Glass International March 2018

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March 2018—Vol.41 No.3

GERRESHEIMER’S NEUTRAL GLASS PROFILE CHINA FLAT GLASS OVERVIEW HUAXING GLASS INTERVIEW I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International March 2018

When efficiency is not negotiable.

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Contents

March 2018 Vol.41 No.3

WWW.GLASS-INTERNATIONAL.COM

GERRESHEIMER’S NEUTRAL GLASS PROFILE

5

International news

17

CHINA FLAT GLASS OVERVIEW HUAXING GLASS INTERVIEW A GLOBAL REVIEW OF GLASSMAKING

Glass International March 2018

17

When efficiency is not negotiable.

27

Phoenix Committee chairman Pennine’s Graham Womersley is privileged to be this year’s Phoenix Committee chairman

21 Refractories P Carlo Ratto and SSV

A new generation of services for the industry 27

ZIPPE – BECAUSE WE DO IT.

Chinese Flat Glass overview An overview of the sector

30 Process Control Tiama

Maximising the output of hot end process control 33 Furnaces CelSian

Improved combustion control using CO laser

36 PaneraTech

Measuring the thickness of high zirconia refractories

Batch Plants • Cullet Plants • Factory Cullet Recycling • Automation Modernization • Engineering • Glass Recycling • Batch Charging Glass Level Controlling • Preheating • Maintenance & Service

www.zippe.de

GI Cover march.indd 1

Editor’s Comment

13 Company profile

Gerresheimer

Gerresheimer’s Neutral Glass unveils Indian furnace

March 2018—Vol.41 No.3

I N T E R N A T I O N A L

2

06/03/2018 08:56:15

Front cover image www.zippe.de

38 Stara Glass Reappraising the role of port necks in

regenerative furnaces 42 Furnace Solutions

The SGT’s Furnace Solutions keeps

informing engineers

Plus find us on Linked-In and Twitter.

Testing and Research American Glass Research AGR opens European testing lab

46 Forming Bürkert

Precise control over flame characteristics

49 History

50

www.glass-international.com

43

43

Glassman Asia Review

54 Profile: Guangdong Huaxing Glass

Huaxing continues to expand @Glass_Int

www.glass-international.com

54

56

Chinese language supplement

1 Glass International March 2018

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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: Sheena Adesilu Tel: +44 (0)1737 855154 Email: sheenaadesilu@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com

All is rosy in the world of glass, isn’t it?

www.glass-international.com

O

lder readers may disagree with me, but it is possible that there has never been a better time to be in the glass packaging industry than at the present moment.

At first glance everything appears to be rosy. Orders are substantial, market sentiment is optimistic and overall the outlook is positive, with anticipated average growth in glass packaging volumes at approximately 3 to 5% a year globally.

Glassmakers continue to invest in new, modern equipment, as evidenced in the news pages this month with Wiegand-Glas, Ardagh and Australia’s Orora Glass spending money to improve their manufacturing operations.

Glass’s main competitor, plastic, continues to get a kicking. More organisations are to stop using the material and its image is at a low. Plastic is the new evil.

Recent groups to stop using plastic include the budget airline Ryanair - which has pledged plastic free flights by 2023 - UK broadcaster BBC and the UK Royal Family, which has told residence staff to ditch straws, eat from china plates and drink from glass bottles.

Rising disposable incomes in developing nations means more glass is being consumed than ever before in countries such as Mexico, Thailand, China and Brazil. I cannot think of a time when glass was in such an ascendency.

Yet the pessimist in me detects all is not

right. There is an uneasiness that glass is not capitalising on the moment. There is an opportunity right now to gain market share from plastic but how much is the glass sector doing to promote itself as a healthier, greener material?

It’s a tiny survey but whenever I ask my family, friends and colleagues what they know about glass and how it is made, they all answer with a shrug and shake of the head.

It’s a longstanding problem but glass is still not attracting enough young talent to the industry. Recent chats with engineers reveal how worried they are about the future of glassmaking and where the knowledge will go when the experienced workers retire.

Glassmakers can achieve still higher manufacturing efficiencies but eventually they will need the next generation of youngsters to do this. Objectives such as the Glass Future project in the UK will hopefully help secure more youngsters in the industry.

My thoughts are that if the glass packaging industry seized the media landscape and put itself on the agenda, more people would both consume glass and would also seek a career in the industry, for what would be a satisfying career. � Greg Morris, Editor gregmorris@quartzltd.com

Quartz Glass Portfolio

Monthly journal for the industry worldwide

Directory 2017 Annual international reference source

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Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com Managing Director: Steve Diprose Chief Executive Officer: Paul Michael Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034.

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

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Glass International March 2018

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International News

NEWS IN BRIEF

Ardagh’s food safety certification award

Australian container manufacturer Orora has signed an agreement to have wind-generated electricity supplied to its Gawler Glass facility.

It has signed the long-term power purchasing agreement with global renewable energy provider Pacific Hydro, to supply wind-generated electricity for the South Australian (SA) operations.

The energy will be supplied from Clements Gap Wind Farm (pictured), for a volume equal to Orora’s total electricity demand in SA. The agreement also includes risk-sharing arrangements to protect Orora’s exposure to variable market prices in South Australia.

Orora CEO, Nigel Garrard, said: “Orora operates energy intensive businesses and is

continuing to actively investigate a range of options to manage higher energy prices and safeguard supply for the Australian operations.

“Renewable energy represents a competitively priced and sustainable energy source and this agreement provides our operations with greater energy price certainty over the long-term.”

..and introduces on-site swabbing technology on its forming lines Mr Garrard added that the Gawler facility has implemented a number of on-site process improvements with the focus on safety.

The installation of a world first trial of automated swabbing technology will allow Orora to improve safety and optimise process stability on an ongoing basis.

The operator’s time is redi-

rected from manual swabbing to focus on process quality.

In addition, mould laser cleaning technology was developed and commissioned at the plant, reducing manual handling of over 20 tonnes each day and improving the quality and life of moulds.

In its half-year financials, the company said glass volumes were ahead of pcp,

driven by continued industry growth in bottled wine exports that offset a marginal decline in beer volumes.

He added that the business had purchased land, including two previously leased warehouse facilities adjacent to the Gawler site.

This will enable further improvements in supply chain optimisation at the site.

LiSEC secures Australian contract LiSEC has installed an automatic cutting line with a loading system at the newly formed glass processing company, Glass 360, based in Queensland, Australia.

The Austrian machinery supplier has installed a cutting

line for laminated or float glass and a moveable double-sided loading system with four stations.

Phil Norman, Glass 360’s CEO, said: “Glass 360 was conceived to cater for small to medium sized glaziers, requiring

a fast and reliable turnaround service. I was aiming to reinvest into our industry and gain tangible assets in a company with genuine growth potential, founded on quality machinery and superior customer service.”

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Anchor Glass appoints Human Resources chief

Anchor Glass Container Corporation has appointed Wendy Larrison as Chief Human Resources Officer and Vice President at its corporate headquarters in Tampa, FL, USA. Anchor Glass CEO Nipesh Shah said: “Wendy has extensive experience in creating performance driven culture in a manufacturing environment.

“I am confident that Wendy will help us advance our Human Resource capabilities and leverage global best practices to ensure that Anchor has the right talent and culture to progress our objectives.”

O-I achieves gold rating

Owens-Illinois (O-I) is the first food and beverage packaging company to achieve a gold rating in material health on the Cradle to Cradle Product Scorecard.

The Cradle to Cradle Certified Products Program is a sustainability certification for products around the world and across industries.

“The certification provides brand owners, consumers, regulators, and shareholders tangible validation of our company’s ongoing commitment to sustainability,” said Jim Nordmeyer, VP, Global Sustainability at O-I.

www.glass-international.com

Orora agrees Gawler Glass renewable energy deal...

Ardagh’s Pevely, Mo., and Sapulpa, Okla., glass manufacturing facilities in the United States have achieved FSSC 22000 Food Safety System Certification.

“FSSC 22000 Certification is a direct reflection of Ardagh Group’s commitment to driving continuous improvement in food safety management systems within our facilities for the safety and well-being of both our customers and consumers,” said Mike Fair, Vice President of Quality for Ardagh Glass, North America.

5 Glass International March 2018

news march.indd 3

07/03/2018 08:24:13

International News

$375 million glass plant opens in Turkmenistan

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The largest glass manufacturing company in the Central Asian region, Türkmen aýna önümleri (Turkmen glass products), has opened in Ovadandepe near Ashgabat.

The company will produce float glass and containers for the food and medical industry. Investments in the project amounted to $375 million and created 800 new jobs.

“At the initial stage, 15 types of products are

planned to be produced here, the assortment will increase with time, and some part of the output will be exported,” Turkmenisthan President Gurbanguly Berdimuhamedov said.

Berdimuhamedov noted that the enterprise will produce 3.95 million m2 of transparent glass, 1 million m2 of tinted glass, 300,000 m2 of tempered glass and 100,000 m2 of laminated glass a year, as well as 400,000 m2 of high-quality

double-glazed windows.

He addeded that 70% of raw materials for glass manufacturing are currently produced in Turkmenistan but aims to increase this to 100%.

Berdimuhamedov stressed that Turkmenistan, which has embarked on industrialisation, will give priority to the construction of high-tech industrial enterprises, which will allow the state to ensure high rates of economic development.

Beer boosts Verallia sales Verallia reported a sales increase of 4.5% last year – thanks in part to the Brazilian beer market.

The French container glassmaker reported revenue at €2,473.7 million for

2017 with adjusted EBITDA of €504.1 million, up 7.9% year-on-year.

In South America its revenue increased by 11% thanks to an increased level of activity in Brazilian

beer bottle volumes.

In Europe, revenue increased by 3.7%, supported by higher volumes in France and Spain in particular.

Horn Glass Industries appoints business unit leaders Horn Glass Industries has appointed Ulrich Imhof and Ekaterina Firsova as the leaders of its two main business units.

Mr Imhof and Mrs Firsova (pictured) were appointed as business unit leaders of the globally expanding company on 1st October 2017.

Mr Imhof is now in charge of the container and speciality glass business unit. He began his career in the container glass industry in 1989 and joined Horn Glass in 2012.

He then became the sales

director and was responsible for the Asian division.

Mrs Firsova is now responsible for the technological glass plant business unit. She has valuable experience in the development of turnkey plants, the float business unit and many roles including project manager.

Horn will continue to be led by its CEO and MD Stephan Meindl.

Mr Christoph Jatzwauk officially retired from the Executive Board of Horn Glass Industries after 18 years of responsibility as

a Managing Director and member of the board.

He left the company at his own request to face new professional challenges.

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International News

NEWS IN BRIEF

Applications open for 2018 Pilkington award

The Society of Glass Technology is accepting applications for the 2018 Pilkington award.

Eligible applicants will be within seven years of joining the glass industry and the winning candidate will receive €1500 and support in attending the ESG Conference in Saint Malo, France, in 2018, where the award will be presented.

Vidrala benefits from Santos Barosa deal

Spanish container glassmaker Vidrala reported sales of €822.7 million in 2017, a 5.1% increase from the year before.

Operating profit, EBITDA, was €195.4 million, an increase of 14.5% over the figure reported last year.

Vidrala acquired Portuguese glassmaker Santos Barosa in October last year. In its financial report for the year 2017 Vidrala stated there is a growing trend among consumers for glass as the packaging material of choice.

Vidrala has manufacturing plants in Spain, Portugal, Italy and UK.

www.glass-international.com

Vitro receives funding for furnace project

Vitro Flat Glass is working on a project to reduce industry cost and energy use by developing a neural network model for glass furnace operations.

Vitro Flat Glass will partner with the Lawrence Livermore National Laboratory (LLNL) to ‘develop real-time glass furnace control using a neural net-based reduced order model of a CFD simulation of molten glass flow in a follow-on project titled ‘Advanced Machine Learning for Glass Furnace Model Enhancement.’

The proposal states: “The enhanced model will enable fast and accurate control of furnace operations.”

“These reductions will help maintain US global competitiveness in this industry.”

Ardagh commissions Heye technology in German project Ardagh’s plant in Neuenhagen, Germany has completed one of the company’s largest furnace repair projects.

A 370 tonne furnace with its feeders has been rebuilt and hot end and cold end technology installed.

The site now uses Industry 4.0 technology.

As well as the furnace repair the company now runs two Heye 12 Section 5 1/2’’ DG SpeedLines as well as Heye inspection equipment at the

cold end.

The two lines started production with 750ml Bordeaux bottles and 500ml wide neck jars.

“This major furnace repair is an important step towards the future and secures production success for the next two decades,” said Plant Manager, Hartmut Treichel.

The implemented closedloop technologies include latest Smart Plant features, such as the Heye Process Control, that monitors the pressing

processes of all plunger mechanisms of the IS-Machine and enables the machine operator to recognise malfunctions at the earliest moment.

Wiegand-Glas invest €50 million in Glaswerk Ernstthal facility Glass container manufacturer Wiegand-Glas intends to invest more than €50 million in its Glaswerk Ernstthal plant in Thuringian, Germany over the next two years.

The investment, announced in December, will include a

new melting furnace which will have a daily capacity of 360 t/d. Investments will also be made in production and inspection technology.

Wiegand-Glas said the investment means it will strengthen its market position

and can react even more flexibly to customer requirements.

“Due to demographic change, fewer and fewer people are available to the labour market,” Wiegand-Glas said.

Sisecam acquires Italian plant Turkish flat glass producer, Sisecam, has submitted an offer for the acquisition of Sangalli’s Manfredonia factory in Monte Sant’ Angelo, Italy.

Professor Ahmet Kirman, Sisecam’s Vice Chairman and CEO, said: “We expect strategic benefits in terms of our European flat glass operations by acquiring the Sangalli Manfredonia plant, which enjoys a favourable geographical location and offers an annual production capacity of 190,000

tons/year.

Sangalli’s flat glass plant operates a 4 million m2/year lamination line, a 4 million m2/year coating line, and a 1.5 million m2/year satin line.

This will be Sisecam’s second flat glass plant in Italy, after acquiring the Sangalli Porto Nogaro plant in 2016 for around €85 million.

Mr Kirman continued: “We are aware that we cannot achieve our strategic targets through organic growth only.

Thus, inorganic growth is important for us, especially outside Turkey.”

Sisecam produces flat glass, glassware, glass packaging, glass fibre and holds soda and chromium compound businesses.

Read the full story at www.glass-international.com.

First with the news.

8 Glass International March 2018

news march.indd 6

07/03/2018 08:24:17

New look, old self.

We are turning ROYAL Our distinction: exceptionally valuable.

Orange turns blue.

We continue to develop.

As an independent subsidiary of Koenig & Bauer AG, we offer the same level of service that we have traditionally provided and remain your specialist in high-end application solutions for all your printing requirements.

International News

NEWS IN BRIEF

German Glass Society event registration open

Registration is now open for the 92nd meeting of the German Society of Glass Technology (DGG).

The event is being held in conjunction with the Annual Meetings of the Czech Glass Society & the Slovak Glass Society.

The event takes place between May 28 and 30 at the Arvena Kongress Hotel, Bayreuth, Germany.

Individual sessions of the 92nd Annual Meeting of the DGG are composed by experts in the respective fields.

American glass scientist wins Schott award

Prof Dr C Austen Angell will be presented with the 15th Otto Schott Research Award

by Schott this year.

Glass scientist Prof Angell from Arizona State University was chosen to receive the award and a €25,000 endowment for his pioneering, lasting scientific contributions throughout his influential research career.

Prof Kathleen, a member of the Schott’s Board of Trustees, said: “Professor Angell has managed to remain constantly active and visible as a researcher.”

www.glass-international.com

Verallia appoints Didier Fontaine as CFO

Verallia has appointed Didier Fontaine as its Chief Financial Officer and Corporate Planning Director.

Michel Giannuzzi, Chairman and CEO of Verallia, said: “I am delighted to welcome Didier onto Verallia’s Executive Committee.”

“His financial and industrial expertise and experience will make a valuable contribution to the deployment of our company’s business strategy.”

Mr Fontaine graduated with a degree in Tax and Finance from Sciences Po Paris and holds a Higher Diploma in Econometrics from the University of Lyon.

Top 10 stories in the news Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1. Sisecam acquires flat glass plant in Italy � 2. Ardagh commissions Heye International technology in furnace project � 3. AGR celebrates opening of Dutch research facility � 4. Glass Futures reveals preferred locations for research sites � 5. Beatson Clark invests £2 million in Rotherham glass plant � 6. $375 million glass plant opens in Turkmenistan � 7. British Glass members present sustainable glass manufacturing… � 8. Gerresheimer CEO resigns � 9. Verallia appoints Didier Fontaine as CFO � 10. Christoph Jatzwauk leaves Horn Glass

FalorniTech secures Mexican and Iranian furnace contracts Glass melting is one of the most important and energy intensive processes in the manufacturing of glass products, consuming 60 to 70% of the total energy used in glass production.

The melting furnace must run as a clock and to do that, the design and engineering of a melting furnace are key points.

Recently Italian furnace provider FalorniTech has concluded the engineering design process for Grupo Pavisa in Mexico and Azar Mehr Co of Iran.

Each project had different situations with various goals managed by the Head of the Technical Office, Mr. Biagio Bifano, and his team.

Both projects had the same approach: first of all understand the problems by an accurate preliminary study, then begin the design process with creativity in generating new ideas that may solve the problem much more than just a systematic application of rules and theory.

Mr Bifano said: “With regard to Grupo Pavisa, we rebuilt the melting furnace de-

signing the entire furnace and the gathering bay system with particular solutions aimed to assure maximum homogeneity of the temperature to avoid defects in response to the high quality glass of customer.

“In regards to the Azar Mehr project we supplied a design for a flexible furnace which was easy to use as it is provided with a single production line as per the customer’s choice.

“But the design is already set for implementation of the second process line if the customer would like to have it in the future”.

Container glassmakers can improve by 25%, states Xpar Vision Xpar Vision contributed to the discussion about the future of the international glass industry, with a keynote by CEO Paul Schreuders at Glassman Asia in Bangkok, Thailand, last month.

“Although we work and live in the 21st century, the container glass industry seems to be stuck in the past, caused

by conservatism and the fear for new developments and/or changes in general,” said Mr Schreuders.

“Only a clear and convinced focus on sensor technology, closed loops and robotics, especially in the hot end forming phase, can improve the industry.

“I am convinced that the

container glass industry can do up to 25% better than today: making better bottles, being less dependent on employees, using less energy and less raw materials.”

“My plea is not about future developments: we are doing this right now, in several factories in the world already. It is all about proven technology.”

Read the full story at www.glass-international.com. First with the news.

10 Glass International March 2018

news march.indd 8

07/03/2018 08:24:20

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The integration of Kammann GmbH into the Koenig & Bauer Group will not affect the range of services that we have traditionally provided.

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GLASS SERVICE

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Company profile: Neutral Glass

Gerresheimer’s Neutral Glass invests in extra furnace Avijit Sanyal, Plant Head of Neutral Glass & Allied Industries discusses the company’s recent furnace investment and acquisition by German glassmaker Gerresheimer. The new furnace K means the company can still produce high quality pharmaceutical and cosmetics glass while being environmentally friendly at the same time.

