one third of the electricity used on site every day if they generated electricity with heat that is currently wasted. r 370,000MWh of energy could be

saved each year by recovering heat from glass factories – this is equivalent to heating 20,000 homes in the UK. This saves 200,000 tonnes of CO2. r If factories become more energy self-sufficient there would be less demand for energy from the grid, and therefore the potential for better fuel security in the UK.

Why isn’t it happening?

So far, the high capital cost of heat recovery technologies has put this beyond the reach of UK glass companies.

There are a number of governmental/EU incentive schemes designed to encourage energy efficiency and low carbon energy generation. Unfortunately, the reality is that none of these incentive schemes work in practice as they do not consider recovered heat as an eligible energy.

The focus of government has been on ‘renewable’ energy sources and has discounted recovered heat as it is not technically ‘renewable’ in the truest sense, yet it achieves the same objectives in reducing carbon dioxide and increasing energy efficiency. Recovering heat is actually more beneficial to the environment than using renewable fuels because it makes use of something which is currently wasted – it does not need any additions such as wood chips. It seems clear that we should be utilising this capability to its full potential.

It is also clear that the government understands the potential savings that could be made from harnessing recovered

heat, as shown through the recent 2013 DECC (Department of Energy and Climate Change) report ‘The potential for recovering and using surplus heat from industry’. This study estimates that savings of up to 11TWh, and 3MtCO2 per year could be achieved through reusing waste heat across the whole industrial sector, equivalent to heating more than 600,000 homes in the UK. As Vince Cable, Secretary of State for Business, Innovation and Skills, has said: “Access to secure, affordable and clean energy is a vital building block for the future of the UK’s economy.” This definition can be applied directly to the use of recovered heat.

Next Steps Currently, there is a clear missing link between potential decarbonisation (through the use of recovered heat) and government incentives. A new incentive for recovered heat should be developed and implemented for the many industrial sectors that could benefit.

In the short term, solutions such as Regional Funding could be used to implement waste heat recovery projects and kick-start the investment in low carbon, energy generation.

British Glass is currently engaging with the Government at all levels to lobby on this issue, with the ultimate aim of influencing policy development. r

*Environmental Manager at British Glass Website: www.britglass.org.uk

28 Glass International November 2014

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History

Prof. John Parker Turner Museum of Glass and ICG

Adding sparkle to life Prof. Parker discusses the history of aventurines, the coloured glass often used as artificial gemstones.

www.glass-international.com

A

venturine is a type of coloured glass used as artificial gemstones, containing distinct reflective crystals, mostly copper or chromic oxide, up to 1mm in size. Forming often orients these crystals approximately parallel, enhancing the optical effect. The name comes from the French term aventure, which hints at adventure but more specifically to chance, and is probably borrowed in turn from the equivalent Italian word avventurino. Unusually its application to a man-made material pre-dates its use in mineralogy where it has been adopted for crystals of quartz containing platelets of sheet minerals such as mica. Mineralogists also describe the way such minerals shimmer as aventurescence. Other names are stellaria because of the starlight twinkle they display and monkstone, the latter linking to folklore that the origin of the glass is associated with a brotherhood of monks.

The Corning Museum of Glass online Glass Dictionary attributes its creation to the 15th century although the earliest confirmed production of aventurines, by the Miotti family in Italy, is in 1626. The Doge gave the Miotti family exclusive rights to its manufacture, which lasted many years, perhaps even until the 19th century. Some suggest it was originally discovered accidentally, possibly much earlier, when a worker dropped copper filings into hot glass, either accidentally or while pursuing the alchemist’s dreams of creating gold. This would require the copper to melt, disperse and recrystallise, which is inconsistent with descriptions of the manufacturing route. Literature suggests that not until the 19th century did French glassmakers discover, or buy at inflated prices, the secrets of its manufacture. Now production is largely limited to the jewellery trade.

To grow well-formed crystals with the simple triangular, hexagonal and cubic shapes found in copper aventurines,

requires shallow concentration gradients i.e. fast diffusion rates. Otherwise random instabilities at the growing crystal surfaces generate dendrites (tree-like structures). Large crystals are also favoured by low nucleation rates, a condition pertaining just below the temperature at which the copper starts to precipitate, and long processing times for growth/coarsening. Finally high copper concentrations raise the temperature at which such processes start and so encourage diffusion. Similar conditions are sometimes reported in dead pockets of glass near AZS refractories where high ZrO2 concentrations build up and zircon tablets can precipitate.

Glass recipe The Miotti family melted under reducing conditions a glass recipe rich in copper salts and held the resulting hot melt in a sealed air-free environment for ‘a long period’ before cooling it to room temperature. Iron filings added to the hot melt aided reduction. The glass block, particularly its centre, revealed the required product when broken open.

The glassy phase in aventurine is also usually ruby red, indicating that not all the copper precipitates during the high temperature hold but sufficient is left to form a copper ruby during cooling; this is consistent with a relatively high holding temperature. Hand drawn pictures of the microstructure by Washington in 1894 indicate that small dendrites can grow from the corners of the regularly shaped lozenges of copper, probably because the final cooling step causes the melt to become supersaturated with copper again. Surprisingly in some cases the excess copper in solution colours the base glass blue.

A copycat product in the 19th century was called goldstone and was said to sell at up to $15 dollars, even though the raw materials needed to make it amounted

to no more than 25 cents. Perhaps the size of the mark-up indicates the difficulty of manufacture as much as the attractiveness of the product. Cobalt and manganese have both been substituted for copper. ‘Goldstones’ can be polished and re-worked but temperatures must be carefully controlled and kept below the melting point of the precipitated metal. Of the three, copper has the lowest melting point of 1084°C. The term aventurine has also been applied to glasses containing chromic oxide. Chromic oxide forms hexagonal crystals with a much greater refractive index than the surrounding glass and hence a high reflectivity. These crystals are suspended in a strongly green coloured glass matrix, enhancing the product’s attraction. A batch recipe of these glasses includes potassium dichromate at levels suggesting chromic oxide concentrations near the solubility limit.