I

� The Gerresheimer site consists of four furnaces.

� Mr Avijit Sanyal.

www.glass-international.com

ndia’s Neutral Glass is one of the oldest pharmaceutical glassmaking plants in the country. In addition to pharma glass, it also manufacturers glass for the cosmetics sector and has recently invested in a new furnace, known as Furnace K, to make Type I glass. The reason for the investment, states Neutral Glass plant head Avijit Sanyal, is to melt high quality glass while maintaining energy efficient operations.

The End Port Gas-Fire Furnace has electric boosters for glass homogeneity and a higher pull rate. The furnace was completed on January 28th this year and streamlined for three lines on Feb 20 and a fourth by Feb 28.

In addition to the furnace, the investment also includes a closed working end, forehearths with electrical heating and an IS machine and annealing lehr.

A cleanroom inspection facility was installed in the cold end as well as ware inspection equipment and camera inspection machines for 100% auto inspection of finished articles.

The company also invested in air compressors with oil free clean air for process and inspection equipment. The company has the flexibility to produce three glass types at the same time.

The more than 80,000m² site at Kosamba consists of 40,000m2 of plant buildings and infrastructure and employs 460 people. There are several furnaces for several production lines.

The site has the capacity to produce more than 1 million glass vials and bottles a year with articles ranging from 2ml to 500ml.

The majority of glass made from the new furnace will be injectable vials and serum bottles for pharmaceutical use. The products will be in Type I borosilicate flint and amber glass as well as Type III soda lime flint and amber glass for both the domestic and export markets. As well as this a smaller part of the production capacity will be for cosmetic bottles in Type III Flint glass.

Mr Sanyal states: “Depending on the article size, the production machines are operated

Continued>>

13 Glass International March 2018

Company profile gerreishmer.indd 1

07/03/2018 09:17:55

Company profile: Neutral Glass

� Furnace K came on stream in February. � The investment included a new IS machine.

multi-functionally. We master all manufacturing processes up to the quadruple drop.”

Strengths

www.glass-international.com

According to Mr Sanyal, the plant has many benefits, which include a nice synergy of experienced and skilled workforce combined with younger staff full of energy. The site has a low employee turnover, which means that staff will learn more about the glassmaking process.

More than 100 staff from various production and administrative functions have received training in the Gerresheimer group’s German and US plants to improve their knowledge base. The site receives regular visits from staff in Europe to exchange knowledge and know-how.

Mr Sanyal states: “Our prime focus is customer service and satisfaction. We resolve our new realities and challenges with good analytical ability. We have continuously reinvented the company by adopting emerging technologies, introducing new processes, products and solutions.

“We also embrace corporate social responsibility and encourage new ideas from existing human

resources to uplift our status.

“We know what our customers want from us, which is a quality product and quality after sales services. These two are our priorities to satisfy our customers. This is our strength and makes us stand out from competitors and improve our business relationship with our customers. Our products are customised as per a customer’s requirement. We take care of all the small needs of customer and we are not only a supplier to a customer but we are also solution provider to our customers.”

The majority of bottles made by the company are for the domestic market it but also exports to the US, Europe, Middle East and South East Asia.

The new furnace will allow it to increase its exports and boost sales in these regions.

Location Kosamba itself is a glassmaking hub in India and has four glass-manufacturing units operating there.

According to Mr Sanyal, the major advantage in Kosamba is the availability of natural gas, which is a clean fuel. Kosamba is geographically situated near major ports and Mumbai commercial centre.

� The revamped cold end includes inspection machinery from Iris Inspection.

14 Glass International March 2018

Company profile gerreishmer.indd 2

07/03/2018 09:18:03

ELECTROGLASS MAKE THE RIGHT MOVE FOR IMPROVED

GLASS QUALITY � A cleanroom inspection facility was installed in the cold end.

In addition, the major raw material and mineral mines are located within 200-300km from Kosamba. The site itself has a natural gas based captive power plant to generate electricity for captive consumption.

History Neutral Glass started as a greenfield project in 1988 at Kosamba and production started with one furnace and three production lines in June 1989. Mr Sanyal states it has served approximately 85% of the domestic customer base during its lifetime.

Over the years, the plant capacity has expanded to four furnaces and 14 production lines. Gerresheimer started business in India from 2010 by selling Gerresheimer Moulded and Tubular glass products. The German company acquired a major share in Neutral Glass and Allied Industries in April, 2012 and subsequently increased its stake in Neutral Glass to 100% in 2013.

Since then, states Mr Sanyal, Gerresheimer has invested in the latest technology in the five years since the acquisition.

This includes an emphasis on automising plant operations at all stages to achieve a completely dependable process and eliminate human errors to the maximum extent.�

Neutral Glass, Kosamba, India www.gerresheimer.com

� The site employs 460 people.

ELECTRIC BOOSTING, BUBBLING & DRAIN TECHNOLOGIES TO IMPROVE QUALITY IN ALL GLASS TYPES

The Specialists in Electric Glass Melting and Conditioning

www.electroglass.co.uk BENFLEET, ENGLAND

Company profile gerreishmer.indd 3

07/03/2018 09:18:08

End of the road for ‘cat-scratch’ cord drains Almost 200 PSR Cord Dispersal Systems installed Money-back guarantee Pay-back time measured in weeks

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Phoenix Award Chairman

� The Phoenix bird.

� Graham Womersley is this year’s chairman of the Phoenix Committee.

Phoenix Award Chairman is honoured to serve committee How flattered are you to be appointed Chairman of the committee?

It was a special honour to be asked to be the Chair of such a highly respected and truly international committee. When looking back at previous Chairpersons of the Phoenix Award Committee (PAC), I realised I had been asked to take on a role previously held by some of the most influential and professional individuals who supply services and goods to the glass industry.

However, it is important to state that

the single, most important aim of the whole committee is to meet each year to select an individual worthy of winning the prestigious Phoenix Award. For 12 months, I have the honour and pleasure of chairing a group of 24 dedicated voting members.

How many years have you been involved with the Phoenix organisation?

I first joined the committee in October 2011. I clearly remember my first Phoenix Award banquet, which was in honour

of Jean Rafael Silva Garcia, the CEO of the Mexican glass bottle producer Fevisa. The banquet was held in the View Terrance, located on the 32nd floor of the Manchester Grand Hyatt on a beautiful Californian evening in San Diego. Seven years later, I am lucky enough to still be involved with such a great group of individuals and suppliers to the glass industry.

Continued>>

www.glass-international.com

The Phoenix Committee met last month to nominate its annual winner for the Glass Person of the Year award. Graham Womersley, this year’s Chairman, discusses the organisation and how it selects an individual who has made a substantial contribution to the glass industry.

17 Glass International March 2018

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Phoenix Award Chairman

What do you enjoy about the group?

The two main events on the Phoenix Award calendar are the spring meeting, where 24 voting members, supported by a group of dedicated past Chairpersons, meet to nominate and decide who should receive the Glass Person of the Year Phoenix Award. This is followed by the important Phoenix Award Banquet, which is held in the autumn of the same year, where the recipient receives their Glass Phoenix Award in recognition of their special contribution to the glass industry. This can be in the field of science, production, or education relating to any sector of glass including: glass containers and tableware, flat glass or electronic glass, fibreglass or scientific glass and architectural or artistic glass.

However, individual members and past Chairs often meet socially, throughout the year, during exhibitions and conferences related to the glass industry all over the world. Individual members, who you may have met for the first time whilst working on the committee, can later become special friends.

The committee works hard to appoint a varied selection of voting members from different sectors and different locations around the world. The 24 voting members in 2018 are made up from nine different countries including the United States, Asia and Europe.

www.glass-international.com

Do you feel you have learned a great deal by being a member?

individual’ in the vast glass industry with all its varied sectors and so many great, dedicated and talented people, is a

What has been your favourite moment/s of being a Phoenix member so far?

“MY PERSONAL AIM IS TO KEEP THE WIDEST POSSIBLE GLOBAL SPREAD OF VOTING COMMITTEE MEMBERS FROM ACROSS THE WORLD - A TRULY INTERNATIONAL PANEL OF MEMBERS FOR A TRULY INTERNATIONAL

”

AWARD.

You certainly learn about different aspects of the glass industry while serving on the committee - not only about other areas within your own market sector, but also about other members of the committee who introduce fellow members to completely different areas within glass.

From my own experience, I knew very little about architectural glass or the production of glass art.

But after being involved in the award for Lino Tegliapietra, a famous Italian glass artist in 2012, and James O Callaghan, a leading British structural engineer in 2017, my understanding of these areas has grown considerably.

Usually the Chairman arranges a meeting with the selected Glass Person of the Year to confirm their acceptance.

Back in 2013, I was privileged to be one of the individuals to meet with the winner, the wonderful Mr Chandra Kumar Somany.

He was a real gentleman and a giant in the Indian glass industry. Sadly, Mr Somany passed away in Kolkata in 2017.

I remember the look of surprise and happiness on his face, when he knew he had been selected to win the Phoenix Award for Glass Person of the Year. It was, in his own words, not only for himself, but also for his company and the whole Indian glass industry. I was humbled to be sitting across the desk from the very proud winner of the 43rd Award.

What are you looking forward to most about being a Chairman?

Being the 2018 PAC Chairman carries a lot of responsibility. I must acknowledge the support of fellow members and especially the past Chairpersons who contributed so much to the work and gave great guidance to the committee.

Following on from my experience back in 2013, I am looking forward to meeting and confirming the nomination of the 2018 winner. As I write these answers, I have absolutely no idea where in the world this meeting will take place.

How would you like to see the committee evolve in the future?

My personal aim is to keep the widest possible global spread of voting committee members from across the world - a truly international panel of members for a truly international award.

This way, we can continue to recognise worthy winners of the prestigious Phoenix Award from all corners of the globe. �

And is the recipient usually keen to receive the award?

In my experience, all recipients in the seven years I have served on the committee have been honoured and gracious in accepting the Phoenix Award.

To be recognised as an ‘outstanding

special accomplishment and something that all our winners are proud of.

I would also like to add, on a lighter note, that the actual glass Phoenix is a beautiful piece of glass art to have in your home or office and will put a smile on your face when you join that elite club of only 47 winners of the award.

� Mr Womersley says meeting 2013 Phoenix recipient Mr Chandra Kumar Somany was one of the highlights of his career.

Phoenix Committee, www.phoenixawardcommittee.org

18 Glass International March 2018

Phoenix Award - 2nd version.indd 2

05/03/2018 12:38:27

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Refractories

A new generation of services for the glass industry P.Carlo Ratto (fused_cast@technologist.com) and Stefano Sanchetti (SSV) discuss a new generation of integrated services that are to be made available to the glass industry that are dedicated to refractories and focus on electrofused materials.

the large financial advantage of buying low-cost refractories or maintaining a prudential procurement policy, spending much more in an insurance policy approach.

It is to be considered that, considering structural performance and glass quality, different refractory prices are associated with different manufacturing technologies and, therefore, imply different scenarios of strong and weak points, and are not simply related to different manufacturing plant locations.

Amazingly, and against the general belief, even major multinational refractory companies do not manage a unique technology across the board, but utilise different technologies and raw materials in different locations to fully capitalize from low-cost locations.

Similar considerations are to be made about the service component that is (or more precisely should be) attached to the refractory, whose importance is steadily

growing, side by side to the streamlining of glassmakers’ technical services.

Can I rely on this supplier for my project?

When considering refractory quality, every specific glass manufacture has different demands concerning refractory durability such as thermo-chemical stress and campaign length, and glass defects allowance, so every specific glass manufacture sets a different level to the minimum qualitative demand for glass contact and superstructure refractories.

Above this threshold level, it is a matter of ratio costs/benefits or most realistically, risks/savings. Whatever the approach, this ratio must be minimised to get the maximum value out of the financial investment that is significant item during a major cold repair.

Continued>>

� �Fig 1. An AZS block with 32%

Na

ZrO2 after a five years campaign

k

and the micro-XRF maps of

Ba

elements from the surface to

Al

the core.

Si

www.glass-international.com

F

used cast refractories have existed for nearly 100 years and play a dominant role in glass furnace lining. But they are not simple, not only in their increased range of qualities covering specialties and niche applications, but mainly they offer a complex variety of costs, quality, technology, advantages and, unfortunately, associated risks.

Fused cast materials are critical materials and, for their role in glass contact and superstructure, pose serious risk potential. Every glassmaker that has had a furnace emptied in the basement due to a bottom’s structural failure, or had to stop production due to an incontrollable (refractory related) glass defects at half campaign life, will know exactly what we are talking about.

Even considering that only a fraction of refractory-related accidents result from refractory intrinsic quality, it is a fact that several glassmakers struggle with the dilemma between capitalising from

Zr

0

1000

2000

3000

4000

5000

6000

7000

8000

µm

21 Glass International March 2018

Ratto refractories.indd 1

05/03/2018 12:39:57

Refractories

� Fig 2. Isocompositional

sample

lines with the depletion

gh

zone of ZrO2 in the upper

Hi

part and the enrichment zone of ZrO2 in the bottom

� Fig 3. An example of the sampling procedure

Casting direction

part of the block.

glass side

for fused cast AZS soldier block.

AZS soldier block

� � Fig 4. In the left side three different performances of the same “nominal” product, in the right side the

www.glass-international.com

multiple samples holder.

While glassmakers are aware of their own needs and how to translate them into a specific furnace design, it is another story when it comes to understanding how much a supplier of fused cast refractory can fit with their project expectations.

Understanding the technological and technical capabilities of a prospect supplier and its reliability in steadily maintaining the minimum acceptable level of quality, is something that requires a deep understanding of the fused cast refractory technological platform in all its shades and flavours, as observed in several low-cost manufactures.

Answering the easy question ‘can I rely on this supplier for my project?,’ implies a great deal of know-how and understanding of the specific plant, process and technology.

Most of these skills are understandably out of the range of glassmakers that, increasingly, must stay focussed on making a profit from their glass production, in an increasingly harsh competitive environment.

This is the background relevant to the refractorists’ auditing, an innovative service provided in recent years, that has been used by major glassmakers to

qualify low-cost producers/vendors of electrofused refractories in relation to their specific needs.

This service is part of a wide package of available services offered to the industry, spanning from post mortem evaluation of furnaces at the campaign end, to technical evaluation of refractory applications, professional inspection of major projects pre-assembled at supplier’s premises, problem-solving relevant to refractory-related in-campaign issues, up to expert witness activity in conflict situations between suppliers and users of such refractories.

Specific testing of electrofused materials Occasionally, during the provision of such services or as a primary requirement of glassmakers, the need arises to perform specific testing of electrofused materials.

These tests, ranging from chemical analysis up to complex technological testing such as exudation, corrosion or blistering potential, are something that only a few world-level independent laboratories can do.

Testing fused cast materials, due to their specific nature and structural

inhomogeneity implies a deep understanding of these materials beside the availability of non-standard testing equipment and long term experience supported with databases, to be used for benchmarking test results that have few or no meaning in absolute terms.

It is important to have a reference benchmark material for every zone of the furnace. It is possible to study a dedicated plan to investigate all the technological parameters for the materials with good performances in the real environment of the plant.

A preparatory tool to understand the interaction between glass and refractories, zone by zone, is the ‘post mortem’ analysis. At the end of a campaign it is possible to organise a strategic sampling of the most important areas of the furnace, for example the metal line, the throat and critical zones of the crown and superstructure.

Fig 1 shows a metal line zone of a plant of coloured glass with the element distribution detected along the thickness of an AZS block with 32% ZrO2.

Continued>>

22 Glass International March 2018

Ratto refractories.indd 2

05/03/2018 12:39:59

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06.03.18 10:48

Refractories

� Fig 6. The blistering specimens (left) and bubbles counting after the test at the microscope (right).

� Fig 5. A low exudation fused cast specimen (left) and an high exudation fused cast specimen (right).

Sampling A key point for the characterisation of fused cast refractories is the sampling procedure. The fused cast microstructure is the result of a direct solidification process (Fig 2), and exhibits an intrinsic level of heterogeneity.

For this reason to compare the analytical results, it is crucial to standardise the sampling procedure.

Fig 3 is an example of the sampling protocol. With this procedure it is possible to assess the glass contact and the internal structure of the block.

www.glass-international.com

Thecnological tests Dynamic corrosion resistance: the specimen for a dynamic corrosion test is an elongated cylinder of 30mm diameter and 230mm height, which is core drilled from the bottom area of the refractory test pieces (Fig 4).

A hole is drilled in the upper part of the cylinder to allow it to be suspended by means of a small alumina rod to an alumina roller, which in turn is connected to an electrical motor, that spins the sample along its vertical axis at a constant speed.

The test is performed in an electric furnace for 24 or 48 hours, at a rotational speed of 15rpm, within a platinum crucible filled with about 1500 grams of glass.

During the test, the sample is immersed inside the glass for about 40mm. The temperature can vary in function of the refractory tested or type of glass from 1200°C to 1650°C (for borosilicate glass applications).

� Fig 7. Typical microstructure of the skin of a FC block (left) and of the core of a FC block (right).

After the test, the sample is extracted from the hot glass, left to cool at a controlled rate, then cut lengthwise with a diamond impregnated saw; the width of each sample was then measured using a gauge or a microscope numerical scale, in correspondence to the ‘metal line’, which usually is the area of greatest corrosion.

The same test can be carried out with a multiple samples holder, up to six specimens (cylinders of 12mm diameter and 120mm in length) per run.

In this case, to avoid turbulence and bubbles forming phenomena, the rotational speed is reduced up to 6rpm.

Exudation: the exudation test is carried out following the method detailed in the ASTM C1223 standard: two cylinders of standard size (25.4mm diameter, 100mm height) are drilled from the block (see Fig 5) and treated as follows:

are performed following the ASTM C-20 standard.

As suggested (but not imposed) by standard ASTM C1223, the test is carried out twice.

The ICG Technical committee TC11 Materials for Furnaces method to evaluate the exudation behavior suggests 10 thermal cycles and is surely more rigorous but we found that the double measurements of the SSV method is a good compromise between reliability and costs.

� RT 1510°C in 12 hours (2.1°C/min); � 1510 1510°C for four hours; � 1510 RT natural cooling (heating power off).

Blistering: Blistering tests are qualitative/ comparative tests devised to evaluate the tendency of a refractory material to produce bubbles when in contact with molten glass at the typical temperatures of the feeder.

Bubbles formed in the feeder are in fact irreversibly incorporated in the glass (no effective fining can take place at such low temperatures), and thus become defects in the final products, so the choice of refractories having a low bubblegeneration potential is advisable in feeder construction.

The exudation of glassy phase is evaluated as the percentage increase of volume of the specimens after the thermal cycle; volume measurements

Continued>>

24 Glass International March 2018

Ratto refractories.indd 3

05/03/2018 12:40:01

www.growth-group.com

Real-time Process & Quality Controls

The refractory specimens for blistering tests are small flatbottom ‘crucibles’, manufactured from 50 x 50 x 20mm sawn prisms by milling an upper cylindrical cavity having 30mm diameter and 10 - 12mm depth, which was then filled with glass (Fig 6).

The thermal treatment used for this test is usually a dwell time at feeder temperature for 48-72 hours.

After treatment, the crucibles are sawn in half and subjected to bubble counting operations. In our internal blistering method we define four indexes: 1 2 3 4

Up to 10 bubbles/gram of glass From 11 to 100 bubbles/gram of glass From 100 to 1500 bubbles/gram of glass More than 1500 bubbles/gram of glass

Microstructure: Important information on the thermal history of the products may be given by SEM-EDS microstructural analyses.

Fig 7 is an example of the typical microstructures of AZS fused cast refractory. In the microstructure we can detect that the Baddeleyite crystals (ZrO2) are split into two different families: � Large white globular grains, slightly elongated, with different degrees of clusterization (cross section of dendritic crystal growth). � Smaller crystals, closely packed with Corundum crystals, forming a mixed ZrO2-Al2O3 eutectic microstructure.

The Corundum (Al2O3) crystals are fine grained and are visible as dark grey areas in the pictures, mainly in association with small sized ZrO2 grains (eutectic microstructure).

The amorphous phase looks light gray and ‘smoother’ than the rest of the sample, especially if compared with Al-rich and eutectic regions.

When you need precise, cold facts… constantly

Integrated services Connecting the technology and materials know-how with the specific analytical knowledge, the integrated services to be made available to the glass industry can offer, for the first time ever at an independent level, specific procedures dictating the best possible sampling plan, so as to maximise the significance of the obtained results.

This point is of paramount importance and represents a unicum in the refractory world, since fused cast refractories, due to their peculiar physical nature, are inhomogeneous bodies and the representativeness of a sample is a major issue that potentially nullifies the best analytical efforts.

The good news for glassmakers is that today they can rely on a partnership providing support to all possible problems relevant to fused cast refractories.

The approach is exempt from any bias or conflict of interests, combining the understanding of glass and electrofused industries under a single roof.

The aim is to provide glassmakers the process of maximising the benefits per cost, minimising the risks associated to the best procurement policy and choice. �

P.Carlo Ratto, owner, fused_cast@technologist.com Stefano Sanchetti, Refractories and Thermophysical Lab. Manager, Experimental Glass Center (SSV), Murano, Italy www.spevetro.it

SELF-LEARNING, COLD-END INSPECTION SYSTEMS We don’t have our heads in the clouds when it comes to the quality of glass, we have real, practical solutions: self-learning inspection systems with sensors providing precise measurements even faster. Like everything else, our cold end inspection is backed by top service, support and training; and our constant research is working towards the Smart Factory – watch this space.

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Ratto refractories.indd 4

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Country overview: Chinese float glass

Flat Glass Industry in China

China Glass 2018 takes place in Shanghai between April 19 and 22. Seema Gahlaut presents an overview of China’s float glass industry and the latest happenings within the sector.

T

he rapid development of its domestic float glass industry in the first 15 years of this century has made China a powerhouse of the global sector. Chinese float glass producers account for about half of the global installed capacity of float glass.

They have bewildered commentators with their stellar growth and low cost production model.

float glass lines due to environmental regulations created a tight demand supply situation in many of China’s key provinces.

With an average capacity use of 67%, domestic producers had a cumulative output of 29.83 million tons of float glass products in the first ten months (January- October) of 2017.

Growth in demand, a limited supply due to closure of a number of lines during 2017 and an increase in input prices has led to an increase of the average selling price of float glass in China.

On a yearly basis, the nationwide average selling price (ASP) in 2017 (figures for first 10 months) registered a growth of nearly 11% in comparison to average selling prices of Rmb 1,331/ton ($209.6) in the year 2016. The ASP has registered a five year high during the last five year (2012-2017) period.

However, the average selling price is Rmb 518 lower than the peak average annual selling price of Rmb 1,996 ($314.3) in 2011.

The increased natural gas and soda ash prices in particular have been the main reasons behind

Capacity additions

Company

ďż˝ Table 1. Installed float Continued>>

glass capacity in China.

Flat glass market share

Number of float

Installed capacity

by installed capacity ( in %)

glass lines

(per annum basis)

Xinyi Glass Group

9.9

19

5.30 million tons

Kibing Group

9.6

22

5.14 million tons

Hebei Yingxin Glass Group

5.7

16

3.05 million tons

Zhongchi

5.5

13

2.94 million tons

Taiwan Glass

5.4

15

2.90 million tons

China Southern Glass ( CSG) Holdings

4.8

14

2.57 million tons

Luoyang Glass

4.5

11

2.40 million tons

Jin Jing Group

3.3

10

1.77 million tons

China Glass Holding

3.3

14

1.71 million tons

Hebei Chnag Cheng Glass

2.8

10

1.45 million tons

Total

54.6

144 float glass lines

29.23 million tons

Others

45.4

162 float glass lines

24.31 million tons

Total

100

306 float glass lines

53.54 million tons

www.glass-international.com

Comprising of 306 float glass (246 operational) lines, Chinese float glass industry and producers have added jaw-dropping capacity in recent years. Fuelled by huge domestic consumption in architectural and automotive sub-segments since 2005, domestic float manufacturers went on an unprecedented spree in capacity additions and float glass lines set ups until 2013, when the government started to implement tougher rules for capacity additions (Table 1).

Demand from the construction and automotive industries led to steady growth in the domestic float glass industry after two years of muted growth in 2015 and 2016. The closure of a number of

27 Glass International March 2018

country overview china.indd 1

07/03/2018 09:00:54

the rise in average selling prices. Average soda ash prices have remained above Rmb 2,000/ton ($315) in the year 2017, compared to Rmb 1525/ ton ($240) in 2016.

Consolidation on the cards

Region/Province

Average float glass selling price (Rmb/Ton)

Guangdong 1,682 Shanghai 1,555 Hubei 1,532 Sichuan 1,502 National average

1,478

Shandong 1,473 Beijing 1,447 Shaanxi 1,407 Hebei 1,366 Liaoning 1,339

� Table 1. Average Selling Prices (ASP) of float glass in different regions in Jan- October 2017.

Float Glass production line size (Tons/day)

Percentage of total Chinese float glass capacity (%)

More than 800

30

600 – 800

37

500- 600

19

400- 500

9

300- 400

4

Less than 300

1

� Table 2. Distribution of float glass capacity on float glass plant size.

Fuel

Number of production lines

Proportion of total

using the fuel category

installed capacity (%)

Natural Gas

73

29.90

Coal gas

77

28.02

Petroleum coke

76

23.02

Coal tar

29

9.00

Heavy oil

31

5.91

Coke oven gas

16

4.14

306

100.00 %

Total

� Table 3. Float glass lines in China according to fuel type.

www.glass-international.com

Float Glass Line

28

Capacity ( TPD)

Shutdown date

Shahe Great Wall line 4

500

6th Nov 2017

Shahe Great Wall line 6

700

15th Nov 2017

Shahe Safe Glass line 5

500

15th Nov 2017

Shahe Safe Glass line 6

700

4th Nov 2017

DeJin Glass line 3

800

7th Nov 2017

DeJin Glass line 4

800

15th Nov 2017

Shahe Ji Heng Yuan

600

15th Nov 2017

Chang Hong Glass line 1

600

15th Nov 2017

Chang Hong Glass line 2

600

15th Nov 2017

Xinli Glass line 2

650

2nd Dec 2017

Xinli Glass line 3

700

2nd Dec 2017

700

2nd Dec 2017

Xinli Glass line 4 Total Capacity

7,850 Tons per day

% of Shahe’s effective capacity

37.4

% of China’s effective capacity

4.9

� Table 4. Float line closures in Shahe City.

The sector in China is gradually consolidating and undergoing structural changes. Production volume and the number of operating float glass lines has registered a slight decline in the past three years. The Chinese government has tightened its policy on constructing new float glass production lines and phased out obsolete and non-compliant lines due to stricter environmental standards on emissions.

Capacity expansion is only allowed in selected provinces such as Anhui and Sichuan provinces, but not in Guangdong and Liaoning provinces.

Most of the leading float glass producers have focused on the production of high-end differentiated products such as ultra-thin, ultraclear and tinted glass to stay competitive in the crowded domestic market.

Sales of these products in the domestic and exports markets have registered steady growth in comparison to raw float glass products.

Tightening supply The Chinese authorities have tightened the policy on constructing new lines and phased out obsolete and non-compliant float glass production lines because of the higher environmental standards on emissions. These policies have stabilised production capacity in the past two years.

Since Nov 2017, glass supply has tightened in the domestic market due to the closure of 12 lines in the glass capital of China, Shahe City. Accounting for about 4.8% of Chinese production capacity, the closure of these lines created a demand supply mismatch, which has resulted in increased prices in the domestic market. Float glass prices rallied to a seven-year high of Rmb 2200 per ton in the Pearl River Delta.

Pollution enforcement is expected to be stricter in 2018. An additional 8-10% of China’s capacity may not get the Pollutant Emission Permit (PEP) in the current year and would have to close, facilitated by the government’s push for coal/ heavy oil based capacities to switch to gas-based.

A new emission standard will also be applied from June 1, 2018, which will lead to the closure of more lines, leading to a predicted supply shortage from 2018 to 2020 in the domestic market.

The year 2018 will also see about 10% of the capacity going off the market due to a cold repair exercise, which will further increase average selling prices (Table 2).

A huge number of the production lines in China use non-gas based fuels. Many of these lines will be phased out in next three years due to the Continued>>

Glass International March 2018

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Real-time Process & Quality Controls

stricter energy efficiency and environmental requirements. This is expected to create further pressure on the demand- supply equation as capacity addition in float glass will be limited until 2020 (Table 3).

Losing its sheen Located about 400km south of Beijing, Shahe, an industrial town in Hebei province is known as China’s float glass capital. The city is home to more than 600 manufacturing and processing firms that churned out a tenth of the world’s flat glass. Hebei also has the dubious distinction of being China’s most polluted province due to the record number of float glass plants.

During November and December 2017, production at 12 float glass lines in the city was suspended due to environmental reasons, which is likely to have a major impact on the sector (Table 4). Between 2011 and 2015, Shahe phased out 57 glass businesses and 66 outdated production lines, reducing 48.6 million weight cases of glass production capacity.

In 2016, Shahe got rid of all sheet glass production lines and 21.8 million weight cases of flat glass.

Exports Despite a tightening supply in the domestic market, float glass exports registered a quantum jump, according to available first six months export data for the year 2017. In terms of volume, the aggregate export volume of China’s flat glass was 106.6 thousand tons in the first half of the 2017, representing a growth of 23.31% compared with the same period of 2016.

Overseas operations Overcapacity and tough competition in the domestic market has encouraged Chinese producers to scout for expansion overseas.

Producers such as Xinyi Glass, Fuyao Glass and Kibling Glass Group have invested in plants in Canada, USA and Malaysia.

Other companies are in the process of setting up plants in African and central Asian countries.

Xinyi Glass commenced float operations in Malaysia in 2017.

The company is constructing two more float lines under a phase two project in Malacca, Malaysia.

These new production lines will enable it to better serve ASEAN-based customers through preferential import duty treatment and appropriate pricing strategy as well as the shorter transport distance that can also benefit the company’s customers in South Asian glass markets.

Xinyi Glass also plans to build two production lines in Canada.

They will start in the middle of this year each with a 1,800 tons per day capacity and a construction period of 18 months.

The lines will cater to glass demand in Canada and USA. According to management, the company preferred Canada over the USA as there is no existing glass plant in Canada plus there are lower taxes and labour costs in the country compared to the USA. Automotive glass giant, Fuyao, has set up a float glass plant in Ohio, USA to support its automotive business in the country.

China’s second largest float glass producer on installed capacity basis, Kibling Group is considering adding another line to its existing production line in Malaysia.

China Glass 2018 takes place at the Shanghai New International Expo Centre, Shanghai, between April 19 and 22. �

Working for a brighter future…

WITH TIAMA HOT-END MONITORING Receiving information faster is possible and easier with our Hot-End Monitoring Sensors. Our system is also more cost effective because it is modular: you choose only what you need. Whatever your choice, it will improve your knowledge of the process and it is backed by our service, support and training, along with constant research. So, watch this space if you are preparing for the Smart Factory.

http://www.chinaglass-expo.com/showgsy/WebReg/default1.htm Intelligence

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Process control

Maximising the output of your Hot End Process control ďż˝ A Standards of Practice meeting between glassmakers and Tiama staff.

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Jean-Vincent Jinot, Hot-End product manager at Tiama, discusses the importance of the Standards of Practices (SOP) when it comes to hot-end process.

T

iama developed several sensors capable of characterising the glass forming process. Those sensors, gathered under the brand name of Tiama HOT systems, are able to generate data required to optimise the glass forming process whether it is at the gob cut with the Tiama HOT mass or on the hot end conveyor with the HOT system suite (I-Care, HOT Eye, HOT Form, HOT Move and HOT Finish).

ďż˝ Tiama HOT mass - sensor at the gob.

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Real-time Process & Quality Controls

For each of those systems, Standards of Practices have been developed in collaboration with our many customers. Each new system installed and each new customer organisation have been an opportunity to strengthen and further elaborate our SOPs, feeding them with the interaction between our sensors and their data, and the optimal way to make use of these data in the forming process.

After several years of exploitation and more than 100 production teams working with Tiama SOPs, we are in a position to develop methods and guide any new comer in the hot end process control in the most efficient and timely manner.

Tiama trainers, former glass plant experts, deliver the optimum approaches to value the customers’ assets.

The approach Tiama’s methodology distinguishes two major phases: First, just before the ‘go live’ stage, the preparation and training phase that corresponds to a transmission of knowledge and SOPs to the teams.

After a presentation of the hot-end product range completed by an introduction of the technologies dedicated to process control, the attendants are guided on how the machines work, how to make use of them, to set them up and how to integrate the machine output into their very own process.

Standards of Practice are implemented.

The second phase then starts, during which all SOPs are reviewed and adapted to the glassmaker’s specifics, taking into account his installation environment, methods and process constraints, production as well as containers specifics.

Once the SOPs are in place, it is time to fine tune the process control.

Based on rich and solid experience from feedback and case studies, Tiama proposes to its customers to adapt to very specific cases its methods. Tiama process and audit experts are deputed to customer lines and disclose all their knowledge to optimise the Tiama HOT systems usage.

Yes, there is intelligence out there... lots of it

A full range of sensors New comers to hot end process control often see the HOT systems as an inspection at the hot end, which it is not.

Although they participate to sort the production, this is only a partial output of what Hot Systems provide to the process control. This range is built around sensors with hundreds of parameters collected and organised in order to deliver process data. Tiama, through the transmission of the Standards of Practice, assists its customers in organising their data collection and data valuation. For each production team, Tiama will propose a time schedule, a reaction standard and a decision tree for any specific conditions identified through the Tiama Hot Systems data management.

Implementing Hot end process control with Tiama Hot Systems is a deep evolution in the way IS operators are conducting their process. Tiama offers to accompany this evolution and to have the community of users benefiting from the Standards of Practice developed by Tiama experts in partnership with our Hot Systems historical users. �

REAL-TIME INTELLIGENT DATA ACCESS By receiving open information from one single, smart database in real-time, you’re even more in touch with all your processes – no matter where you are – which means greater efficiency and productivity, less defects and losses. In fact, it’s like having your own personal satellite backed by our service, support and training.

So, watch this space if you are gearing up for Manufacturing Intelligence.

Tiama, Vourles, France Email jv.jinot@tiama.com www.tiama.com Monitoring

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Closer to The Heat Source Energy Savings

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GLASSTEC 2018

Furnaces

Improved combustion control via advanced CO laser sensor Lieke de Cock, Marco van Kersbergen, Joost Laven and Sjon Brouwer discuss the achievement of improved combustion control in glass furnaces by the application of a CO and O2 laser sensor.

C

ombustion control is of key importance to ensure stable and profitable operation of glass melting furnaces. Most furnaces are fired on >1% O2 excess to be safe and not find any CO in the regenerators.

This results in higher NOx values and lower efficiencies, 1% higher oxygen excess ~1% more energy. Understoichiometric firing is not recommended, due to increased refractory corrosion, increased chance of clogged chambers (more evaporation) and higher SOx emissions.

The thermic most efficient point can be found just above stoichiometric conditions (~0.5% oxygen excess).

Close to stoichiometric conditions, the CO concentrations can vary significantly (+/- 500 ppm) while the oxygen level remains within the accuracy of the oxygen measurements. Small variations in air leakage, temperature or gas composition are not visible in the measured O2 levels, but can easily be detected by the measured CO concentration. Therefore, control is

only possible based on CO concentration measurements when operating at optimal near stoichiometric conditions.

Optimal combustion control There are a series of key factors to achieve optimal combustion control.

Measurements of flue species in the flue gas should be taken as close to the combustion process as possible to avoid influences like air leakages (additional O2) and post combustion (decreasing CO).

The reaction time of the measurements should be fast and sensitive, especially when operating near stoichiometric combustion. The measurements should also be representative for the real values in the furnace.

Most glass producers currently choose to be on the safe side and control on higher O2 excess values to ensure low CO levels. That is why measuring CO is that important.

“Combustion control is changed from controlling O2 only to CO control. Target is to

achieve a complete combustion with various settings for the individual burners to achieve an optimized setting for each zone in the furnace. – Sjon Brouwer, Batch and Furnace manager, Ardagh Moerdijk.”

Some furnaces are still operating without any measurement of O2 or CO. Concentrations up to 8% of excess oxygen and 4% of CO are observed at these furnaces.

Most furnaces are equipped with O2 sensors measuring only at one point (normally the top of the regenerator). In Fig 1 the O2 concentrations in the burner port are shown (range 0-2%).

A point measurement does not give a representative value for the O2 values.

In the top of the regenerator even larger differences can be seen due to the large flue gas circulations.

The laser sensor gives you the average value for the whole width of the burner port which results in a value that is Continued>>

� Fig 1. Oxygen distribution in the burner port of an end-port

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fired furnace (range 0-2%).

33 Glass International March 2018

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Furnaces

Flue gases

� Fig 2. Sketch and picture of the sensor setup.

Sensor

Retro reflector*

2 Lasers 2 Detectors

www.glass-international.com

Also, with aging furnaces, air leakage increases. This can be prevented with repairs, but the furnace will experience varying amounts of leakage air during its lifetime.

When leakage air increases, and there is no burner control, the oxygen excess will also increase resulting in a decreased furnace efficiency (less performing regenerators due to additional cold air).

If burner control is applied, the amount of combustion air will vary to keep the oxygen excess constant.

The primary combustion will therefore become more reducing which might lead to higher CO concentrations in the combustion chamber.

Leakage air doesn’t mix well with the flue gases, and therefore CO can move into the regenerator while the measured O2 levels can still be good.

The increased leakage air goes unnoticed and the thermic efficiency of the furnace will decrease while in the meanwhile refractory corrosion can take place.

Both cases yield to less efficiency, and additional disadvantages like higher NOx levels and higher corrosion of refractory

5000 4500

900 4000 3500

800

3000 2500

700

2000 600

1500

CO in top regenerator [ppm]

“There is no post-combustion anymore and we therefore prevent damage to the steam boiler of furnace 1 and the flue gas cooler of furnace 2. – Sjon Brouwer, Batch and Furnace manager, Ardagh Moerdijk.