Copper aventurines have been used to make Lutz marbles, prized for their beauty and rarity and the pinnacle of any marble collection. Now other aventurines are on the market including blue ones based on cobalt. Ceramics manufacturers have also created similar effects in glazes, making red aventurines by doping with high concentrations of hematite (Fe2O3), which precipitates as hexagonal tablets on cooling.

Those selling these artificial gemstones claim that wearing red aventurines confers energy and vitality, blue apparently contributes to learning and communication while greens link to growth and abundance. No wonder the original Venetian manufacturers were keen to maintain their monopoly! r

Bibliography: Weyl, Coloured Glasses; SGT Wikipedia on Aventurine. http://www. mindat.org/article.php/112/%22Goldstone%22+-+Aventurine+Glass by Daniel E Russell

30 Glass International November 2014

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Furnaces

Old solutions to a new problem Neil Simpson* discusses furnace optical temperature surveys and profiles.

www.glass-international.com

I

t is becoming evident that many of the glass furnaces which had environmental abatement equipment installed at last rebuild are now coming to the twilight of their operating lives.

In both air and oxy-fuel furnaces as the furnaces deteriorate, it is often the abatement devices such as an Electorstatic Precipitator (EP) which risk becoming the bottleneck in future.

Most abatement devices are sized on actual volumetric flow and therefore limited by the temperature and velocity.

Through an increase in the performance of refractories, combustion systems and market demands, furnaces are tending to be pushed beyond their original ‘boiler plate capacity’.

In the short-term this is beneficial from a furnace performance and financial return. However in future it will increasingly become a problem, as in addition to increased pull there is then an increase to extend the furnace campaign and delay the re-build.

As most furnaces age the refractories decay and there are increases in heat loss through the superstructure of both the furnace and flue system. In the furnace you have to add more fuel plus oxidant, however, as products of combustion these have to go to the abatement device.

On air fuel furnaces as regenerators age and decay there is an inevitable reduction in efficiency, resulting in a reduction in air preheat but increase in flue gas temperature after the reversal valves.

The reduction in regenerator efficiency and lower air preheat once again requires more energy, oxidant and therefore more mass of flue gas.

With higher mass flow-rate and higher temperature according to the gas laws, there has to be an increase in the product of pressure and volume. Since there is not much opportunity to operate as a pressure vessel there is an inevitable increase in actual volume of the products of combustion entering the abatement device. Building a by-pass around the regenerator will risk further increase in flue gas temperatures. In some cases the

ID fan will be unable to maintain the flow and in others it will be an emissions limit.

With a clean sheet of paper at a re-build or repair there is an opportunity to have improved insulation, larger or more efficient regenerators, larger abatement device, larger capacity ID fan, and additional heat recovery including batch and cullet preheating.

However, this is not always technically practical or financially feasible with an aging furnace in its last quartile. Oxygen, oxy-gas boosting and electric boosting in isolation or combination may be solutions with increased operating costs.

Traditionally oxy fuel furnaces often use induced or forced air to quench and cool the products of combustion. For many years the furnace operation has been relatively easy and forgiving. However, as oxy furnaces reach the end of their life the refractories are saturated and there is less flexibility to change either operating temperatures or pressures.

Increasingly there is now the need to go back to the old methods of regularly checking the exhaust port gas composition. Through time even the best instruments drift. Just because the computer states the furnace is running with 5% excess oxidant this may not be the reality.

Furnace inspection During furnace inspections (typically to establish pull/quality or emission issues) I have identified solutions to many problems through measurement of

furnace optical, port flue gas analysis and pressure tests.

On one new end-fired regenerative furnace we identified sub 800mg on one side and over double on the other.

Through visual observations it transpired the furnace was running positive on one side and negative on the other. The problem was that the pressure tapping on one side of the furnace fed the positive side of the pressure instrument, and the other side fed the negative. It was basically a plumbing issue! The instrument thought the furnace was positive on both reversals but clearly was not.

On one oxy furnace the overall oxygengas ratio was a combination of over 30 pressure and temperatures sensors and gave a single display of 2.1 oxygen gas ratio. Unfortunately we identified over 10% CO in the exhaust port which was an explanation for the furnace refractory damage. Everything looked good from the air conditioned control room!

On another furnace, we measured 33% oxygen in the stack which explained the high oxygen cost and poor fuel efficiency.

On an end-fired furnace I was asked to look to see if oxygen boosting would solve a melting problem. The batch line was well back and one of the best mirrors I had ever seen on a container furnace.

An optical survey identified the hot spot was at 25% of the furnace length.

We removed an under-port burner, lengthened the flames and the problem was solved.

Continued>>

1600 1580 1560

î ś Optical thermal profile of an endport furnace.

1540 1520

LHS Optics

1500

RHS Optics

1480 1460 1440 0

20

40

50

80

100

32 Glass International November 2014

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Furnaces

On more than one occasion I have identified under-port brackets which are at the limits of the slots as would be expected prior to and during heat-up. The burners and brackets were never set up correctly during commissioning.

An incorrectly adjusted bracket will risk air ingress and potential for increase in NOx and reduction in furnace efficiency. Higher heat transfer typically results in lower NOx, so use the NOx to optimise the combustion.

Timing The timing of making furnace observations is important; you ideally want to talk with two different shift operators to get their perspectives, as often they may know the answer but don’t realise it.

It is sometimes best to take measurements after normal hours. Refractory and pressure issues can often be seen better after dark. I have only once in my career had to fly at less than eight hours notice to investigate a problem. Due to the urgency of the call I thought it prudent to undertake the furnace inspection that night. Just before midnight it was obvious that the furnace was visibly running negative yet the pressure transmitter indicated it was positive. The sample tube was not full of condensate although I have seen this previously.

The pressure sensor was in the basement and there was no static reference point. It transpired that the furnace building ran at a different pressure at night than during the day when everyone else had investigated the problem. The problem was solved by bringing the static pressure point back to the same vertical position as the furnace tapping.