1000

NOx [mg/smn3]

more representative for the real O2 concentration. In this way you can go to lower O2 values in a safe way.

Operating close to the stoichiometric point without a reliable and representative measurement of O2 is unwise. Adding a CO measurement makes it easier and safer to operate with lower oxygen consumption.

1000

500

500 400

0 0

1000

2000

3000

4000

5000

Set point CO control in burner port [ppm] NOx [mg/smn3]

� Fig 3. Furnace specific relationship between CO and NOx. materials due to increased CO levels.

When CO is measured, the combustion can be controlled on the CO signal with O2 as indicator for leakage air.

Sensor development CelSian started to develop and test the laser sensor many years ago. The proven technology is now being deployed globally on any type of furnace.

This sensor is the first of its kind in the glass industry and has become an economically viable solution.

The CelSian CO+ sensor is placed on the side of the burner port or flue gas channel to be as close to the combustion process as possible. The CO+ sensor provides average, representative values for the CO and O2 concentration. It is reliable (no drift) and sustainable (non-invasive), because it is not subjected to the harsh flue gases. This leads to low maintenance

and a long sensor lifetime. The typical sensor setup can be seen in Fig 2.

“Measurement works stable and is reliable.

We now have a stable combustion process due to CO & O2 control. - Sjon Brouwer, Batch and Furnace manager, Ardagh Moerdijk.”

Sensor signals can easily be used as an input for the furnace control system.

In this way the optimised combustion process can be controlled by varying the ratio between air/oxygen and fuel based on the CO levels.

In this way the effect of a changing gas composition can also be controlled.

Next to optimising the combustion process (resulting in improved energy efficiency), the CO+ sensor enables the glass plant to operate at the lowest Continued>>

34 Glass International March 2018

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possible NOx concentration of the furnace.

There is a furnace specific relationship between CO and NOx when operating conditions of the furnace are stable. Fig 3 shows such a relationship. By controlling the CO values in the flue gas, the NOx levels will be stabilised as well.

Increasing CO to the highest allowed levels in the furnace will result in a decrease of the NOx levels to the lowest possible levels for this furnace.

Reductions of 20% are observed in industry and this can be enough to avoid implementation of expensive secondary measures to decrease the NOx emissions or, if secondary NOx reduction is needed, to minimize the ammonia consumption of a de-NOx system.

Also SOx can be optimised and controlled as this is affected by the CO levels just above the batch blanket.

“No CO values above set upper limits anymore, so no premature release of sulphates from batch blanket. – Sjon Brouwer, Batch and Furnace manager, Ardagh Moerdijk.”

Real-time Process & Quality Controls

Find the one you’re looking for among the 1,000,000,000,000,000,000,000,000 others out there

It is expected that controlling the CO will also lead to a reduction of defects and has a stabilising effect on product quality due to a more stable combustion process.

Installations After a long industrial testing period, commercial sales of the CelSian CO+ sensor were started last year. One of the first customers was Ardagh Glass, who was already involved in the development of the sensor. Ardagh uses CO+ sensors in their production of soda-lime container glass on oxy-fuel furnaces.

The results of these applications show that for their typical 280 tons/day oxy-fuel container furnaces, NOx emissions drop by 20%, energy savings are 2% and the oxygen savings are 1100m3/day. Return on investments typically range from six months to two years.

“Due to the direct savings of oxygen the application of the sensor is financially even more attractive, cryogenic oxygen is expensive.” – Sjon Brouwer, Batch and furnace manager, Ardagh Moerdijk.”

A leading global glass fibre producer has chosen to go exclusively with the CelSian CO+ sensor on any rebuild of its furnaces, while a furnace designer now delivers furnace designs including holes in the flue gas channel/burner port for application of the CelSian CO+ sensor.

If you aim for the most efficient combustion and aim to have optimal knowledge and control of your process, you have to measure both CO & O2 and both in a representative way.

Only measuring O2 has been the standard for years because there were no other (economically interesting) options. If we want to develop further then the laser sensor is the only solution. �

Lieke de Cock, Project leader, Marco van Kersbergen, Glass Technologist, Joost Laven, Furnace Support Team Leader all at CelSian Glass & Solar.

Sjon Brouwer, Batch and furnace manager, Ardagh Moerdijk.

CelSian Glass & Solar BV, Eindhoven, The Netherlands tel: +31 40 249 0100 email: lieke.decock@celsian.nl web: www.celsian.nl

TRACEABILITY WITH UNIQUE BOTTLE IDENTIFICATION It’s like DNA for glass: an engraved data matrix code with which one can trace any bottle to its point of origin. The hot and cold-end data from all the sensors are assembled in this unique code making it a powerful tool, essential for “big” analysis. Backed by our service, support and training, it’s one of the many ways we’re helping you to get ready for Big Data in the Smart Factory.

Ardagh Moerdijk, The Netherlands www.ardaghgroup.com Intelligence

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05/03/2018 12:44:25

Furnaces

Measuring the thickness of high zirconia refractories Yakup Bayram* discusses how SmartMelter technology has been expanded to monitor high zirconia refractories High zirconia Metal line

� � Fig 1. SmartMelter measurement capabilities of high zirconia block.

Demonstrated SmartMelter capability in the field

A

Location

Probe

Maximum sensing range through high zirconia (scimos CZ)

Metal line

RTS

250mm

A (no grating)

FTS

125mm

B (with grating)

FTS

50mm

B

Grating sillimanite

www.glass-international.com

I

High zirconia sidewall block

8” 16” 21”

26”

5

ML

10

A

B C

Height from top (in)

n 2017, SmartMelter furnace health monitoring created excitement in the glass industry. After years of research and blind validation trials, the technology was released to the public to monitor glass infiltration and refractory thickness. While deterministic data is valuable to all glass manufacturers, the composition of refractory walls vary according to the product. Each segment of the glass industry has unique challenges.

PaneraTech welcomes these challenges by continuing its work with customers to adapt SmartMelter technology to meet their needs. As a result, the company's refractory portfolio is expanding, and high zirconia refractories are one of its most recent additions.

SmartMelter sensors were first validated as a way to measure glass penetration and residual thickness of refractories made of fused-cast AZS block. SmartMelter monitoring programmes have since been used on multiple furnace types to accurately measure bonded AZS, chrome alumina and clay flux furnace bottoms, which has created a new industry standard in furnace inspection. The news of SmartMelter's capabilities generated

D 31”

15 20 25 30

35 2

� Fig 2. Erosion profile of a high zirconia

3

4

5

6

7

8

Block thickness (in)

furnace measured by SmartMelter.

interest throughout the glass industry, and PaneraTech was eventually contacted by speciality glass manufacturers to test the technology on their furnaces.

There are a few considerable differences between high-end glass and standard container or float glass. Firstly, the glass is melted at much higher temperatures. This requires the refractory to be constructed from stronger materials. Most high-end

glass refractories are for furnaces made with high zirconia. These speciality glass furnaces are more expensive than other furnaces and have a notably shorter lifespan. The high operating cost creates a clear value for technology such as SmartMelter, which is designed to extend furnace life.

Continued>>

36 Glass International March 2018

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High zirconia furnaces also tend to create an erosion profile, with the lower block areas weakening first. Because of this pattern of erosion, the manufacturer cannot evaluate the condition of the refractory walls based on the thickness at the metal (glass) line. This area can be strong while lower parts of the refractory walls are thin. It is therefore essential to know the thickness of the block behind the insulation for an accurate assessment of the furnace's condition. If SmartMelter could be used to give accurate measurements of this high zirconia block, it would have a substantial effect on operational costs and productivity.

PaneraTech uses a careful three-step process to test its sensors on new materials. When a manufacturer inquires about measuring a new type of refractory, the SmartMelter team completes an internal validation first.

The block is brought into their facility for comparison and measurements to determine what to expect in a real furnace.

Next, field testing is done to further test the capabilities of the SmartMelter sensors and make adjustments as needed. Finally, a blind validation trial is completed to verify the accuracy of SmartMelter measurements.

www.growth-group.com – Photo: ©ESA

Erosion profile

Real-time Process & Quality Controls

Monitoring programmes PaneraTech worked with speciality glass manufacturers to test and develop its sensors for measurement of the high zirconia refractory. The project was successful, and now SmartMelter monitoring programmes are in demand from speciality glass manufacturers.

The technology has successfully measured the thickness of high zirconia refractory behind insulations such as Siliminate up to 125mm. When grating is used on the outside of a furnace, that depth can be reduced to 50mm.

However, there is a SmartMelter-friendly grating available that eliminates this issue. At the metal line, SmartMelter can measure 250 mm into high zirconia refractory (depending on the type of high zirconia). Therefore, monitoring can begin on the first day a speciality glass furnace begins to operate.

Confidentiality can also be of high concern for these glass manufacturers. This can cause hesitation to begin a monitoring programme despite the clear financial benefits.

PaneraTech recognises this issue and has worked with several glass manufacturers to give the accurate data and recommendations they need without compromising security standards.

The SmartMelter Monitoring programme provides comprehensive technical support to customers while maintaining confidentiality of intellectual property.

For the speciality glass industry, the addition of a high zirconia refractory to SmartMelter’s portfolio is transformational. The ability to “see” behind insulation and measure refractory thickness eliminates the guesswork and allows manufacturers to safely push production to get the most value from these expensive furnaces.

Much of SmartMelter’s success is due to collaboration with the glass industry to customise the technology. As glass manufacturers present unique needs, specific problems and new materials, PaneraTech embraces these challenges. As a result, the applications of SmartMelter monitoring continues to grow. �

When it comes to service, the sky is not the limit...

GLOBAL SUPPORT TO MAKE THE MOST OF YOUR INVESTMENT We’re not in space (yet) but the Tiama team is there for you with more than 70 international experts, offering the best in service, support and training backup. We offer local customer support, on-line spare-parts catalogs, a 24/7 hotline and remote troubleshooting. Our team also provides excellent training programs which help you make the most of your investment and help you identify problems before they happen. So, watch this space to see how our service will help you prepare for Manufacturing Intelligence.

*CEO, Paneratech, Chantilly, VA, USA www.smartmelter.com Intelligence

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Furnaces

Reappraising the role of port-necks in regenerative furnaces Ernesto Cattaneo, Giorgio Minestrini, Alessandro Mola* and Alessandro Spoladore** discuss how, within the Prime Glass project, two techniques were developed to contain NOx in regenerative end-port furnaces.

T

oday’s glass industry faces the problem of nitrogen oxides that come from its typical hightemperature diffusive combustion systems. The first step to contain NOx pollution is to proceed at the level of the combustion chamber employing primary containment measures, which are techniques for the non-generation of nitrogen oxides.

Within the Prime Glass project, Stara Glass, together with the University of Genova and Stazione Sperimentale del Vetro (SSV), developed and patented two techniques for the primary containment of NOx in regenerative end-port glass furnaces that gave excellent field results thanks to the percentages of NOx abatement in the order of 30/40%.

� Fig 1. SWGR system layout.

www.glass-international.com

Strategic waste gas recirculation (SWGR)

1300

Nox [mg/Nm3 @8% O2]

It is scientifically known that a combustion, even at a high temperature, if it is developed in an atmosphere that presents an oxygen concentration, which is lower than the atmospheric one, will produce a lower amount of NOx. In different industrial fields, it is common to lead a part of combustion gas flow inside the combustion airflow, in order to reduce oxygen concentration and, consequently, NOx production.

Stara Glass, within the Prime Glass project, has developed a system that allows applying the waste gas recirculation technique to regenerative glass furnaces maximising the general benefits (Fig 1).

The obtained abatement levels have been >35 % (Fig 2). In the near future, Stara Glass will explore a coupled design of chambers and recirculation system.

Please visit www.primeglass.it for more details about the SWGR system and its interesting energy implications.

Recirculation test: 10%-20%-30% of waste gas in combustion air

1200

1100

1000 Recirculation 900

OFF

ON 10%

Recirculation OFF

ON

Recirculation

ON

Recirculation

20%

OFF

30%

OFF

� Fig 2. NOx furnace’s production during the SWGR system test.

High-Efficiency Air-Staging (HEAS) This technique can be seen as an evolution of the cold air staging, which consists in the development of a reduced combustion inside the combustion chamber, followed by the admission of a post-combustion air inside the waste gas port in order to complete the oxidation.

From the point of view of thermal NOx formation, this technique is effective, because of the reduced oxidation level of the flame.

The cold air staging technique consists of inserting a cold airflow inside the port obtaining a good mix between waste gas, Continued>>

38 Glass International March 2018

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Furnaces

HEAS off 1200

mg/Nm3NOx

800 NOx RC a 400

NOx RC p HEAS on

NOx Torrino

0 0

2000

Seconds

4000

� Fig 4. NOx furnace’s production during the HEAS system test.

1200,0

5000,0 4500,0

1000,0

4000,0 3500,0

800,0

3000,0

CO RC1 mg/Nmc 8%O2

2500,0

NOx RC1 mg/Nmc 8%O2 NOx RC2 mg/Nmc 8%O2

2000,0

NOx RC2 mg/Nmc 8%O2

600,0

400,0

mg/Nm3 8%O2

still rich in CO, and post combustion cold air, but with a high decay of energy efficiency (≈-3.5%), due to the low temperature of the post-combustion air.

With the aim of developing an air staging system without affecting the global efficiency of the furnace, Stara Glass studied a hot air staging system connecting the two ports with a ceramic duct, but it was evident since the beginning that to recover of energy efficiency (≈-0.5%) corresponded to a poor mixing.

In front of this challenge Stara Glass, thanks also to the CFD support, decided to mix the two-previous systems: cold and hot air staging realising a hybrid one i.e. the HEAS system (Fig 3).

In the final solution, an external double cold air flow (CFD optimised air jets with 10-15% of total staging air) at high velocity (250-300m/s) drives the hot air through the connection duct between the ports, thus achieving an energy efficiency that is absolutely comparable to the hot solution (> -0.5/-1.0%) and a satisfactory oxidation of the waste gas flow.

The two air jets are always working, in fact a minimum of compressed air mass flow must be guaranteed in the metallic spears to keep them in good working condition. Synchronously with the inversion of the regenerative cycle, one of the two spears, the closer at the waste gas port, introduces a higher compressed air flow to realise a localised head loss in order to control the preheated air extraction.

As shown by Fig 4 the real results went

ppm CO

www.glass-international.com

� Fig 3. HEAS system layout.

1500,0 1000,0

200,0

500,0 0,0

0,0 0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

5.5

6

%O2

� Fig. 5 NOx (O2), CO (O2).

Continued>>

40 Glass International March 2018

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beyond expectations, in effect since the first test, the NOx abatement has been ≥ 40% (Fig 4).

The system as well as being easily manageable is also reversible by using the damper in the middle of the duct and then closing the by-pass duct, creating two separate and independent ports.

The experimental data show that the HEAS utilisation has consequences on the smoking point; more in detail the CO in the backward position is negligible even at low O2 level and the linear equation of NOx f(O2) are substantially overlapping. This underlines that working at the level of 2% of O2 in the backward position, which is the reference value (which corresponds to approximately 3.2 to 3.5% of the forward position) the NOx values are always below 600mg/Nm3. (Fig 5).

The combination between the DeNOx effect of reduced combustion and high efficiency in removing CO reveals an important advantage: the increment of extraction flow strongly increases the turbulence and shows a fast CO reduction in the top of regenerator, this means a more efficient mixing due to high-speed jet with quicker CO decreasing.

This phenomenon highlights the new role of the port as a reactor, as a thermodynamic mixer. Thanks to the observation of the Reynolds number, it is defined as turbulent and therefore mixing the motion regime inside the port. From this point, the possible design relapse goes in the direction of a probably longer port, or in general with different geometries, to promote the rapid consumption of CO in the waste gas before their arrival in the regenerator, always guaranteeing low NOx emissions.

All theoretical considerations and CFD results have been confirmed during the Prime Glass project by the field analysis of Stazione Sperimentale del Vetro (SSV) with its innovative Multipoint Continuous Monitoring System (MCMS) that was able to collect a grid of chemical analysis data, that proved to be absolutely in line with the CFD models and were useful to further fine tune them.

After the experimental plant of the Prime Glass project, Stara Glass received different orders for the HEAS system, thus having the chance to explore different optimising solutions.

The port-neck is not just a duct, today it is a reactor too The trend for glass furnace combustion today is to use reduced combustions, in order to avoid a higher NOx formation, thus paying the price of a residual quota of CO in the waste gas flow. Naturally, either by physiological air infiltration or by advanced post-combustion systems like HEAS, all waste gas CO ends up oxidised to CO2 before leaving the heat recovery system. The point is: while until a little time ago the waste gas port was just a duct for a fluid whose composition was constant, nowadays the port has raised itself to a more central role in the combustion process, it is in fact a reactor, whose possibilities to affect the furnace ambient and energy performance are yet quite unexplored. Stara Glass is focused on analysing how a new generation of port design can lead a glass furnace to better achievements. �

Acknowledgements The project has been co-funded by the LIFE instrument of the European Community.

*Stara Glass, Genova, Italy, ernesto.cattaneo@hydragroup.it www.staraglass.com www.primeglass.it ** Università degli Studi di Genova, Italy

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Furnaces

The SGT’s Furnace Solutions keeps informing glass engineers This year’s Furnace Solutions conference and training day takes place on June 6 and 7. Melting Technical Committee Chairman, Nigel Longshaw, presents an overview of the event.

I

UK glass industry but international glass producers.

The first Wednesday and Thursday of June is firmly in delegates’ diaries.

History In 1916 Dr. W. E. S. Turner, a chemistry lecturer at Sheffield University recognised the importance of drawing together in one organisation the various groups of people interested in glass.

The Society of Glass Technology was inaugurated at a meeting in the University of Sheffield. Its object was defined as the general advancement of the various branches of glass technology.

From the following century the Society has responded to the needs of industry and academia, and remains a model for other glass societies. The Society continues to grow in importance with members in more than 50 countries.

The MTC continues to proactively promote the values of Dr Turner and the society by attracting new members where ever members meet and discuss industry relevant ideas.

In the factory, at an exhibition or attending a conference, members of the MTC will be happy to tell anyone why

they should be a member of the SGT. At the recent Glassman Asia exhibition Stuart Hakes of FIC UK and other members manned a SGT stand.

Stuart and travelling members will again be happy to see potential new members visiting the SGT stand at Glassman Latin America in Mexico in March.

At Glass Problems 2017, SGT members from the UK, USA and Europe held an informal meeting with the intention to reach out to members from other countries so they feel part of the SGT. This first meeting was so successful members agreed to promote the work of the Society by manning a stand cosponsored by the Glass Manufacturing Industry Council (GMIC) at this year’s Glass Problems to promote the membership of the Society.

Furnace Solutions 13 and Training Day takes place at Lucideon, Stoke-on-Trent, UK on June 6 and 7. �

For more details about Furnace Solutions, the Training Day and Membership of the SGT visit its web sites www.furnacesolutions.org or www.sgt.org

www.glass-international.com

n 2005 the Melting Technical Committee chaired by Chris Windle wanted to give the glass industry something that was relevant, interesting and of value to both young and experienced glass engineers.