The message is to regularly take port flue gas measurements, optical temperature proflle measurements and confirm positive pressure. It is important to take measurements when everything is working well, since there is then a reference point to compare to if there is a problem. As a minimum it can eliminate a source of problems. Most batch and furnace managers spend more time troubleshooting and filling in spreadsheets than having time for weekly inspections. Consider training or having operators trained by others to do the measurements.

The measurements can be taken at night when there are less deliveries to worry about. Every operator is the specialist on their own furnaces. They see them every day and know their ‘personalities’. Through time there are small subtle changes that are not always recognised. If part of a large organisation there may be opportunities from personnel from sister plants to perform audits and establish best operating practice. For companies with fewer furnaces, one option is to have someone independent to come in and review very three-four months.

The actual cost is less than a couple of tonnes typically which are normally quickly recovered.

Annealing LEHRS

Hot-end coating • Thermal shock test systems • Belt and spindles tempering lines • Hot end coating hoods • Cold end coating spraying • Annealing and decorating lehrs • Chemical tempering ovens • Roller annealing lehrs • Mold pre-heating kilns • Stackers + cross conveyors • Scraper conveyors • Cullet crushers

Cold-end Coating

Summary If you aren’t already, start taking regular furnace optical temperature surveys and profiles. Check for positive pressure at all peep sites. Check target wall %O2, CO and NO. Clean and service burners before they need it. Train operators in order to be able to do these tasks. Know the limits of the abatement devices and have a strategy in place that limits the need to lower glass pull. When all else fails, get someone in to help. 

Neil G Simpson, Simpson Combustion and Energy Ltd Email neilsimpsonfsgt@btinternet.com www.simpsoncombustionandenergy.com Glass International November 2014

neil simpson.indd 2

Contact us now: vidromecanica@vidromecanica.com www.vidromecanica.com Tel: +351 244 555 060 11/6/14 10:58 AM

Furnaces

Glass furnaces: Combined energy recovery and pollution abatement Ulisse Armeni* discusses how to combine energy recovery from waste heat and pollution abatement into one system that achieves two targets.

www.glass-international.com

I

t is internationally well known that the glass industry is energy intensive with a large pollution level.

Energy prices are rapidly increasing in the US and other industrialised countries, rising by 37% in the three years since October 2010.

As well as this, more carbon dioxide (CO2) was emitted into the atmosphere between 2012 and 2013 than in any other year since 1984, putting humans on the fast track toward irreversible global warming, according to the United Nation’s weather agency in a report released in September this year.

Technological and non-technological barriers have negatively influenced the introduction of energy efficient systems able to recover the heat from process effluents to produce power in energy intensive industries.

Power generated from the flue gases, currently considered as waste, could drastically reduce, and in certain cases eliminate, the electric power spent to abate the pollution, helping to mitigate CO2 emissions and other environmental troubles. On the basis of these evaluations, in January 2010 the first European project concerning the mapping of ‘waste heat recovery in energy intensive industries’ started at a pilot plant, co-financed by a European Commission grant.

Largely anticipating today’s focus on the Energy and Environmental solutions needed to be competitive in the glass world, BDF Industries Group established

its Energy Division at the end of 2008.

Thus, BDF introduced its customers, for the first time, to the concepts of energy saving, energy efficiency and pollution abatement, by its own designed enthalpy recovery and high performances filtration modules.

The targets have been clearly focused and followed by in-depth technical investigations, audits, monitoring and evaluations conducted directly on glass factory sites.

Road map Glass factories’ heat recovery and filtration projects will be characterised and pre-assigned in accordance with the following road map: Factory location:

Continent, country, city, geographical position, altitude, climate (°C, RH%), seaside area, mountain area, abundance or lack of water.

Continued>>

Oxy-fuel furnace 4.000Nm3/h 800°C

Oxy-fuel furnace 2.800Nm3/h 800°C

WGHRU 2

WGHRU 1

Heat dissipater

Bag filter

Thermal oil 160-310°C ORC

Cooling water 30-39°C

Cooling tower

 Fig. 1 Energy recovery plant in normal operation, as discussed in case study one.

34 Glass International November 2014

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Furnaces

60717 Nm3/h 1709 PPM-SO2 450 °C (5) mbar-pressure Plant

Duct DP Mbar 2

Ceramic filter + DeNOx

Compressed Air 50 Nm3/h pulse-jet cleaning

Dp Desox mbar =25 60717 Nm3/h Scrubber elevation 1709 PPM-SO2 H (m)=10 450 °C -34 mbar-pressure -59 mbar Scrubber SOx removal Duct DP Mbar 2

60717 Nm3/h 1709 PPM-SO2 450 °C -32 mbar-pressure WGHRU

Fan

60717 Nm3/h <25 PPM-SO2 25,0°C 2 mbar-pressure

Stack

70’435 Nm3/h Actual flow 61 mbar -pressure 149 kW - absorbed power 80% total efficiency

ASH + SOLID 48Kg/h ORC UNIT Electricity production

Make-up srubber

Discharge scrubber 19,1 °C 2.91 PH 2 bar - pressure 75% total efficiency Type OCEAN 2600milmolkg=sv alacalinity

PH=

PH=

291 >5.5

SEA

Costs of: Energy and other utilities and ancillary services (electricity, gas, fuels, heating, air conditioning, compressed air, maintenance).

Type of furnaces: Regenerative, side or end port, recuperative, unit melter, oxy fuel.

Type of fuel: Natural gas, diesel, oil, heavy oil.

Glass daily pull, kind of glass, raw material: MTD, hollow, flat, flint, UV green, containers, cullet %.

Working time: Hours/year.

Flue gases characteristics: Physical, chemical analysis, total flow, PM, SOx, NOx, HF, HCl, flue gas temperature at the exit of furnace, at the inlet side of the chimney and/or other existing equipments (filter, quencher).

Heat transfer existing equipment: Heat exchangers, boilers, dissipaters, dry coolers, cooling towers.

Pollution abatement existing equipment: Bag filters, ESP, water quenching tower, dry adsorbent.

3,5 bar pressure 75% total efficiency SEA PUMP

 Fig. 2 Waste gases treatment, as discussed in case study two.

Factory equipments installed/ installation (€, USD). equipment size and r Main consumed power: displacement on the factory site (m, kg, Electricity, fuels (kW, MWh/Year) MT, m2, m3). r Main equipment installed power Factory utilities consumption and and electrical consumption (kW, KWh, specs: MWh/year).

Water, compressed air, MPa, m3/h. r Main equipment utilities feeding Standard/limits for the pollutants and consumption (cum/h, MPa, Bar, °C).

Chemicals estimated consumption emissions: as dry adsorbents, lime, mg/m3, kg/MT, ppm.

Ca(OH)2, NH3, Urea (kg/h, MT/Year, l/h). r Energy balance between the Other active power (electrical and thermal) Technical/economical issues produced by the system (energy Based on the above indicators and recovery) and the passive power on a BDF engineer evaluation, the consumed by the pollution abatement customer will be able to receive a system (Filtration) (kW, MWh/year). technical/economical estimation with r Financial and economical the following main information to be estimation based on a calculated considered as project milestones: BP to give the most indicative data r Producible electric power by the (Investment, direct /indirect costs, proposed heat recovery system (kW, amortisation, net present value (NPV), MWh/year).

IRR, ROI). r Producible thermal/cooling power r Avoided CO2 emission (MT/year). r Available incentives by to be used for district heating, cooling, factory processes, air conditioning, Governments (Carbon credits, energy distilled water production, water efficiency credits /bonds, grants, loans). r Estimated life expectancy of the treatment evaporation (kW, MWh/year). quality and system (Years). r Estimated r Other quantity of the pollutant emissions compared with the assumed limits/ standards (mg/m3, kg/MT, ppm). r Main equipment list and budgetary offer for energy recovery and filtration system supply and Continued>>

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PH buffering sea water

16° C Type OCEAN 2600 millmol/kg= (Alacalinity)

35 Glass International November 2014

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Furnaces

Case study one An Italian glass plant is converting two existing recuperative unit melter furnaces from a gas/air combustion system to an oxy fuel system, with a total estimated pull of 500 MTD and about 7.000 Nm3/h flow.

A bag filter with a 120kWe centrifugal fan, a water quencher with about 200m3/d consumption and a dry DeSox system complete the original plant configuration.

The new design installed a customer’s batch preheating system with an exhaust of waste gases, to flow at about 800°C just upstream of the BDF energy recovery plant.

The energy recovery system with the specific heat exchangers design, collects the waste gases from both the new oxy fuels furnaces, transfers the recovered heat via thermal oil at 310/160°C and finally feeds an ORC turbine (Organic Rankine Cycle) with a net electric power production of about 543kWe, equal to 4.507MWe/year and saving 3100 MT/ year of CO2.

The existing centrifugal fan on the bag house is replaced by two new 15kWe

fans (one in stand-by) with an absorbed electric power of 15kWe each, additional savings of 87MWe/year and 58MT/year of CO2. Moreover, the water quencher is removed thanks to the temperature abatement at 200-220°C via BDF’s heat exchangers; this situation allows for savings of 200m3/day, equal to 1660MT/ year of water (Fig 1).

During the first period of five years the return on investment will also be supported with an additional €60/MWe as an incentive for energy recovery and efficiency application programmes, courtesy of the Italian Government.

Case study two A Middle East glass plant is currently operating with four furnaces (three recuperative and one regenerative), with a total amount of waste gases of about 60,000 Nm3/h at an average temperature of 500°C. The requirement is a waste gases treatment, (mainly dust, NOx and SOx abatement). BDF has proposed a sustainable solution, both environmentally and economically, to switch the cost of operation to an

investment for the glass plant as well.

By a specific connection of the four exhausting lines of the furnaces it will be possible to mix together the waste gases, obtaining a waste gas volume.

Said gas flow is then convoyed to a ceramic candles filtration unit where dust abatement takes place.

Thanks to ceramic filters, which combine high filtration efficiency with a high temperature working range, the gases keep the thermal energy up to the heat exchangers.

Recovered energy is used to obtain electricity by means of an ORC turbine partially used for thermal water treatments, with the aim of obtaining distilled water via a distillation tower and chilled water via a Br-Li absorption unit.

An SNCR to abate NOx is installed before the thermal recovery units.

SOx emissions are drastically reduced by taking advantage from the sea proximity. Salty water is used as an alkaline absorber reagent in the water towers (Fig 2). r

*BDF Industries, Vicenza, Italy www.bdfindustriesgroup.com

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Furnaces

The crucial role of industrial gases in float glass production Stephen Harrison* discusses the role played by industrial gases throughout the production of float glass, including the role they play in protecting equipment, improving the quality of the product, and monitoring emissions.

A

Final stages Towards the end of the float glass production process, molten glass is ‘fed’ through metal rollers. In this reactive environment, measures must be taken

be a highly effective glass coating in reducing the ability of ultra violet light to penetrate glass.

the molten glass reacting with metals that would damage the rollers and compromise the quality of the glass.

Linde is heavily involved in the supply of SO2 for this application. The gas is usually supplied in 50kg quantities in cylinders or 500kg quantities in drum tanks where it is stored in liquid form until utilised in the production process in gaseous form. These containers are heavy and SO2 is a toxic gas, therefore product stewardship must be prioritised.

Coatings for performance glass

z New legislation will mean a leap for glass manufactures in regards to emissions monitoring and reduction.

to prevent the glass from reacting with the rollers and other materials’ handling equipment in order to mitigate damage to the final glass product and to extend the life of expensive capital equipment such as the rollers. This is achieved by injecting an atmosphere of sulphur dioxide (SO2) around the equipment, so that the rollers and the sheets of glass are never actually in contact with each other. Instead, a thin film of SO2 gas reacts with the surface of the glass to produce desirable chemicals that prevent

The role of industrial gases continues to the final stages of float glass manufacture.