The challenge was, “what could the MTC deliver to the float, container, fibre and special glass producers that was relevant to these very different glassmaking disciplines!”.

After many discussions it was decided to organise a conference for the UK glass producers that was practical, friendly and informal. The Furnace Solutions Conference concept was born.

In the early days Geoff Evans and Chris Windle, with the help of Nicola Johnson, Sarah Baxendale and others set the goals which are now the standard of a successful international conference.

For 2013 Furnace Solutions the MTC created a Training Day to compliment the conference. The training day is delivered by passionate glass people who have a vast amount of knowledge which they want to pass onto others.

Since those early beginnings Furnace Solutions has continued to grow in stature and is recognised by not only the

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Testing and research

American Glass Research opens European testing laboratory American Glass Research (AGR) officially opened its testing laboratory in Delft, The Netherlands last month. For its manager, Peter de Haan*, the building and opening of the facility was a career highlight.

How pleased are you with the new research centre?

What products and services do you provide from this site?

The research facility in Delft, in general, offers the same services to our European customers as our main research facility in Butler, PA. It is fully equipped with testing equipment and can conduct all types of testing and analysis of packaging glass. Specific examples include proof of design testing, coating evaluations and fracture analysis to name a few.

Furthermore, the full array of our educational/training and consulting services is now also offered from our location in Delft.

Why did you choose Delft as a location?

The strategy was mainly two-fold; the proximity of the Netherlands to a majority of our European customers makes it an ideal location. Specifically, the Netherlands has a very strong glass packaging industry and is also home to some significant brand owners that utilize packaging glass. Approximately 40% of the beer volume and 50% of the glass packaging volume in Europe originates from locations within a 500 km radius from the Netherlands.

One of the major reasons to choose the City of Delft is its reputation as the premier research hub in The Netherlands.

We have a partnership with the Technical University of Delft that grants us access to their research capabilities.

This enables us to utilise a range of analysis methods and instruments to enhance the results for our customer.

Can you tell me more about the work you and your staff have put into it?

Our goal was to create a workspace where we could easily move between our offices and various laboratories while promoting easy interaction among the team. The

space now occupied by the research facility was previously two separate businesses; one unit housed an art gallery and the other a children’s day care facility.

Both units were required to realise our vison for the research facility; a combination of research areas, office areas and storage space.

The two units were connected and the entire interior was restored to pristine condition. Substantial effort was invested into the infrastructure of the facility. The testing labs all needed to be rewired to accommodate a large number of power outlets for all our analysis equipment.

Additional plumbing was required for our equipment utilising water or compressed air for operation.

How long has it taken to start this centre up?

The initial operational and financial plan for our European research facility was presented to AGR’s Board of Directors in April 2017. We acquired the units in June 2017 and were operational by December 2017. In those five months we were able to fully build the research facility, send the staff for an extended training period Continued>>

www.glass-international.com

The research facility in Delft is a great addition to the capabilities of American Glass Research in total. The building that houses the research facility was chosen specifically to accommodate multiple laboratory areas, office spaces and a large storage space. There are separate labs for fracture analysis, dimensional testing and structural strength testing. All of the research areas are laid out in such a way that they fully accommodate an efficient workflow when working on multiple customer projects. The interior design of the research facility was built from the ground up by our Delft staff members.

Needless to say, that everyone is pleased and proud with how it turned out.

43 Glass International March 2018

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Testing and research

www.glass-international.com

to our main research facility in Butler, PA, and prepare to receive our first customer projects in December. However, learning and training is continuous at AGR. As a Senior Scientist, one of the most important tasks for me is to coach, facilitate and train our technical staff.

Every year both technical staffs (in Butler, PA and now also in Delft) are recertified

Champagne bottles sabered to open facility The research facility was officially opened on February 8th, with a ribbon cutting by the Delft Official City Council Member, Ferrie Förster.

The grand opening included two seminars and welcome speeches.

There was also a unique opening of two champagne bottles by AGR’s CEO, Henry Dimmick, Jr. and AGR’s Director of Research, William (Bill) Slusser, who travelled from the United States to attend the event (pictured right).

They used sabers to expertly cut off the top of the champagne bottles to open the site in front of local dignitaries, demonstrating a technique, which they would not normally endorse. However,

on all our testing and calibration procedures as part of our quality system.

This guarantees that our reports always meet the highest quality standard of our customers. Presently, we are in the process of hiring a new scientist for the Delft location. This hire will free up more time for me to address the managerial side of running a research facility.

However, I must admit that the blood of a researcher runs through my veins and that I will always feel the pull towards the actual research and science taking place in our laboratories. I feel blessed that my new responsibilities allow me to do both; managing the research facility and continuing to work on customer projects.

Whether I am in front of our customers during our seminars or working on their projects I always enjoy the interaction.

food and even pharmaceutical fillers as these segments continue to grow.

Who do you anticipate will use this centre?

How will customers benefit from using this centre?

Our research facility in The Netherlands was specifically created to address the requirements of our European customers including Russia and the Middle East.

Those customers have already started to access more of our services on a regular basis. We are also very pleased with the fact that new customers are becoming familiar with AGR now and the new research facility. The majority of our customers are the large brand owners and glass packaging manufacturers in Europe.

Our plan is to attract smaller beverage,

Our new location will provide our European and adjacent region customers, with quicker response times, at reduced shipping costs. It will also allow us to deliver answers in the same time zone, currency and languages as the customers we are serving.

How long have you worked for AGR? After 18 years of combined experience in the flat glass and packaging glass industry, I joined AGR as a senior scientist in May

in light of the festive occasion they made an exception.

According to Mr Dimmick, Jr: “The new AGR testing laboratory in Delft will provide numerous benefits to our customers including shorter turnaround times which will save money. In addition, they will enjoy the added convenience of transacting business in the same language, time zone and currency.”

More than 50 guests attended the opening, including Verallia, O-I, CanPack, Sisecam, Unilever, Campari and Celsian. The European glass manufacturers and brand owners were provided with a tour of the facility and assorted refreshments, along with the

2013. Joining AGR and ultimately building our European lab was the highlight of my professional career so far. One can say that our strength is essentially the combined knowledge that resides within our staff and the disciplined application of that knowledge to assist our customers.

Everyone has their own area of expertise within AGR, but we are all bound by our common passion for glass.

I specifically enjoy the ‘can do’ mentality of AGR which translates into being there for our customers whenever they need us. Furthermore, the direct interaction with our customers, either in front of a class or working on a project is something which I enjoy on a daily basis. �

44 Glass International March 2018

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Testing and research

opportunity to attend complimentary seminars entitled ‘The Do’s and Don’ts of Lightweighting’ and ‘Understanding and Establishing Impact Criteria’.

AGR demonstrated its capabilities in regards to modern analysis and testing equipment for fracture diagnosis, performance testing and defect identification of glass packing while guests were provided with opportunities to get some hands on experience.

The new testing lab is managed by AGR’s Senior Scientist, Peter de Haan, and his team, including; Office Manager Jennifer Hu-a-ng and Lab Technicians Laura van der Harg and Samantha Beijersbergen van Henegouwen (pictured first page).

The Delft lab team is now fully supported by Commercial Representatives, Aleksander Broda and Ewa Prokulewicz.

American Glass Research is a division of AGR International Inc. �

*Senior Scientist, AGR Europe, Delft, The Netherlands www.americanglassresearch.com

NOSCO ASIA NOSCO ASIA is one of the leading group in Asia and fast growing group in other continents since 2010.

Provides excellent services of hot repairs and customer satisfaction is our main focus.

After Repair

Before Repair

NOSCO ASIA is providing service of ceramic welding repair to all kinds of glass furnaces in Malaysia, Indonesia, Thailand, Philippines, Vietnam, China, South Korea, Japan, Pakistan, UAE, Oman, India, Saudi Arabia and more.

NOSCO ASIA Services: * Endoscope Inspection www.glass-international.com

* Ceramic Welding Repair * Rider Arch Welding Repair * Hanging Crown & Bottom Paving Repair * Checker Cleaning

Tel: +60 127110788 (MY) Tel: +86 13923111639 (CHN)

www.noscoasia.com

Nosco Asia Hot repair specialist

soonlee.ng@noscoasia.com

45 Glass International March 2018

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Forming

� Image1. Compact mass flow controllers (MFCs) from Bürkert Fluid Control Systems enable responsive gas dosing.

Precise control over flame characteristics Lukas Hammer* discusses how modern mass flow controllers with a pressure and temperature independent measuring principle help achieve lower energy costs, improved process control and minimised exhaust gas emissions.

www.glass-international.com

A

s a transparent, largely inert and easily formable material, glass is the perfect choice for a variety of individually formed products. Its hollow body, which can be transparent or pigmented, depending on requirements, is manufactured in huge numbers for the pharmaceutical industry in particular.

In this context, it must satisfy all the characteristics specified in the applicable regulations, such as constant volumes, wall thickness and precise predetermined break points. To achieve this, exact process control is essential. Depending on the product and glass formulation, the processing steps require different burner temperatures and therefore different gas mixtures and quantities of the process gases. Compact mass flow controllers (MFC) by Bürkert Fluid Control Systems enable fast and precise gas dosing, which in turn guarantees efficient process control even with fluctuating gas supply

quality and frequent product changes (Image 1).

Glass production basics The principles of glass production have remained unchanged since ancient times, but the methods used have been refined.

The premixed materials depending on the type of glass are first placed in smelting furnaces or melting zones, where they are melted at defined temperatures and intimately mixed with one another. As is the case during the preparatory process steps, adherence to a defined viscosity or temperature range during the further processing that now follows is essential to ensure product quality.

Mass production The mass production of what are referred to as hollow glass bodies, originated with the high demand for beer bottles towards the end of the 19th century. This demand

led to the development of the first fully automated glass bottle blowing plant.

Here too, the methods used were refined over time and adapted to increasingly stringent product requirements. Due to the high quality requirements of pharmaceutical glassware, suitable glass tubes are not blown, but drawn from the molten material and used as semi-finished products for further production steps.

The different shapes of the tube sections cut to length result from the heating of specific sections and further processing.

In this case, additional gas pressure or supplementary drawing processes are used to create the desired basic shape of the bottles, ampoules or tubes. (Image 2). Since the glass continuously cools during the process, the raw body acquires sufficient dimensional stability to be conveyed onwards to additional work Continued>>

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Forming

taken in a specially shaped flow channel, in which the walls contain a Si chip with an exposed diaphragm (Image 4).

On this diaphragm, a heating element is symmetrically installed between two temperature sensors, which measure the gas temperature before and after the heating. The heating element is at a constant voltage and different to the temperature sensors, which is a dimension for the mass flow of gas flowing through.

Formulation control by bus

(Source: Robert Gerhardt – stock.adobe.com)

steps, which give the product its final shape (Image 3). These include tasks such as drawing necks on ampoules, applying beads and indentations or a special surface treatment known as fire polishing. For these purposes, the glass body must be subjected once again to defined heating (often only at certain points) in order to set the viscosity in the optimum range and make the glass formable. This process uses numerous small gas burners, which are precisely controlled to selectively heat the glass wall, which are usually only millimetres thick.

Flame temperature is key Since the gas composition has a decisive influence on the flame temperature, the burners in the glass processing plants must operate using a precisely adjusted gas mixture. The characteristics of the resulting flame will vary depending on the fuel gas used; examples include hydrogen, natural gas or propane. However, the pressure conditions as well as the temperature of the gases often change in everyday practice. Conventional volumetric gas quantity measurements using variable area flow meters are unable to take this into account because the volume flow measuring devices no longer measure accurately once the pressure or temperature changes.

In a modern, traceable production process that must also be documented, this is simply unacceptable. In this case, the use of mass flow controllers represents a reliable alternative.

The measuring principle of the mass flow controllers used is sophisticated

and based on the thermal method. The heat transfer of the gas used is a direct measure for the mass flow. This weight of gas is independent of pressure and temperature. In this context, the heat transfer depends both on the mass of individual gas molecules and on the absolute quantity that flows. Light gases such as hydrogen rapidly absorb a great deal of heat, whereas heavier propane absorbs less. For this reason, the sensors can be adjusted in advance to suit multiple types of gasses.

In most mass flow controllers used; this measured value is recorded in a bypass channel. A laminar-flow element in the main channel generates a slight pressure drop, which drives a small defined proportion of the full flow through the bypass channel. The measurement is

Continued>>

www.glass-international.com

� Image 2. The versatile material ‘glass’ for bottles, ampoules, syringes, etc.

For the strict requirements of the glass industry, Bürkert’s mass flow controllers not only offer accurate mass flow control for gases in a compact package, but also meet the requirements of a modern and flexible production process. A plant of this type often uses up to 60 burners, which means that up to 120 mass flow controllers control the gas mixtures.

These can be installed as part of a compact and customised system solution and can communicate with one another as specified by the customer using different fieldbus or Industrial Ethernet standards. These systems often feature additional safety shut-off valves for each gas flow, which can also be part of the intelligent burner control block.

The modular structure supports various bus systems (PROFINET, PROFIBUS-DP, Modbus TCP, Ethernet/IP or EtherCAT), making integration in existing system controls much easier. To facilitate swift, market-driven product changes, the corresponding formulations can be

� Image 3. The raw body can be further transported and finally moulded in further work steps.

(Source: Tomáš Belloň – stock.adobe.com)

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Forming

stored in the higher-level control system, which means they can then be loaded simply by the press of a button. The field devices send valuable information round the clock about the device status and the process for the system controls.

This enables predictive maintenance and ensures that any malfunctions that do occur can be quickly localised and rectified. Therefore, the concept allows highly flexible, but robust and economic process control, in line with the trend for digitisation and automation of production processes.

�Image 4. The measurement is taken in a specially shaped flow channel in which the walls contain a Si chip in one place with an exposed diaphragm.

Silicon chip with heating resistance element and two temperature sensors

Technical details in brief The mass flow controllers (MFC) DS8741 and DS8742 are suitable for a broad nominal flow range from 0.01 to 160 lN/min at a gas pressure of up to 10 bar and with rapid response times. The media temperature for neutral, noncontaminated gases can fluctuate in the range from -10°C to +70°C (-10°C to +60°C for oxygen), the measuring accuracy is around ±0.8% of the measurement value (after 1 min. heating time). Up to four different gases can be calibrated as an option. An integrated PI controller ensures excellent control characteristics;

Laminar flow element By-pass channel

the correction time is <300ms.

Depending on the model and version, the controllers offer interfaces for analogue signals, CANopen, PROFINET, Ethernet/ IP, Modbus TCP and EtherCAT. ATEX II Cat. 3G/D approval is also possible. The modules measuring just 84 x 111 x 28 mm (H x L x W) feature a base block made of aluminium or steel with a polycarbonate (IP20) or cast aluminium body. The line

connections are designed with NPT, G threads, compression fitting or flanges.

Others are available on request. The MFC designs can be combined with numerous solenoid valves. �

*Product Manager Mass Flow Controllers, Bürkert Fluid Control Systems, Ingelfingen, Germany www.burkert.com

Efficient burner control made simple When it comes to glass production, everything is under control: Our versatile mass flow controllers allow gas flows to be set precisely and with maximum repeatability – irrespective of pressure and temperature fluctuations. The Type 8741 MFC is also a genuine communications expert: Flexible interfaces ensure seamless data exchange between control and field levels, with minimum installation effort.

That means crystal clear benefits for your production.

Mass Flow Controller Type 8741: This communications expert will keep everything under control.

We make ideas flow. www.burkert.com/BurnerControl

Buckert.indd 3

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History

Prof. John Parker

In a spin I

n my last article, I described the casting and cylinder methods for making flat glass. This article continues the theme, starting with the crown method.

Firstly, a flattened bubble of glass was blown into a hollow disc, and then a pontil rod was attached on the reverse side for support. Next the blowing iron was broken off, which opened the disc.

Finally, it was reheated in the furnace and spun rapidly.

The centrifugal forces generated caused the hollow disc to flip dramatically into a circular glass sheet.

Panes, which are significantly thinner than what could be produced by casting, were cut systematically from the outer rim.

The centre where the pontil rod had been attached was of poorer quality and lesser interest.

Nevertheless, an imaginative glazier could incorporate such pieces, with their ‘bull’s eye’, into his work. For example, to stop the prying eyes of irate wives from watching the antics of their husbands as they spent the family income in the alehouses of the time.

The earliest samples of discs found date back to the 4th century. They were small and mounted in circular plaster frames, measuring no more than 200mm across the whole disc. Because of the way it was made, this type of glass is slightly convex and has circular features.

For example, in the trails of bubbles trapped in the original glass. These make its origins identifiable even from relatively small fragments.

Sections cut from a larger disc have been found in excavations near the church of San Vitale in Ravenna, Italy, dating back to 547 AD, one fragment having evidence of rudimentary Christian symbols drawn on it.

The crown method, at least earlier on, gave a higher quality surface finish

- ‘brighter and more transparent’ due to being fire polished on both sides - but was more expensive and its production resulted in more waste.

Developments of the process continued over time and during the 12th century it became known as the Normandy method, based on the main area of its production.

With the ongoing improvements in technique and the greater quantities of glass that could be melted in a single pot, much larger discs could be made.

By the 14th century, these were up to 600mm across. In 1700, the best discs were Dutch and reached 800mm.

In response to this challenge, Normandy sales ledgers from 1724 reported that diameters of just over a metre were available. In the UK, crown glass remained on sale until at least 1832.

While cylinder glass had the major share of production, the final choice of crown, cylinder or cast glass depended on the cost, application and fashion. Other factors included taxation and whether suitable products were available locally or had to be imported. Cylinder glass production gave larger sheets but crown glass gave better optical quality.

For stained glass windows in cathedrals, one of the main drivers in developing these technologies in the 11th century, the view beyond the window would have been a distraction and image distortion was an advantage. Later, manor houses may have been glazed with one quality downstairs and a lesser quality upstairs.

Manufacturing methods steadily improved over the centuries but were not radically changed until the introduction of mechanisation and with it new processes in the early 1900s. For example, surface decorated sheets were made by squeezing hot glass at 1050°C through patterned, water-cooled metal rollers.

As a counterfoil to mechanisation, the

Arts and Crafts movement developed with the goal of returning glassmaking to its roots.

The late 1800s and 1900s were characterised by increasing experimentation in decorative glass making. Another Roman method for making sheets was re-introduced in 1889.

The approach was to blow a square bottle and then use the sidewalls and base as sheets. This product was characteristically much thicker in the middle of each face than at the edges. Sheets were sold as ‘Prior’s Early English’ or ‘Norman’ slab glass and were often brightly coloured.

Later, another old technology also reinvented itself. Glass casting returned in 1959.

This time around, the glass was cast onto molten tin rather than solid tables and then cooled from 1050°C to 650°C before entering the annealing lehr. Tin proved to be an appropriate support based on cost, melting point, volatility, and surface tension among other things.

The liquid glass, given time, naturally achieved a commercially useful equilibrium thickness (6-7mm), defined by the relative densities of tin and glass together with the surface energies of the tin, melt and contact layer.