The rare gas, krypton, can be used in a technology known as ‘sputtering deposition’ to coat the surface of the glass with a thin film of metal. This surface treatment maximises its energy efficiency and reduces the requirement for electrical heating in a building. This application is often strictly specified for buildings in the USA and in Europe to ensure these structures comply with energy efficiency regulations.

Additionally, silane (SiH4), has proved itself to be an effective glass coating in reducing the ability of ultra violet (UV) light to penetrate glass – particularly that which is destined for use in window manufacture. Silane reacts with the glass surface in a chemical reaction and forms Continued>>

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lthough glassmaking dates back to ancient times, today’s production industry still reflects many of the same basic operational processes.

A substantial development is the mass manufacturing of float glass to comply with modern building standards and environmental legislation. It is here that industrial gases play a vital role.

The primary process of glass production is melting, using burners typically fired by natural gas and air, or air enriched with pure oxygen. The best way to ensure optimal operation of the burner is to measure and control the amount of oxygen in the burner flue gas to ensure there is a small residual amount of oxygen emerging in the escaping flue gases. To achieve the right balance, oxygen should be measured in the furnace through a feedback process control loop, using instrumentation such as a Zirconia oxygen analyser, which is reliable and robust in this extremely hot operating environment. The instrument’s sensor requires periodic calibration with a speciality gas mixture of typically percentage level oxygen in nitrogen, close to the measurement point, to ensure accuracy of measurement.

 Silane gas has proved itself to

37 Glass International November 2014

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Glassman Europe returns to Lyon in 2015 due to popular demand. Join us 6-7 May for this international exhibition and technical conference.

We are looking for: 6-7 May 2015 Cité Centre de Congrès, Lyon, France www.glassmaneurope.com

6-7 May 2015 Cité Centre de Congrès, Lyon, France www.glassmaneurope.com

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Equipment manufacturers, suppliers and service providers who want to meet an international audience of glass producers

Technical experts in the primary glass manufacturing process who can discuss the opportunities and challenges in the market and/or present case studies

Professionals and decision-makers working within the glass industry who are looking to develop competitive advantage and new opportunities for their business

Visit the website for more information www.glassmaneurope.com For more details contact: Jeremy Fordrey 01737 855133 | jeremyfordrey@quartzltd.com Ken Clark 01737 855117 | kenclark@quartzltd.com Greg Morris 01737 855132 | gregmorris@quartzltd.com

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Furnaces

a coating which helps to mitigate the adverse effects of UV rays on human health, including short-term issues such as sunburn and potential longer-term issues including skin cancer. These are points of concern to health authorities, particularly in countries where intense sunlight and heat are unrelenting. In a similar application, the speciality gas hydrogen fluoride is used to etch the surface of the finished glass.

Emissions monitoring

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Float glass production facilities are often obliged to monitor and control their emissions profile in order to manage the associated gaseous environmental pollutants such as carbon dioxide, oxides of nitrogen (NOx) and SO2. Burning air and the fuel produces large quantities of oxides of nitrogen. At high temperatures, nitrogen reacts with oxygen from the air to produce NOx, while some chemicals typically present in natural gas, such as sulphur compounds, also react with oxygen from air to produce SO2.

Therefore typical stages in flue gas clean-up from the burner are DeNOx and desulphurisation via a SO2 scrubber, occasionally with carbon dioxide knock down, before gas is emitted to the atmosphere. In some technologies, as emissions gases flow through the DeNOx unit ammonia is added to the flue gas to reduce the NOx back to their molecular nitrogen, while in the SO2 stripper various chemicals absorb the SO2, changing it from a gaseous form into a liquid form, where it can be handled and treated more efficiently.

Ammonia can be added to the DeNOx unit because it contains a large amount of hydrogen that is able to reduce the NOx to react with the oxygen in nitric oxide and convert nitric oxide back to nitrogen, which is regarded as a safe gas to emit.

Often included under the banner of a speciality gas, ammonia is supplied in bulk deliveries to major float glass facilities, or in drums and cylinders to smaller scale R&D and pilot glass production facilities.

Essential to monitoring the different clean-up operations are process control gas mixtures containing, in this application, oxides of nitrogen or SO2, and frequent calibration is needed with accurate speciality gas mixtures. These mixtures calibrate the continuous emissions monitoring (CEM) instrumentation in the process train, measuring the flue gas as it comes through all the process steps and eventually goes up the smoke stack.

In general, nondispersive infrared sensor (NDIR) sensors or Fourier transform infrared gas analysers (FTIR) are used for these measurements, both of which require a range of calibration gas mixtures, typically mixtures of nitric oxide in nitrogen, or mixtures of SO2 in nitrogen at relatively low concentrations, sometimes in parts per million.

The European Union Directive 2010/75/EU on industrial emissions integrated pollution prevention and control (IPPC) comes into force on January 1, 2016. The new legislation will mean a considerable leap for glass manufactures in terms of what is required of them from an emissions monitoring and reduction viewpoint. The role of speciality gases will be critical to ensuring compliance with Directive 2010/75/EU as they are essential for calibration of the emissions measuring instruments â&#x20AC;&#x201C; and are precisely prepared for each glass manufacturer to meet their emission monitoring needs. î ˛

*Global Head Specialty Gases & Speciality Equipment, Linde, Germany http://www.the-linde-group.com/

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Container glass

Heye delivers speedy Thai project L Lighting’s cold end at its Thailand factory

Mark Ziegler* discusses L. Lighting’s transfomation from a lighting plant to a container glass plant and how it implemented Heye’s HiSpeed project.

www.glass-international.com

L

ighting Glass in Thailand is well known for the production of lamps for various applications. But this spring, it rewrote its company profile and started to produce glass bottles.

What has happened? The domestic market in Thailand as well as in the surrounding region has rapidly developed but there is still a lack of production capacity. So the Lighting Glass board decided to invest in production technology for container glass.

Less than two years ago, staff from L. Lighting Glass met Heye at Glasstec in October 2012 to discuss their ideas. It often takes ages before projects of this scale really start-off. Not this time.

But by January, two 12 section triplegob IS-machines went into production for an amber furnace. Then in May, another 12-section triple-gob machine was added in flint, all in NNPB. Remarkably, “We did not have any container glass experience”, says Khun Yanattha and Khun Lerdchai from Lighting Glass.

So what was the reason for the success?

It was the decision by Lighting Glass to book the full training and assistance package from Heye.

From top-management to warehousestaff, everybody was trained by Heye Glass People. The team-spirit was important in the common project groups.

Bernd Dreier, responsible project manager from Heye, expressed his thanks to Lighting Glass for this exceptional cooperation and teamwork.

Behind a successful project there

is always a clear strategy and set of methods. Heye offers dedicated solutions for project management as well as for training and production optimisation The structured project management covers: r Clear milestones r Defined work packages r A responsibility matrix r A project organigram with all relevant people The different steps are written down in a project management handbook, called PM@Heye, which is based on international PMI rules.

The project managers who give continuous progress reports are responsible for making sure that the project is finalised up to quality standards, on budget and on time.

Then, modern glass container

production is more than just using equipment. The largest portion is determined by production methods and procedures and how all the stages of the process work and fit together.

Heye offers direct access to production facilities and real on-the-job trainings.

The training covers: Raw material and energy, Machine operator training, Production optimizing (speed and quality), Quality control in the Cold End and a maintenance workshop with a special regard to reduce job change times.

The result of this 360-degree view of container glass production is the ability to deliver complex projects on time and on budget. r

Marketing Manager, Heye International, Germany. www.heye-international.com

Installation of Heye’s IS machine at L Lighting in Thailand

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Events world

The 12th European Society of Glass conference

z Fig1. Attendees of this year’s ESG conference gather outside the conference venue at the University of Parma.

T

he event was a busy affair in terms of both number of attendees and activities, with 350 delegates and five sessions running alongside meetings held by the European Society of Glass (ESG) and the International Commission on Glass (ICG). As well as this, the event hosted a poster session which had around 40 entries, and awards were presented during the opening ceremony of the conference.

Opening ceremony Alessandro Bandini, President of the Association of Italian Glass Technologists (ATIV) opened the conference, welcoming everyone to the cultural city of Parma. He noted: “We have around 350 participants from 20 countries, and 200 papers covering a multitude of important issues from the glass sector, presenting innovations from the sectors of glass and glass ceramic”, and confirmed that “This is by far the best conference we’ve ever had, with the greatest number of participants.”

Dr. Stefano Manoli, President of ESG, was next to address the room. He noted that despite the recent financial crisis in

z Fig 2. Dr. Julian Jones receiving the ICG Vittorio Gottardi Award.

Europe, the glass community still makes an effort to meet at occasions such as this conference, and commented again on how pleased the ESG was to attract such a high number of participants.

He continued: “These kinds of events represent not only the chance to meet and exchange information on glass, but also the opportunity to create new collaborations and innovations”.

The awards ceremony then took place, with two ICG awards followed by one from the UK’s Society of Glass Technology (SGT).

This year the ICG Vittorio Gottardi award was awarded to Dr. Julian Jones, of Imperial College, London. This award is presented each year to a young person who has made outstanding achievements in the field of glass in research and development, teaching, writing, management or commerce.

This was followed by the second ICG award, the William E.S. Turner award, which rewards those who have made a noteworthy contribution to the ICG Technical Committees. This year the

z Fig 3. Dr. Emma Barney receiving the SGT Pilkington Award.

Continued>>

www.glass-international.com

This year’s 12th European Society of Glass conference was held in Parma, Italy, in conjunction with the 29th ATIV meeting, the Glass Trend seminar, and the annual International Commission on Glass meeting.

41 Glass International November 2014

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Events world

z Fig 4. M. Hubert of Celsian Glass & Solar delivering a presentation entitled ‘Control of glass colouration in amber component glasses’.

award was presented (in absentia) to Dr. Bianca Maria Scalet, of the Italian Ministry of Economic Development.

The SGT Pilkington award was next, named in honour of Sir Alistair Pilkington and his incredible achievements in the glass industry. The award is designed to encourage and recognise excellent work in glass research achieved by someone who has come into the field of glass studies relatively recently, and is not restricted to hard science or engineering; this award spans all dimensions of glass studies, creativity and research. This year’s SGT Pilkington award winner was Dr. Emma Barney, of the University of Nottingham, UK.

www.glass-international.com

The main event The three day event took place at the University of Parma, with five sessions running concurrently entitled ‘Glass Technology’, ‘Glass and Environment’, ‘Properties and Measures’, ‘Special Glasses’ and ‘Glass in Architecture’.

Across these five sessions around 200 papers were delivered on a diverse range of topics, with keynote lectures including ‘Is the (flat) glass half full?’ by Massimo Pipino of AGC; ‘Design of structural glass – towards a harmonised Eurocode’

by Markus Feldmann of RWTH Aachen University; and ‘Chemical-mechanical effects at glass surfaces’ by G. Carlo Pantano of Pennsylvania State University.

A significant amount of the presentations in the ‘Glass Technology’ and ‘Glass and Environment’ sessions dealt with the subject of reducing NOx and other emissions due to the forthcoming changes in EU regulations, due to come in to play at the beginning of 2016. This encouraged a focus on oxy-

fuel technology, energy savings and the use of alternative sources of energy in the manufacture of glass.