The liquid interface at the lower glass surface gives a finish matching the top ‘fire polished’ surface.

Stretching the glass sideways using angled wheels gripping the edges makes thinner sheets; thicker products are made using dams to stop the glass spreading.

To minimise tin oxidation the atmosphere above the melt contains a fraction of hydrogen. So now float glass has been cast in the starring role in modern sheet glass production. �

* Curator of the Turner Museum of Glass, The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk

www.glass-international.com

Prof Parker* discusses how the crown method was used to make glass sheets and highlights recent developments in the process.

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Event review: Glassman Asia

Bangkok welcomes the glass industry at Glassman Asia event Members of the Thai container and hollow glass sectors visited the Glassman Asia event in their numbers recently. The event included a conference focused on Industry 4.0 as well as an exhibition which featured more than 75 international technology providers to the industry. Greg Morris reports.

� Keynote speaker, Viwat

� Gilles Weber, a Vice

� Marco Veri, CEO of

� Erik Muijsenberg of Glass

� Fabio Galliano,

Supatham, Chairman of the

President at Siemens

Socabelec

Service

R&D Manager, Bottero

GMFTI and AFGM

www.glass-international.com

A

n event dedicated to container and hollow glassmaking was deemed a success.

Glassmakers from around the region attended the Glassman Asia event in Bangkok, Thailand, which included an exhibition and conference dedicated to glassmaking.

Viwat Supatham, Chairman of the Glass Manufacturers Industry Club, the Federation of Thai Industries (GMFTI), and Managing Director at Siam Glass, helped officially open the event and provided a keynote speech at the parallel conference.

He discussed the glassmaking capacity of the region and its recent, sustained growth.

Representatives from prestigious glassmakers ofn Thailand including Thai Glass Industries, Bangkok Glass, Thai Malaya Glass, Asia Pacific Glass (APG), Siam Glass, Ocean Glass and Bangkok Crystal were in attendance.

Overseas glassmakers that attended included

Iranian tableware group Noritazeh, Austrian container glassmaker Stölzle and Indian container and float glass company Hindusthan National Glass & Industries.

There were 763 visitors in total, a figure boosted by the fact that some of the Thai glassmakers sent staff from different shifts to attend.

Continued>>

50 Glass International March 2018

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Event review: Glassman Asia

� Viwat Supatham (centre) with Jean-Luc Logel of Iris Inspection machines, officially opened the event alongside staff from organiser Quartz Business Media.

� Danile Hilfiker, President

� Martin Küstner, Managing

� Rene Meuleman, Busi-

� Paul Schreuders, CEO at

� Jean-Luc Logel, CEO at

of Pneumofore

Director, AGR Bangkok

ness leader, Global Glass, at

Xpar Vision

Iris Inspection machines

� left: Xuqing Xie, of AGC Ceramics

� centre: Gregory Lecat, Sales Manager, Heye International

� Right: Yakup Bayram, CEO of PaneraTech

Delegates mingled with numerous technology suppliers who had travelled from all around the world to exhibit.

Exhibitors included Iris Inspection Machines of France, GPS of Germany, BDF Industries, Xpar Vision, Heye International, FIC UK and All Glass.

Glassman Asia included two conferences devoted to topical issues in glassmaking.

The first was titled Future Glass Forum and investigated the increased use of Industry 4.0 in glassmaking. Conference presenters from Siemens, Glass Service, Heye International, Bottero, Socabelec, Eurotherm, Xpar Vision and AGC Ceramics discussed how this new concept can be implemented in glassmaking.

The aim of the conference was to introduce phrases such as Industry 4.0, digitalisation, smart manufacturing, Big Data and the smart factory and to explain their various meanings.

Speakers aimed to answer questions such as

what is Industry 4.0 and how can it assist the glass industry in their presentations.

A separate conference, titled Technology in Glass, outlined new trends in glassmaking. Papers were given by Pneumofore, AGR Bangkok and PaneraTech.

Steve Diprose, Managing Director of show organiser, Quartz Business Media, said: “I would like to extend my thanks to all the exhibitors and visitors who have helped make the show a success.

“I would also like to thank our Thai hosts and in particular the GMFTI who supported the show and encouraged their members to attend in such numbers. The initial feedback we have had from exhibitors has been very positive.

“They were pleased to have had discussions with a variety of manufacturers both from the region and further afield.

“We will explore opportunities to bring the show back to the region in the very near future.” �

www.glass-international.com

Eurotherm

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Event review: Glassman Asia

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CONNECTING THE INTERNATIONAL GLASS INDUSTRY

Glass International magazine Glass International offers readers the latest news from across the hollow, container, flat, and speciality glassmaking industry. It is the official publication for the Glassman Events.

Features include:

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articles

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case studies

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07/09/2017 12:12

Company profile: Guangdong Huaxing Glass

Huaxing Glass continues to grow Li Shenhua, Chairman of Guangdong Huaxing Glass discusses the evolution of the company since its formation in 1987. He is also a member of the executive council of the China National Association for Glass Industry (CNAGI).

G

uangdong Huaxing Glass operates 14 production facilities across China with an annual production capacity of more than 3 million tons, or about 16% of the total output in the country.

The company was established in 1987 in Luocun village, Guangdong province.

It was a small glass factory making bottles for customers in the local area.

Its breakthrough came in 1996 when it built a new furnace and installed fully automatic IS machines. It received its ISO 9002 three years later.

In 2002 it expanded its capacity by building a new factory in Wuzhou city in Guangxi province. In mid-2003, it began the construction of Daye factory in Hubei. Today, it has production facilities in Fujian, Jiangxu, Henan, Guangdong, Guangxi, Xinjiang, Hebei, Zhejiang, Guizhou, and Hubei.

www.glass-international.com

What makes you stand out from other Chinese glassmakers?

We focus on areas where we have a clear competitive advantage. We have many distinctive capabilities. We develop our business of glassmaking around a model based on responsible growth, cleaner energy and the rational use of resources.

We cannot accept the tag of product surplus, high-energy consumption and high pollution.

What are the companyâ&#x20AC;&#x2122;s strengths?

We are a company powered by integrity, teamwork, excellence and caring.

We have a proven track record in providing specialist solutions on complex, challenging, and quality products. In addition, we have a wide network of production facilities in major regions, to serve long term customers domestically and abroad. We always adhere to the principle of quality and maintain our own inspection centres in the central and southern region respectively to enhance the quality of our products.

What is your most popular product?

We produce a variety of goods for the cosmetic, food and beverage industries.

We believe that the demand is market oriented, and customer is the centric of change. With this belief, we have developed a harmonious relationship of cooperation among suppliers and customers.

How many furnaces and how many production lines do you have?

There are 34 glass furnaces and 167 glass bottles production lines today.

Do you use modern machinery in your glassmaking process?

We manage our production with highly efficient and innovative solutions largely based on: clean energy, efficiency, and state of the art technology.

We installed dust and sulphur removing apparatus, where nitrogen and oxygen substances removal are necessary.

We work with reputable and leading machinery and equipment suppliers. We also work closely with our suppliers to test out new production equipment for better production process, efficiency and product quality in glassmaking.

Is the Chinese container glassmaking market a competitive market to be in?

The Chinese market is going through a series of reforms to keep pace with development, innovation, and market conditions. It is transforming from extensive to intensive economy, and from simply getting bigger to getting better.

It has the capacity and competency to sustain business for glassmaking across the country.

Q: What challenges do you face as a glassmaker?

Our main goals are the safety, environment protection and sustainable development.

We apply science and innovation to

find better, safer, cleaner and efficient ways to glassmaking.

In the areas of production R&D, we have been cooperating with several organisations, such as Tsinghua University, Shaanxi University of Science and Technology, and South China University of Technology.

We also conduct our own independent research and development for testing, design, installation, commissioning, operation guidance and personnel training.

How would you like to see the company evolve in the next five years?

We would like to continue to play a role in supporting the economy growth, technological advancement and the wellbeing of the communities.

Our experience will enable us to go wherever clients go and respond to the challenges, minimise the risks and maximise the opportunities by setting up production facilities when necessary to support their businesses and markets. ďż˝

Guangdong Huaxing Glass, Foshan City, Guangdong, China www.h-xglass.com

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Tableware

Handling / Assembly

Container Glass Beverage Processing

Bulk Materials We are your partner for innovative and customized solutions in automation technology.

futronic GmbH | Tolnauer StraĂ&#x;e 3- 4 | 88069 Tettnang Tel. +49 7542 5307- 0 | info@futronic.de | www.futronic.de

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INDUSTRY 4.0 INSIGHT SORG TECHNICAL PAPER ZHAOQING TONGCHAN OVERVIEW I N T E R N A T I O N A L

GI Cover chinese.indd 1

CHINESE LANGUAGE SUPPLEMENT

06/03/2018 14:48:29

成型

▼

TG 4 .1/4”玻璃内层计划采用双滴料和三滴料方法生产。

GPS顺利与Bangkok Glass Containers签订大型合同 Bangkok Glass下属子公司BG Container Glass Company目前在 泰国叻丕府（Ratchaburi）有一处新工厂在建。 其已委托德国IS机器 专家GPS供应五条新型热端IS机器加工线，及配套的安装后支持。

BG

Container Glass Company

支持。这家新型超现代的工厂配备

Limited (BGC)， Bangkok

高 效 生 产 工 具 ， 有 助 于 BGC继 续

不过，在这样规模大小的项目里，IS机器

加强在泰国，乃至整个亚洲市场的

及执行阶段都并不是唯一重要的。GPS必须

领导力。

有效地配合客户，经过深入讨论与交流才能

Glass

Public

Company

Limited下属子公司，计划在2018年新增瓶

www.glass-international.com

罐玻璃产量达约144,000吨。

证明。

GPS为客户提供模块调整和全包解决方

启动项目，全面的员工培训、启动支持和长

为此，这家亚洲瓶罐玻璃制造商目前在

案。在此项目中，为了长期的国际合作伙伴

期支援也必不可少。这个整体概念也同样运

泰国叻丕府建造一家新工厂——Ratchaburi

BGC，GPS再次彰显全力兑现打造全方位服

用在大型BGC项目中，体现出GPS“全盘掌

务供应商承诺的决心。

控”的理念。

Glass Industry Company Limited。 BCG同样委托德国GPS(GlassproduktionsService)在叻丕府新工厂安装IS机器，进一

在叻丕府Glass Industry工厂内新建的五条 IS机器加工线将从2018年7月起开始投产。

步推动技术创新。IS机器专家GPS以其定制

新厂安装的双滴料和三滴料IS机器全部都

化解决方案和全面服务组合顺利赢得此大

是GPS制造——从伺服送料机到横向传送带

型项目合同。

和堆垛机，包括控制和驱动系统。为新厂

也正是我们的工作品质才让GPS顺利赢 得合同。核心项目阶段将在2018年8月前完 成。鉴于项目2017年5月才动工，这个目标 相当具有挑战性，但GPS并不担心。 “我们自信可以在规定时间内，不超预算

将 供 应 何 调 试 五 条 新 型 热 端 IS机

供应所有设备于是GPS目前承接的最大项目

的完成项目”GPS CEO Rolf Themann表示。

器加工线，并提供配套的安装后

之一，也是德国IS机器专家稳健发展的有力

继续>>

58 Glass International，2018

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成型

�

使用新型TT运送系统，完美地将滴料装载至空白

模具(Blank Mould)中。

伺服平行剪切机，搭配CD 3”，适合三滴料转换为双滴料。

最新IS机器

关的初始问题。所以我们将在IS机器投入

GPS自近两年前管理层收购后，在创新和技

运行后的12个月时期内继续为BGC提供支

关于BGC

术优势方面都有重大发展。在公司独立后

持，”Themann解释道。

公司成立于1974年，目前拥有五家玻璃瓶

不久，IS机器专家就实现真正地创新发展， 并注册多个新专利。目前GPS就在BGC项目 中充分运用公司优势。 多数IS机器都采用现代伺服技术。也同样 融合新型机制和程序，比如Proko滴料重量 控制系统。所有模块都是针对工厂具体要 求情况配置的。 “我们希望通过IS机器帮助BGC进一步开 拓市场。我们一如既往地为客户寻找最优 化的技术解决方案，不论是标准的还是定 制的，”Themann先生表示。 新厂生产能力提升，加上使用超先进高 效的GPS技术，BGC无疑会继续成为市场领 导者。 最先进的技术可以推动发展、提升效 率，为瓶罐玻璃产业未来的收益保驾护 航。不过，要想实现这一目标，工厂人员 需要具备必要的技术专业知识。 这也正是GPS提供全方位服务支持的出发 点。为了在IS机器调试前，尽可能为机器操 作人员提供最好的培训，GPS设立培训站进 行培训和测试。 BGC将 从 GPS长 期 支 持 中 获 益 更 多 。 “我们在IS机器安装完成后会继续配合合作 伙伴，保证客户不会遇到任何GPS技术相

BGC是亚洲最大的瓶罐玻璃制造商之一。 罐工厂，每日总产量达3,335吨。相当于大

创新与稳定性

在复杂项目中，比如新生产机构设备、创 新与技术优势都并不是唯一的关键。“这类 大型项目需要大量的协调工作。 比如要就机器选型择和技术水平做出基 本决策。我们的客户相信我们可以运用丰 富的经验帮助他们做出选择，”Themann在 说明项目框架时表示道。GPS已有近100 年从业经验，丰富的行业经验搭配创新能 力、迅捷反应和特别紧密的客户关系都为 公司获益奠定基础。对于瓶罐玻璃制造商 而言，这些都是关键决定因素，也是促使 BGC选择GPS作为此项目合作伙伴的核心因 素之一。 “我们的客户清楚GPS是个比以往更加强 大、可靠的合作伙伴，致力于发挥技术和 经营优势，提供创新型解决方案、交付德

概1200-1700万个玻璃瓶。BGC不仅是泰国 最大的瓶罐玻璃制造商，也是整个东盟地 区最大的。其为国内外食品饮料市场制造 玻璃包装产品，并且提供其他包装材料。 Bangkok Glass Public Company，BGC的 母公司，近期扩大BGF品牌下的浮法玻璃 业务范围，进军施工建造与汽车行业。 GPS是一家德国IS机器开发与供应商，致 力于满足国际瓶罐玻璃制造业的需求。全 方位服务商的产品组合包括IS机器与配件、 伺服机制、送料机与传送带以及不同应用 控制与驱动系统。公司同样为客户提供瓶 罐玻璃制造业相关咨询与培训服务。 GPS针对单个项目、各类规模的普通客户 与公司制定定制化和标准化解决方案，如 有必要，甚至包括融资，因为全包解决方 案并不一定可以满足所有瓶罐玻璃制造商 的要求。■

国制造的品质产品、技术和服务，” Themann表 示 ， 随 即 补 充 道 ： 这 份对于品质与合作关系的理解， 加 上 我 们 的 灵 活 应 变 计 双 方 交 流 ， 为 我 们 赢 得 了 BGC的 信 任 与 合作。”

GPS (Glasproduktions-Service), Essen, Germany www.gps-essen.com

www.glass-international.com

�

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玻璃制造业中的工业4.0

工业4.0如何改善瓶罐玻璃 制造业

技术专家就工业4.0将如何影响玻璃制造业给出了自己的答案。 Erik Muijsenberg，副总裁，Glass Service

1. 工业4.0/数字概念对中空和瓶罐

4. 数字化玻璃制造是否是贵公司执

玻璃制造工艺自动化程度提升是不可避 免的趋势。而今越来越难找到愿意在高

配备专业的研发团队？

温玻璃制造业工作的人员，而自动化程

作重点转到这个方向，而我们的研发就集

度更高的生产无疑会提高产量，在消耗

中在新型感应器的开发上，比方说我们的

更少能源的同时实现更高效的生产。

控制系统Expert System4.0就会添加新型高

不过，工业4.0在我看来只不过是件已有

清远红外摄像头和在线氧化还原感应器。

玻璃制造业有多重要？

行的重要概念？比如贵公司是否为此 是的，对我们而言，工业4.0促使我们将工

一段时日的事件标题而已。有助于我们 不断推进，更多地关注玻璃制造业高级 管理层。

2. 您认为中空玻璃制造业是否会接 纳数字化概念？

5. 贵公司的技术是如何发展，应对数 字时代的挑战？

我们的某些产品之前就是以工业4.0为导向 的，甚至在人们尚未听说过工业4.0前就已 有此类产品。

会，实际上已经开始接受：自动擦拭就 是个简单的例证。下一步就是整合整个 流程，因为热端和冷端通常是分离的。 好处就是节省能源、提高产量与灵活 性，同时可以减少人力投入。

6. 数字时代是否有 任何负面因素？

个人是没有看出任

提高自动化后，经过一段时间就难以再 回到原来自动化不高的状态。比如，在 配备自动化擦拭后，操作人员就会没有 玻璃擦拭的经验。但这个过程也是不可 避免的，也在朝着这个方向不断发展。 以前熔炉也都是人工控制的，并没有热 电偶测量温度，但如今肯定不会有人再 考虑在不清楚测量温度的情况下如何控 制玻璃熔化熔炉。

7. 您对瓶罐玻璃厂未来5到10年有 何预测？

我认为未来实际生产工艺会有更多地整 合和自动化。你将仅需要操作人员来维 护设备，保证机器运转即可。 比方说你可以将目前的浮法玻璃生产 与瓶罐玻璃相比较，在成型过程中 自动化程度已经提高，所以更少的 人也可以产出更多的玻璃。

何负面因素。唯一

3. 贵公司在工业4.0/数字化玻璃制

的负面因素就是在

造概念方面可以为客户提供什么？

Glass Service顺利开发出适用于玻璃熔

www.glass-international.com

化与调节的全自动控制系统，目前已 有超过18年的装机使用经验。这套系统 名 为 Expert System III， 目 前 在 升 级 为 Expert System 4.0，我们在此系统中整合 更多的新型感应器，比如批次成像，提 高工艺自动化程度，也体现其对工业4.0 运动的推进。

Erik Muijsenberg，副总裁，Glass Service

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最终传输链

工业设备 “您可以在中国国际 玻璃工业技术展览 会和俄罗斯莫斯科克 拉斯纳玻璃展览会 mirstekla上看到我们 的身影”