On this theme, Jorgen Backhausen of UAS Messtechnik gave a presentation in the ‘Glass and Environment’ session entitled ‘Substantial energy savings by preheating oxygen and gas on oxygenfired glass furnaces’, in which he discussed how the pre-heating of the combustion components provides a reduction of the primary energy in glass melting. With the help of pre-heating technology from German company UAS, the oxygen and gas used can be pre-heated up to 400˚C, substantially reducing the primary need of energy for oxygen/gas fired glass furnaces. This equipment can also be installed on regenerative and recuperative furnaces for the pre-heating of natural gas. The pre-heating system is designed to operate per burner, to fully ensure the adjustability of the burner firing profile in the furnace, to achieve the best melting performance. Mr. Backhausen confirmed when asked that an energy saving of more than 10% can be saved by changing one burner compared to a normal burner, and noted that if all the burners were replaced with pre-heated oxygen technology, then energy savings of between 10 and 50% can be expected, with a realistic estimate of around 12%.

BDF also gave a presentation in the ‘Glass and Environment’ session, entitled ‘Energy recovery from waste heat and ceramic filtration technology’.

Mr. Ulisse Armeni focused on systems for energy recovery from waste flue gas, giving examples of case studies where BDF equipment is in use. This topic is further discussed in this issue of Glass

International, in Mr. Armeni’s article entitled ‘Glass furnaces: Combined energy recovery and pollution’. The second part of Mr. Armeni’s presentation dealt with ceramic filtration technology as a solution in the field of energy recovery.

Another popular presentation was given by Denis Lalart, of Arc International, which discussed findings from the Glass Alliance Europe on the ‘possible impact and potential benefits’ of the new European regulations affecting food contact materials in relation to the glass industry. From packaging to tableware to technical applications glass is often a food contact material, however at the moment no EU-wide regulations exist for glass that comes in to contact with food – instead, when required, limit values that apply to ceramics are used.

This is currently under revision, with upcoming legislation set to tackle three main points: A reduction in the exposure to lead by a factor of 400; a revision of the testing protocol, to evaluate the transfer of constituents in conditions of use; and the extension of the scope to up to 20 elements of further potential concern.

Closing ceremony The closing ceremony rounded off the event, with Mr. Bandini and Dr. Manoli again thanking everyone for attending, before handing over the reins to Dr. Ing. Tepiwan Jitwatcharakomol of the ICG and Dr. Prof. Russell Hand of the SGT. Dr. Jitwatcharakomol announced the next annual ICG meeting which will take place from the 20-23rd September 2015, in Bangkok, alongside Glassman Asia 2015 which will be held concurrently in the Centara Grand hotel. She underlined how the meeting will be the first held by the ICG in the ASEAN region and will be a great opportunity to meet the glass industry of Asia.

Prof. Russell Hand then announced the 2016 centenary meeting of the Society of Glass Technology, which will coincide with the next ESG meeting. The two meetings will be held jointly from the 4th-9th September 2016 at the University of Sheffield. As it will be the centenary anniversary of the SGT, the theme will be ‘Looking to the future whilst celebrating the past’, as Prof. Hand stressed the need to look to the next 100 years of glass technology and innovation. r

European Society of Glass www.esg2014.it

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Events world

glasstec 2014 deemed a success Despite tough times recently for much of the industry, this year’s glasstec was deemed a success, with many attendees optimistic that it signals a positive outlook for the industry’s future. 1,217 exhibitors took part in the event at the Messe Dusseldorf, which attracted more than 43,000 visitors.

Sally Roberts reports.

T

www.glass-international.com

he four-day event was a busy hub of activity as industry professionals renewed existing and developed new acquaintances, and, most importantly, did business.

“We’ve generated lots of momentum, which should translate into plenty of new business”, noted Arne Klofkorn, Board Member of Bohle, a sentiment echoed

by Bystronic Glass’s Peter Nischwitz: “We’re confident that the industry as a whole will return to a positive trajectory.

We look forward to some great follow-up business after the trade fair”.

Designed to cater to every aspect of the glass industry, glasstec 2014 welcomed exhibitors and visitors from mechanical engineering; glass manufacturing, processing and finishing; crafts; architecture and construction; glazing and facades; and the solar sector.

The event was officially opened on the Monday night, with a dinner for members of the press and key figures from the industry. Hosted by the organisers at the Classic Remise in Dusseldorf, the dinner included a panel discussion entitled ‘Quo Vadis glass industry 2020’. Prominent

figures from the glass manufacturing community gave their views on the challenges and opportunities present in their respective sectors of the glass industry, and discussed their predictions for the industry over the coming years.

Present at the panel discussion were Dr. Frank Heinricht, Chairman of the Board at Schott AG; Jean-Francois Heris, President and CEO of AGC Glass Europe; Michael J. Lonsway, Vice President Global Product Innovation at Owens-Illinois; Houchan Shoeibi, CEO of Saint-Gobain Glass; and Zhang Fan, CEO of Flat Glass Division at CSG Holding Co.

Exhibitor comments Exhibitors said their stands had attracted high-quality visitors who were often decision makers.

German company MSK Covertech – Group was displaying some of its cold end equipment, including a new solution for bottle transportation.

Sales Director Uwe Jonkmans said the company had had a successful first day and had completed a cold end order to a Middle East company:

“glasstec is a very important show for us and is an opportunity to talk to current customers and to meet new customers.

After the first day, there were perhaps not as many visitors as before but the people who came here were decision makers, who were here for a specific reason.

“We had a number of high level, technical discussions.”

He said the company had seen a number of people from South America and Africa, including Tanzania and Nigeria.

A few steps away from the MSK stand in Hall 13 was fellow German company Horn Glass Industries. Horn, alongside MSK, Zippe and Bucher Emhart Glass, is a member of the Container Glass Alliance.

The Glass Alliance provides targeted know-how, from experts in their fields, for the manufacture of container glass or individual projects and production steps in a glass plant.