推动 玻璃业 向前发展

两端安装针型激光仪的传输链

Jean-Luc Logel，CEO Iris Inspection Machines 1. 工业4.0/数字概念对中空和瓶罐

4. 数字化玻璃制造是否是贵公司执

工业4.0对于我们这个行业至关重要，就 像各行各业一样，可以推动整个行业的

配备专业的研发团队？

进一步发展。这是一个宝贵的工具，有

用先进的软件与光学技术提供检查解决

助于提升产品质量和生产能力。

方案，每年花费15%营业额进行研发再投

“数 据 就 是 21世 纪 的 石 油 ， ”Gartner

2. 您认为中空玻璃制造业是否会接

资，时刻保持领先地位。

Research执行副总裁Peter

比如，有一支团队致力于DataMatrix读取器

示道。与石油一样，数据也是宝贵的。

的研发，通过读取dataMatrix代码提供可追

最关键的风险就是数据丢失……或者更

是，因为从质量提升和生产能力提高的

溯性。采用这项技术，我们可以追踪/跟踪/

糟糕！之前，“大数据”代表大量数据，大

角度而言，行业可以从中大量获益。以

追溯瓶子在整个生命周期中的情况，了解

到无法在普通服务器上存储。而今，这

Evolution检查机器为例，机器就已引入

与其相关的所有信息，包括何时、何地制

代表您的数据存储在“云”里，如果把数据

自主学习和自主提升功能，包括自动鉴

造及来自哪个模具。

比作新型黄金，我们无疑会妥善保管！

玻璃制造业有多重要？

纳数字化概念？

别雕饰。Evolution 12 和 5 模型均可以根 据反复设置的生产趋势自主调节，同时

行的重要概念？比如贵公司是否为此 数字化对Iris而言始终都是关键。我们运

的兼容性，遵循全球标准，实现生产力 的提升。此外，当然检查机器和感应器 必须兼容。

6. 数字时代是否有任何负面因素？

Sondergaard表

我们的解决方案可以保证数据安全存储

5. 贵公司的技术是如何发展，应对数

在制造信息系统。

业物联网的引入相似，Smart生态系统让

字时代的挑战？

Iris团队有机会开始合作创新。工业4.0是

人和感应器的重要意义。这类设备不仅可

以客户为中心，但工作人员仍是整个流

以保障质量与生产能力，也可以为系统提

机器将独立运行，无需人为操作，反而

程的关键，特别是“售后服务”。

供必要的量化信息与测量结果。

会生成更多数据、监控和监督。不过，

从操作层面看，已经完成大量数字化工

如果没有合适的在线机器，整个数据分析

人类仍然是整个流程的关键。他们是创

作，不少玻璃工厂都已建立专利信息系

系统也就无用武之地。不合适的设备可能

造新信息资源附加值的核心所在。

统，包括Vertech的SIL，EKF的lafys和

导致处理的信息不准确，行动未经调整，

Heye的PlantPilot系统。目前已经实现热

需要纠正。

端信息反馈、反复调整，且具备摆脱人

此外，在线机器应该可以沟

工操作的能力，更具能动性。

通交流，放弃中空玻璃

3. 贵公司在工业4.0/数字化玻璃制

行业广泛采用的常规

我们在4.0概念上已有相当长一段时间的

的世界，沟通的

经验。在公司2002年建立时，我们的检

标准也有充分

机器与操作人员也可以实时互动。与工

造概念方面可以为客户提供什么？

首先，必须强调在生产线上安装一流机器

7. 您对瓶罐玻璃厂未来5到10年有 何预测？

沟通交流方式。工 业4.0是一个开放

查机器设计定位就是“智能化”。Evolution 机器可以从生产条件中学习，自主调整 设置检测缺陷，不论瓶子位置，哪怕是 在雕饰中也不例外。 在Evolution 5中，每个摄像头都是自动化

www.glass-international.com

的。这也就意味着通过与操作人员的互 动，Evolution 5可以根据信息系统指示重 新调整摄像头的位置。 Iris所有的创新都是为每个客户提供的， 多数客户都可以从中获益。这是我们公 司自诞生之日起就秉承的核心——与客 户分享最新发布产品。在Iris，客户始终 都是我们关注的焦点。

Jean-Luc Logel，CEO Iris Inspection Machines

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06/03/2018 14:53:32

Mark Ziegler，营销经理，Heye International 1. 工业4.0/数字概念对中空和瓶罐 玻璃制造业有多重要？

这绝对是必须的。玻璃作为包装材料始终 都面临来自PET和易拉罐之类材料的竞争 压力。所以玻璃制造必须逐渐更好。这条 路永远不会停止，玻璃必须更轻、能耗更 低、玻璃瓶罐也必须对生产价值链上的所 有合作伙伴都具有经济吸引力。

2. 您认为中空玻璃制造业是否会接 纳数字化概念？

如果我们在杂志社看到这样的文章标题或 是在会议上听到这样的演讲题目，答案是

技术解决方案集有三栏，智能数据（比如

高。我们的工作就是选择有意义的事物，

PlantPilot、Tracking & Tracing或数据矩阵

选择可能带来相关利益，提升生产力的事

特殊容器编码）、智能数据机器控制（比

物。

如先进的HML E-Timers或Smart Motion， 最后还有智能工艺控制（适用于滴料重

6. 数字时代是否有任何负面因素？

量、壁厚、器皿间距和冷却控制的大型闭

作步骤。并非所有从技术角度有可能操作

环工艺控制解决方案）。

的事情从经济或复杂性的角度看也是有意

4. 数字化玻璃制造是否是贵公司执

义的。我们认为专注和聚焦时关键。比如

配有不同重量生产或擦拭机器人），以及

行的重要概念？比如贵公司是否为此 配备专业的研发团队？

当然，我们也有一支专业的团队在分析每

肯定的。同样如果您了解一流供应商的产

一生产步骤的问题和改良可能性。Heye拥

品组合是如何发展演变的，答案也是无疑

有的优势在于我们是玻璃业专家，而不仅

的。好处就在于成本、能耗和瓶重都会降

仅是机器制造商。所以我们可以将玻璃业

低，而工作安全性却会提高，生产也更加

相关专业经验与高端工程相结合。

灵活。

3. 贵公司在工业4.0/数字化玻璃制

造概念方面可以为客户提供什么？

5. 贵公司的技术是如何发展，应对数 字时代的挑战？

相比于10或20年前，自动化和软件概念更

我们提供全面的概念，从工程到先进技

加重要。此外，新的工业4.0技术，比如

术，再到服务和生产优化的合作。我们的

强化实境费用也更低可以承受，而且感应

Heye尝试关注的是生产工艺中最重要的工

空白模具的擦拭就是最关键的手工操作步 骤。对此步骤，我们提供的是先进的机器 人解决方案，相对有助于预防损失和提高 生产力。

7. 您对瓶罐玻璃厂未来5到10年有 何预测？

我们的目标是打造智能工厂。一家智能化 玻璃生产工厂在融合最好的工业4.0概念就 可以节能高效、可获利的方式生产玻璃瓶 罐。智能工厂都是高度自动化的，可以在 低单位成本的情况下保持产品高质量。

器和参与者、新的移动设备等灵活性也更 Mark Ziegler，营销经理，

www.glass-international.com

Heye International

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SORG AnzA4 Group_fĂźr Chinesisch_Anzeige A4 Sorg_Chinesisch 24.03.17 14:03 Seite 1

www.sorg.de

www.sorg.de

www.eme.de

www.sks.net

特性

Benoît Burin des Roziers，销售与市场总监，Tiama

1. 工业4.0/数字概念对中空和瓶罐 玻璃制造业有多重要？

2. 您认为中空玻璃制造业是否会接纳 数字化概念？

3. 工业4.0是否会为客户带来好处？ 会，客户会得到好处。一切都是为了保

截至目前，Tiama还在评估如何有效地执行

证在瓶罐玻璃制造业中顺利运行工业4.0

序 。 瓶 罐 玻 璃 制 造 业 在 没 有 工 业 4.0的

商业智能的解决方案。

解决方案。复杂的流程、数据、大量工

情况下是否可以实现目标？整个行业都

我们并不想为客户提议尚未完成验证的解

充满挑战，我们的目标是逐年提升生产

决方案：这也是为什么Tiama目前在同时

厂资源、IT支持、挑战及市场需求。那 �� � 题注 么什么时候会体会到这样的好处呢？这

力、灵活性和创新能力，但客户却每天

处理多个客户案件。其中一个项目目标就

点我无法回答，不过我可以肯定的所有

都在不断的要求我们超越极限。如果我

是将热端感应器观察结果与冷端检查感应

大型企业都不用多久就会开始转型。

们同样考虑人类资源的演变及玻璃行业

器结果相联系。最终的结果都是积极有益

积累的经验，我们真的迫切需要执行新

的：Tiama过去能够提出生产建议，有助

的解决方案。我们相信智能工厂概念是

于改善全球生产线效率。但这只是概念验

一笔潜在巨额的资产，相当适合我们这

证。Tiama目前在工厂层面也是采用同样的

个行业。

方法。

我们打造智能工厂的方法相当简单直

对 Tiama而 言 ， 智 能 工 厂 的 潜 在 好 处 有

接。玻璃工厂全是数据。多年来，这类

三点。

数据都适用于描绘工厂工艺，帮助工厂

首先，让我们自己的客户提升全球效率和

及生产线经理了解生产力状况。我们不

可盈利性。

妨 称 之 为 工 业 3.0， 也 就 是 数 据 构 建 时

其次，将注重从所有Tiama感应器收集的数

代。Tiama早已顺应时代潮流，其IQ产品

据——不论是热端工艺控制系统还是冷质

线就是专门的质量追踪系统。工业4.0就

量检查机器，更别提智能工厂可以追溯产

是评估这类已有数据，利用数据控制玻

品线逐条记录的无限可能（热端激光雕刻

璃制造工艺。为了参与这项挑战，Tiama

特别时间戳及内槽同步代码），从滴料切

目前采取两条路线：一方面，我们正在

割刀托盘装架追踪每个瓶罐的生产轨迹。

开发玻璃工厂热端和冷端适用的工艺控

第三，这也是Tiama创新的指南。

这个问题不错，但我想要颠倒一下顺

4. 数字化玻璃制造是否是贵公司执 行的重要概念？比如贵公司是否为 此配备专业的研发团队？

Tiama整个公司架构都是为了维持智能 工厂活动。通过我们目前主导的多个项 目，我们特别安排一支团队来回答愿意 加入其中的瓶罐玻璃制造商的问题。

5. 数字时代是否有任何负面因素？ 没有负面因素，但挑战在于整个行业和 人员的思维框架演变。这也是Tiama全 力以服务为重点，配备专业团队配合工 厂适应变化。我们仍在开发调整新的服 务，比如强化版、预测性维护程序，支 持这样的新环境。

制与质量控制感应器。另一方，Tiama目 前在开发服务解决方案，利用现有和未

6. 您对瓶罐玻璃厂未来5到10年有

来收集的数据。

何预测？

这是工业4.0的一个方面。基于Tiama所拥

玻璃瓶罐制造业对更年轻的一代具有吸

有的背景、知识和产品，这个方法是可 行的。不过，工厂实行数字化，也是工

引力，数据就像是朋友和同事，瓶罐是

业4.0的另一方面，就是必须为客户打造

与众不同的，而自动化也可以让自由的

灵活变通的工厂应该紧随其后。为了应

大脑更好地创新。

对挑战，Tiama所有产品都具备模块化特 性，不论是流程控制还是质量控制，所 有都共享相同的架构和硬件，可以模式 化，并融入工厂网络之中。 Benoît Burin 销售与市场总 监，Tiama

通往智能工厂之路

www.glass-international.com

des Roziers，

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Stephan Pies，销售总监，futronic 3. 贵公司在工业4.0/数字化玻璃制造

▲

Stephan Pies,

销售总监，futronic

1. 工业4.0/数字概念对中空和瓶罐 玻璃制造业有多重要？

数字化技术仍然在深入工业制造业。作 为自动化专家，futronic全力关注工业4.0

概念方面可以为客户提供什么？

大量的数据并非是个问题。更耗费时间

从 一 开 始 ， futronic追 求 的 就 是 配 合 机 器

与金钱的是如何有序组织信息、解读信

控制与驱动，执行开放资源策略。我们的

息、决定什么信息是重要的，且可以有

系统可以灵活针对不同制造商供应的不同

效地运用。不过这些步骤在很大程度上

规格的机器定制。Futronic在开发FMT24S

可以自动化实现。数字化显然也是在

机器控制过程中就严格遵循这项原则。当

其他领域产生深远影响的，比如人力

然，这也是我们退火窑控制的基础（FLC)

资源。我们面临着一系列的挑战，而个

。我们目前计划将这两个系统连结在一

人、社会、政治家、高等教育机构以及

起。这两个配件都有自由配置的以太网接

提供培训的公司都必须做出调整，而适

口，控制也就可以与更高级的流程控制系

合满足未来需求的工作和职业也必须相

统及FMT24S相连。机器状态、生产能力

应的进行定义。比方说，我确信会需要

或工作变更相关信息——都是对于退火窑

人工机器操作人员。但关键问题是需要

温度控制至关重要的因素，因而也是质量

多少，又要具备什么样的资历。这个问

保证的关键——均可以此方式记录在系统

题关乎我们所有人。

之 中 。 这 可 能 只 是 通 往 工 业 4.0之 路 的 第 一步，但我们决定继续前行，走到最后， 在未来开发出网络化更高的自动化解决 方案。

保障在数字化转型方面的领先地位，开 发可持续的自动化解决方案。

4. 数字化玻璃制造是否是贵公司执行 的重要概念？比如贵公司是否为此配 备专业的研发团队？

我们目前并没有为此建立专门的团队。作

2. 您认为中空玻璃制造业是否会接 纳数字化概念？

力自行投资此类复杂技术和项目所需的资 源。这也是我们与行业中其他合作伙伴紧

而实际也的确已经开始接纳。然而虽在

密配合的原因。您想必也知道在我们所有

在不少行业领域已经将此理论转化为实

研发人员开发新的控制系统时都时刻谨记

际行动，至少部分已经开始，但在瓶罐

这一点。他们必须这么做。我们所有人都

玻璃制造业，生产线的多数机器和配件

必须这么做。如果不这样，新的开发产品

都仍然是独立装置。虽然孤立的解决方

就不太可能在市场上占有一席之地。

同制造商提供的机器也逐渐成为事实。

字时代的挑战？

注价值创造过程，全面优化。优势是不

数据又是另一件事。系统生成的数据在工

可辨驳的：更加节能高效、生产力和操

业4.0中发挥着重要的作用。关键的并不是

作可靠性更高。更不用提对公司盈利性

数据的数量，而是质量。我们因此需要更

的积极影响。

多地考虑实际可以如何处理这些数据。我

66

4.0 industry 60 62 63 65 66.indd 5

何预测？

我们已经讨论过几点：随着数字化、工

更加节能高效，生产力和可盈利性也会 提高。并且也会更加安全。安全性在这 里也是关键。除此之外呢？预计工厂和 设备制造商可以更加灵活地应对客户的 需求，而玻璃制造也显然不例外。不过 我也从未想过我们会以同样的价格生产 一次性产品作为标准产品。我觉得这也 是 工 业 4.0可 能 面 临 的 限 制 。 不 过 最 后 还是难以预测未来到底会什么样。关键 是如果要想在打造自动化未来中占据一 席之地就要集中注意力，不能等待太长 时间。

5. 贵公司的技术是如何发展，应对数

地改良单个机器或工作流，而是整体关

与过去常规做法不同，工业4.0并非简单

www.glass-international.com

为一家中端市场公司，我们目前并没有能

毫无疑问，中空玻璃制造业将会接纳，

案也的确有过辉煌之日，但整合连结不

7. 您对瓶罐玻璃厂未来5到10年有

业 4.0及 相 关 技 术 的 推 广 ， 玻 璃 制 造 会

已有一段时间。我们已经在此方面积累 大量的专业知识和经验。我们的目标是

6. 数字时代是否有任何负面因素？

技术——硬件和软件——是一件事情。大

们需要明确哪些数据可以为客户增加真正 的价值。也需要了解生产网络中的哪些机 器可以带来利润，特别是哪些数据可以， 以及如何带来利润。这才是在开发可持续 性自动化解决方案时面临的真正挑战。 并且，同样的，我们也在逐步掌握的过程 中。

06/03/2018 14:53:40

We Don’t Make the Glass, We Make it Possible • Glass Melting Furnaces • Batch Plants • Engineering • Turnkey Projects • Annealing Lehrs • Project Management

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Etienne Gruyez，总经理，Stölzle Masnières

最后，来自一位玻璃制造商的观点：

Etienne Gruyez，总经理，Stölzle Masnières Parfumerie

1. 在您看来，工业4.0/数字概念对 中空和瓶罐玻璃制造业有多重要？

4. 玻璃制造技术是如何发展，应对数 字时代的挑战？

我们持续在投资市场可得的新技术，但同

预测？

方式。工业4.0不仅限于公司本身。而是

样也在于某些重要制造商合作开发新型机

道五年内技术和市场到底会是什么样的。

覆盖所有供应商和客户。核心理念就是

器，更好地满足我们的需求。我们也在不

所以，我并不清楚未来会是什么样的，但

始终共享信息。考虑到市场是不断变化

停地适应新的可能性，所以也需要在工艺

可以肯定的是，更加贴合市场需求，可能

的，必须可以迅速应对。数字化概念相

和决策中更灵活。

甚至更贴合最终用户需求。

这是一套新的关键工具，也是一种工作

7. 瓶罐玻璃厂未来5到10年有何 相当具有难度的一个问题，我们没办法知

比于投入的成本，的确可以大幅提升应 对速度。同样，工业4.0可以在获得更多 数据进行分析的同时创造更好地产品。

5. 贵公司是否有专家致力于数字化玻 璃制造？

我们已有人员在研究这项新型数字技术， 但与此同时，你需要将整个公司都融入这 个过程之中，因为可能影响方方面面。

2. 贵公司是否接受这项技术？

6. 数时代是否有任何负面因素？

更流线、更高效的方式开发新产品。我

但最主要的问题是为参与使用此类新技术

们可以在四周内提供新的装饰玻璃样

的人员提供培训。他们需要接受学习新工

品。这也是客户要求呈现产品时我们所

具和新的工作方式。需要学着适应。我们

拥有的关键优势。这可不仅是3D打印样

作为公司所面临的挑战就是保证为工作

品，而是真正的样品。

人员提供适当的培训，以便他们可

同样，数字技术在生产工艺中也对我们

以适应持续的变化。而这些变化

有帮助。在玻璃制造工艺中，我们从滴

可能速度更快。

是，我们已经开始。首先，我们能够以

与任何新技术一样，可能会有负面因素，

料、模具温度、玻璃经销等面收集大量 的关键绩效指标。在我们向所有数据集 添加大数据分析时，就可以选择某些趋 势、参数之间的关系，有助于我们更 快、更好、更可靠地生产。机器现在已

www.glass-international.com

经可以根据生成的参数变化自动调整。

3. 工业4.0是否会为客户带来好处？ 是，就像已经解释过的，客户进驻市场 的速度不断加快，并且针对成本特征而 言，产品质量也更好。的确可以提高客 户的灵活性和变通性。

68 Glass International，2018

4.0 industry 60 62 63 65 66.indd 6

06/03/2018 14:53:45

年 高品质级生产

从前... 对于玻璃的热情... 自1946年起实行玻璃机械化， Antonini始终在您身边。 回火炉 玻璃块退火炉 高压绝缘体退火炉 模具预热窑 升级与翻修

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熔炉

缩短安装时间及 减少阻碍困难

来自Nikolaus Sorg的Fred Aker*和Torsten Neudeck**讨论的 是玻璃制造商如何才能优化熔炉安装流程。 引用自11月9日GMIC Symposium（俄亥俄州哥伦布）；“减少玻璃生产熔炉施工、重建和 热修次数。 ”