The co-operation provides a quicker and more direct flow of information between the four companies and leads to Continued>>

 The panel discussion at the opening event was attended by (left to right): Dr. Frank Heinricht, Chairman of the Board, Schott AG; Jean-Francois Heris, President & CEO, AGC Glass Europe; Michael J. Lonsway, Vice President Global Product Innovation, Owens-Illinois; the panel discussion chairwoman; Houchan Shoeibi, CEO of Saint-Gobain Glass; Zhang Fan, CEO of Flat Glass Division, CSG Holding; and Mr. Fan’s translator.

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Events world

z The Bucher Emhart stand (left) and the Sorg stand (right), which housed the Sorg family of Sorg, EME and Sorg Keramics, were busy with visitors throughout the four day event. Zippe sold a machine on the first day (below).

SOLD

sales team had been busy all week. The company had a 228m2 stand where it presented its latest innovations.

In line with its strategy of being present at the Cold End and in the Hot End, and being able to link both ends, the company had structured its stand with its Cold End machines on one side and its new Hot systems on the other side. In the middle, it presented its IQ Intelligence tools ,Tiama IQ Scan and Tiama IQ Track, which gather data from the two sides to

help the glass plant improve its process.

A total of 13 LED wall screens underlined its new Hot systems product range with its Hot Mass (weight regulation and gob temperature and shape), Hot Move (X&Y transport analysis) and the Hot Form (glass repartition).

On the Cold End, the MCAL4 displayed some HD cameras, an improved low contrast module and new software improving detection in container with engraving.

The MULTI4 displayed improved software, an improved mould number reader and a non-contact dip and saddle.

The MX4 displayed its Non-Contact Leaner (NCL device) and its wide band probes for thickness and the Atlas.

In Hall 15, EME and Shanghai Precision presented a completely new design under the roof of the Sorg Group. The company said it had four fruitful days and it had Continued>>

www.glass-international.com

advantages for its customers.

Horn’s Sales Director Matthias Kunz said the company had enjoyed a good first day with a number of visitors from the Middle East, as well as from Brazil and Argentina.

“The people who visited were not just passing by our stand but came for a reason and had many high-quality questions.”

Dr Philipp Zippe, Managing Partner at Zippe Industrieanlagen, said the company had already sold two machines on the first day.

“Glasstec is an opportunity to meet people from all around the world and to make new contacts. We have had vistors from Africa, which seems to be getting an increasingly stronger area, as well as from Brazil and Mexico.”

Benoit Burin Des Roziers, Sales & Marketing Director at French company Tiama- msc & sgcc, said this year’s glasstec was better than 2012 and its

z The Tiama team at the event.

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Events world

been a positive exhibition.

Egbert Wenninger, Managing Director, said: “We had many fruitful discussions with customers from all around the world and the demand for batch plants and cullet return systems has increased.

“The presentation of the new EMENEND Batch Charger was an absolute highlight which attracted the particular interest of all customers.

“In particular, the modular concept is unique and enables the glass manufacturers to apply a redundant charging system with all relevant advantages.

“By launching the third generation of EME-NEND Charger, customers can benefit from the experience for many years with sealed charging systems.”

Samuel Leaper, of UK firm E.W Bowman, described this year’s glasstec as the best in several years.

The company met glass manufacturers from North and South America, Europe and Africa, whose attendees ranged from plant operatives through to owners and directors. The company showcased its M2 range of lehrs and received several enquiries from current and potential customers alike.

German trade association the VDMA reported that the event had gone better than expected. The association, which represents German glass machinery and plant manufacturers, stressed the high number of top and mediummanagement levels among the 43,000 visitors as well as the international character of the fair. “glasstec seems to have provided the push the industry needs to get through these times unscathed.

“Some companies were given orders, others made direct sales and generated lots of momentum, which should translate into plenty of new business.

“The sector is confident that the industry as a whole will also return to a positive trajectory after difficult times in large parts of the glass sector due to over-capacities, lacking investments and pressure growing from fierce competition.”

Additional features A programme of lectures, conferences, and live exhibits also supported the event.

In particular, the ‘glass technology live’ show drew people in with a display of ‘intelligent glass’ products demonstrating trends that are currently

dominating the glass industry. This included a 3.2m x 14m pane of glass that had been finished using a ceramic digital printing process, and a four layered insulation glass façade.

Within this mini exhibition area, glass technology live offered a variety

of lectures on different subjects, including a morning dedicated to batch handling and processing which included presentations from Dr.-Ing. Matthias Lindig of Nikolaus Sorg, and Uyi Iyoha of PraxAir. Dr Lindig explored a ‘Technical and Economic Approach for Heat Recovery with Glass Melting Furnaces’, while Mr Iyoha gave a commercial demonstration of a heat recovery technology for oxyfuel fired glass furnaces.

As well as this symposium, glasstec was host to the ‘Solar meets Glass’, ‘Engineered Transparency’, and ‘Architecture Congress’ conferences, all of which were well attended. ‘Solar meets Glass’ brought together 80 industry experts to discuss the topics and technology that affect both sectors, with the aim of enhancing communication between the two industries.

Dr. Florian Wessendorf, Managing Director VDMA Photovoltaic Equipment, noted that: “Something I took home with me is that we have to tackle problems together. While an exchange between both sectors already exists, it could certainly still be enhanced”.

Worldwide appeal This year, roughly 60% of visitors to the show came from outside Germany, representing 80 countries between them.

Commenting on the level of worldwide interest received by the show, Martin Strab, Executive Vice President and CMO of Grenzebach Maschinenbau, said: “This is an amazing platform for our international clientele, offering an excellent opportunity to both gain new customers and set appointments with our existing customers”.

Further cementing the show’s reputation for having worldwide appeal, this year’s exhibitors represented 51 countries, all of which must have been pleased with the fact that 40% of visitors stated that they had come to the show with the specific intention of investing.

This should translate into excellent business opportunities for the 1,217 exhibitors in the coming months, a positive indication that the situation of the glass industry as a whole may be improving: “Following a few rather difficult years”, continued Mr. Strab, “we look to the future with optimism”. r

The next glasstec will be held in Dusseldorf from the 20th-23rd September 2016.

46 Glass International November 2014

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