玻

璃制造商在提高生产能力方面

承受着巨大的压力，包括产出/ 工人、人均使用的产出、每个

炉龄生产和包装的玻璃更多，而每次熔炉

初次体验数字化

全球生产能力

实际总增加值，1995=100 每工作小时

整体经济

故障修理都会导致市场极度低效。 即便目前已采用新方法减少重建次数，

引用自2017年2月McKinsey Global Institute

制造

施工建设

包括机械与电气安装，我们面临的局势仍 然日益艰巨。2017年8月17日出版的经济学 人（Economist）就运用少量统计数据突出 强调此类挑战。 虽 然 自 1995年 起 ， 作 为 全 球 所 有 行 业

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▲

图1 部分西方主要经济体的建设生产能力下降

（来源：The Economist）

少是当地律师。强制要求寄送所有现场工 人的警方背景调查与薪资记录也是常规做

番，但施工建设行业却出现某些文章强调

法。法国近期一处施工场地将每天轮班时

的问题“我们能否解决？施工建设行业的生

间限制在八小时。除注册增加流动性成本

产能力问题。”

外，工作现场持续时间越长也就产生更多

分之一。”

相关差旅费用。我们甚至在将德国工人派 遣至周边国家时考虑不同的聘用体制。就

“德国和日本几乎没有提升。”

像俄亥俄州和印第安纳州的退休金有所不

“美国甚至更差：从20世纪60年代末至

同一样。我们已经将社会保险缴款调低至

今，施工建设行业生产能力已经下降一

12分。虽然可能听起来并不贵，但是不同

半。”（强调补充）（图1——经济学人）

语言之间会产生票据翻译费用，比如从丹

虽然在这其中更注重安全性是个因素，

麦语翻译为德语，之后还有跨国付款相关

但想要施工建设更快、更便宜也仍需克服

的处理费用。并且所有上述需求都要以成

其他困难。经济学人提到多数施工建设公

员国本地语言提交。英语并不适用。

司都是没有形成规模经济的小公司。这类

在工作场地进行合规性检查是普遍情

公司更倾向于避开资本投资，在下一次经

况。针对工作现场持续60天的情况，会给

济下滑时期就可以解雇工人，但与此同时

地方承包商提供某种形式的保护。

有更易于陷入昂贵资产陷阱。

随着施工建设生产能力下降，作为熔炉

过度监管也起到一定作用。过度监管影

承包商，我们的工作就是尽可能快的安装

响Sorg日常方面之一就是保护主义。即便

设备，缩短停工时间，保证即便是关注成

是在欧盟，将工人从一个成员国送往另一

本费用的客户也愿意且能够支付停工造成

个也是常见的。高价劳动力和公司注册都

的损失。我们可以通过更明智的做法完成

并不少见。欧盟成员国要求您在希望派遣

这个目标。更明智的做法意味着要接受数

主管和施工工人的国家聘有本地代表或至

字化。

70

业”，“举例而言：施工建造业是全球数字 化运用最低的行业，据MGI数字化指数显 示。在美国，施工建造业排名倒数第二， 而欧洲则在指数排名中垫底。”这也让Sorg 及其他公司可以利用熔炉重建的机会。出

制造生产能力衡量指标的人均产出均已翻

“在法国和意大利，生产能力下降越有六

报告，“通过生产力变革重新洗牌施工建造

于好奇，经调查在美国只有农业和狩猎的 数字化更低。

方案

在谈及熔炉机械与电气安装时，会有不同 类型的工作，配有不同的解决方案。 1.

未开发土地。这类工作最为简单。仅

占不到5%工作量。 2.

原样重建。假设过去重建文件和记录

没有问题，这就是第二简单的项目类型。 3.

增加吨位或改变排放要求。可能涉及

额外升压或额外升压外加升级设备。 4.

技术变更。最常见的情况就是将侧端

熔炉改为现代端部孔口设计，且尽可能地 缩短停工时间。这是最具挑战性的工作， 需要最多的规划。 针对未开发土地，我们目前在开发高参 量3D模型，为我们迅速制成标书奠定基础 （ 图2 ）。端口孔口瓶罐熔炉时Sorg业务 的主要核心，所以这个模型也是最先开发 的。氧燃烧与侧端模型也在开发之中。 针对原样重建项目，我们尝试从过去重 建的项目中收集尽可能多的文件资料。如 果业主满意过去的项目，我们会尝试聘请 继续>>

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熔炉

2a

▲

图3 激光扫描仪与2维切割，确定滴料点位置。

2b

� 图2 a和b 3维模型，功能全部关闭，以查看管道系统和电缆槽。 上一重建项目的机械与电气承包商。他们 具备本地相关知识与经验。在此情况下， 可能尽快的执行项目，而不会生成大量3D 数据。 针 对 增 加 吨 位 或 技 术 转 换 项 目 ， 3D数 据 生 成 是 关 键 。 为 此 ， 我 们 首 先 采 用3D

�

图4 激光扫描仪与新

�

图5 技术转化。 临时支

型3D几何结构组合。

激光扫描（ 图3/4/5）。Sorg已经具备此项 能力，且我们相比于聘用本地调查人员而 言，更乐于调用具有玻璃行业经验的工作 人员和设备。我们的工作人员清楚需要收

撑日间料斗。

集捕捉的重要内容，并且我们的设备可以 承受玻璃环境的高温考验。一旦我们的人 员进入现场，经常业主会请求我们也为其 他工厂区域进行扫描。激光扫描仪有时会 带来惊人结果。 比如，在我们使用激光扫描确认滴料点 位置时，结果却显示现有的CAD图纸每个 滴料点都误差500mm！ 在进行3D扫描时，Sorg不会过度注重将

如果钢铁出现弯曲，我们希望发现问 题，但没有可以确定横梁的算法，希望可

有助于我们为机械和电气安装妥善准备。

具有经验的玻璃承包商

在另一例中，我们扫描出一处具有200年历

璃安装的电气与机械承包商（图6）。

以模拟原始的情况。了解钢铁的具体情况

德国大量的玻璃工厂衍生出一波专业进行玻

史的旧厂，只有显示在手绘稿中，但却没

除在德国境内采用此类承包商外，我们发

人相信其存在。在强调工程的同事，我们

现在整个欧盟，甚至是欠发达国家里采用也

也可以避免现场的问题和拖延。我们最主

同样成本合算。

要的目标就是节约成本与实践，避免现场 变化。

但在美国等不接受德国标准与劳力的国 家，我们会采用不同的方法。在美国，我们

会配合本地工程合作伙伴的工作，比如JHI SSOE和Borton Lawson。 我们会让他们用本地投标商熟悉的方式 将工程到本地代码都生成出来。之后让其生 成投标书和现场初始问题。Sorg随后基于整 体效果，而绝非只有价格来做出最终决定。 理想安装情况：我们在耐火建造的同时开 继续>>

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整个点云转化为3D CAD模型。

71

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熔炉 始机械与电气安装。换而言之，在钢铁覆盖

可能的情况下尽快开始零碎地机械与电气安

平台结束后。我们采用小队经验丰富的玻璃

装。我们会被迫使用梯子和杠杆升降机来代

承包商。一队负责熔炉。另一队负责前炉。

替尚未建好的平台。我们会监督客户选择的

如果所有平台都按时完成，安装时间在三周

无经验的承包商。且随着项目节点流逝，客

到三周半。目标是在点火前两天完成，冷检

户会派更多没有经验的人来插手问题。在此

■ 滑轨需要测试。

查所有项目。

类情况下，工作几乎不可能在点火前完成。

■ 水冷准备妥善且经过测试。

不太理想情况：平台推迟完成。我们会在

如果Sorg无法在点火前完成机械与电气安

装，我们会有下列最低要求： ■ 客户书面承担推进项目的责任。 ■ 交流蓄热炉逆转需要准备妥善，且可 以运行。

如果无法在加热的同时完成工程，持续高 温状态也可能让我们赶上进度。

结论：

■ 增加工程量，突出数字化，相比于现

场变更费用更少。 ▲

图6。 德国目前已有大量玻璃工

厂。 Pic source glassglobal.com

■ Sorg更倾向于采用专业的玻璃承包商 而非本地可用的。 ■ 调用费用，包括国际差旅，可能通过 提高生产力弥补。 ■ S o r g 通 常 在 与 专 业 玻 璃 承 包商合作时，仅需要一半的安装 时间。■

* 销售总监，** 服务与安装部

经理，Sorg, Lohr-Am-Main, Germany www.sorg.de

数字思维 数码打印

梦想照进现实。 JETARTSERIES Fermac china.indd Furnaces SORG 70 171 72.indd 3

中空玻璃项目的全数字化打印工作流程 2017/4/3 21:45:44 06/03/2018 14:56:36

碎玻璃

评估在氧化还原状态下的碎 玻璃质量 Stefano Ceola*、Nicola Favaro**和Antonio Daneo***重点强调一 款分析工具，适用于控制和评估碎玻璃对玻璃最后氧化还原状态 的影响。

本

论文提出在玻璃行业使用碎玻

原(I-Redox)，以检查制造的碎玻璃品质和

璃作为次级原材料所遇到的几

稳定性。

个常见问题。首先概括说明欧

范围

玻璃行业研究和担心的主要参数之一就是玻

本文从理论和实验两个角度说明如何确

璃的氧化还原状态。其会决定硫/硫酸盐的

定氧化还原比例，而在玻璃行业通常适用于

溶解度及玻璃的颜色[1]，并且其稳定性在成

在概括说明碎玻璃利用产生的最常见

作为质量检查的工具，随后描述和讨论的是

品玻璃质量控制体系中具有关键作用。

问题后，特别强调碎玻璃可能导致成品玻

I-Redox作为新工具来确定碎玻璃在批次产

在目前的做法中，碎玻璃占了一大部分分

璃最终氧化还原比例不稳定的问题。在此

品中对于氧化还原的影响及作为参数监测碎

批加料量，在某些欧洲玻璃工艺中甚至达到

介绍一款新的分析方法学，即无机氧化还

玻璃氧化还原的变化性。

批次加料的90%。

盟利用碎玻璃的水平及其优势与劣势。

▼

图1.2014年欧洲瓶罐玻璃循环利用收集率。

继续>>

瓶罐玻璃——2014年 欧洲收集回收利用率

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平均利用率 欧盟28国：74% 欧洲（包括挪威、瑞士、土尔其）：70%

FEVE

欧洲瓶罐玻璃协会 “基于各国联络点提供的近期可得数据进行行业预测”

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碎玻璃 概况。

优势

劣势

使用更少的原材料。

能耗（碎玻璃加工）。

不同，主要取决于来料类型。

原材料直接排放的CO2更少

玻璃质量问题（氧化还原、金属等）。

用物，而输出可能是混合碎玻璃或是通过

熔化耗能更少。

某些系统磨料磨损更高。

二氧化碳排放更少，降低熔化能

对于某些公司而言，操作顺序可能有所

间接二氧化碳排放（碎玻璃收集）。

为加工处理原材料。

交通运输成本更低。

熔化排放的CO2更少。

颜色区分生成的燧石碎玻璃以及剩下的碎

间接能耗和CO2排放更少。 （提取）。

▲

输入材料来自市政废弃干燥可循环利

玻璃。 如果管理得到，上述处理可以产生最终

表1.碎玻璃循环利用的优势和劣势。

混合碎玻璃产品，实际上没有任何陶瓷、 石块、塑料和金属污染物。

输入

粉末

铁/钢

铝

颜色区分机器的选用有助于增加循环利 用的碎玻璃量，不过也出现某些意料之外 的矛盾。投料碎玻璃的氧化还原情况取决 于不同颜色的相对量。 通常掺有燧石碎玻璃的混合碎玻璃市

塑料分离

筛滤

磁铁分离

非磁铁分离

场上已不多见，并且在分离燧石玻璃后获 得的有色碎玻璃通常是绿色和琥珀色混合 的。 这种颜色构成的变化进而产生不同的产

颜色分离

玻璃陶瓷

铅分离

CSP

品。比如，在生产有色玻璃中使用时，小 变化可能改变批次产品的氧化还原情况， 为玻璃颜色增加不稳定性，特别是在约化 玻璃的情况下（琥珀色和UVAG）。

输出

无机氧化还原 玻璃陶瓷碎片

铅碎片

陶瓷等

方法论说明

下列段落描述的是在决定碎玻璃氧化还原 率，也就是无机氧化还原时采用的步骤，

�

图2.设计可行的工艺获得干净的碎玻璃。

其可利用各种能源与环境优势，已经成为 多数大型玻璃生产不可替代的构成。 玻璃行业在碎玻璃使用方面已积累丰富 的经验，从八十年代[2]初次使用就已克服数

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道难题，通过找到合适的技术解决方案或与

74

从在玻璃工厂适当进行材料取样开始。 将至少50kg碎玻璃样本磨碎到大小不超 碎玻璃的使用于玻璃行业而言有利。主要 优势与劣势参见表1。

处理工艺

处理工艺包括清洗废弃玻璃上的污染物，比

碎玻璃供应商合作，生产更清洁、更稳定的

如塑料、陶瓷、石块和金属，从而获得近乎

产品。

干净的碎玻璃。

本文提及一款新型分析工具，适用于控制

这不仅是在玻璃熔炉中循环利用碎玻

和评估碎玻璃对玻璃最后氧化还原状态的影

璃所必要的，也是为了遵守End of Waste

响。此外，经SSV开发，适用于确定无机氧

European条例。

化还原的新方法也在文中说明，并选用实例

这项条例制定的标准明确的是如何不再

应用加以解释。

让材料变为废弃品，而是作为次级原材料存

研究背景

储、装运和使用。

碎玻璃是欧洲玻璃行业最主要的原材料之

清洁，从可循环利用材料上清除任何非玻璃

一。超过60%碎玻璃都会经过循环利用生产

材料。

过3mm。磨碎的材料随后平均分在取样分 隔器，获得1kg样本，随后提交熔化。 熔化的第一步就是以550℃高温将材料放 在陶瓷坩埚里三小时，为了烧尽剩下的有 机材料（比如木材、纸张或塑料）。 在有机清除后，以1350℃进一步加热和 熔化碎玻璃，直至玻璃没有任何气泡，之 后铸型再以530℃退火。 随后获得的样本进行切割打磨，获得适 合XRF分析和紫外可见光谱光度测量分析 的样本。

处理工艺包括一系列步骤，希望可以高效

出新的玻璃包装，甚至某些熔炉生产的绿色

不同公司的工艺细节可能不同：图2中的

玻璃循环利用率可以达到90%以上（图1）。

原理图就是旨在获取干净碎玻璃的可行工艺

继续>>

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tb635_TECO_A4_Advert_2017Style_v3_4Ads.qxp_Layout 1 21/03/2017 16:50 Page 3

熔炉 技术

不断设计、 建造和现代化

www.teco.com 熔炉总容量

®

TOLEDO ENGINEERING / TECOGLAS / ZEDTEC / KTG ENGINEERING / KTG SYSTEMS / EAE TECH

意大利威尼斯慕拉诺岛SSV大楼。

1 2 3 4 中等

偏差

氧化铁 0.30 0.30 0.29 0.31 0.30 0.006 氧化亚铁 0.092 0.089 0.094 0.10 0.093 0.004 氧化还原比 34 33.2 35.9 36.2 34.8 1.3 ▲

表2.针对每项测量和计算后的氧化还原率计算的标准偏差结果。

1 2 3 4 5 6 7 标准偏差 氧化亚铁 0.22 0.2 0.23 0.22 0.23 0.18 0.17 0.022

氧化铁 0.37 0.39 0.38 0.37 0.38 0.36 0.36 0.010 氧化还原 66.1% 57.0% 67.3% 66.1% 67.3% 55.6% 52.5% 5.9%

▲

表3.无机氧化还原变化性的文本结果。

实验确定氧化还原率

氧化还原率是合成值，可以下列公式表示： % Redox = Fe(II) / Fe2O3(tot) 还原铁值，Fe(II)，以FeO表示，通过可 见远红外(Vis-NIR)分光光度法确定。 将尺寸合适的玻璃样本放在分光光度计 上，就可以显示器Vis-NIR光谱。 1050nm处的信号可以其他地方描述的程 序[1]表示，以此计算玻璃中的FeO浓度。 总铁量通过X-光荧光光谱（WDS-XRF） 测量，并以Fe2O3表示。在对比分析分析相 关的每个化学物种校准曲线后计算结果。

www.glass-international.com

计算

也就是碎玻璃含有的有机污染物内容。 仅了解LOI通常无法避免颜色和氧化还 原不稳定相关问题的产生，特别是约化 玻璃。 混合碎玻璃可能在碎玻璃处理工艺中经 过颜色区分获得，当然也有不同数量的燧 石玻璃掺杂其中。 针对控制和修正碎玻璃氧化还原变化性 提出一种不同的方法。 针对确定碎玻璃氧化还原率提出一种标 准方法，也称之为无机氧化还原。 这项参数可以说明碎玻璃对于制成容器

从 针 对 XRF和 UV-NIR光 谱 每 项 测 试 评

最终氧化还原状态的影响特点，特别是在

估实验误差来看，每项测试分别预测在

评估其在最终玻璃容器质量参数中的不稳

50ppm，而约化玻璃无极氧化还原的分析不

定性时可以参考。■

确定性在氧化还原单位元素的1.2%-1.8%。

方法论验证——反复性

测量一系列样本的（采用相同流程收集每 份样本）氧化还原情况，以此对同一堆碎 玻璃采用上述方法。

表2中的结果显示的是针对每项测量和计 算后的氧化还原率计算的标准偏差结果。

方法论

引用 [1]

“Diffusion and Redox Reactions of Sulfur in

silicate Melts”, H. Beherens, J. Stelling, Review in Mineralogy and Geochemistry, Vol. 73, pg 79-103, (2011) [2]

“Problems related to the use of Cullet and to

the reuse of dust from Fumes Treatment Plants”, B.

为了检测无机氧化还原变化性，针对取自

M. Scalet, International Glass Journal, No. 87, pg

日常使用操作的样品碎玻璃的一系列碎玻

65-69, (1996)

璃样品运用此方法论。结果请参见表3。

[3]

“Fast Spectrophotometric Determination of

在I-Redox分析不确定性的计算过程中会考

在表3中，可以观察到无机氧化还原出现

Fe3+ and Fe2+ in commercial glass”, A. Daneo, P.

虑总铁量XRF值的分析不确定性（以Fe2O3

意料之外的大幅变化：考虑到三分之二的熔

Polato, M. L. Scandellari, M. Verità, Proceedings of

表示）和通过紫外可见光谱光度测量分析

炉加料都是混合碎玻璃，在此情况下，最终

XVII International Congress of Glass, vol. 3, pg 83-

法确定的FeO值的不确定性。

玻璃氧化还原变化的变化率大概为4%。

88, Chinese Ceramic Society Beijing (1995).

下列公式描述的是氧化还原值的分析不确 定性，其中A是FeO的浓度（Vis-NIR）， B是代表Fe2O3浓度（XRF)。 1 B

2

� uA2

+ A2 u 2 B B

结论

在本文中，作者提出监督和控制玻璃碎片 的新方法。这种方法适用于清除塑料、金 属、CSP石块等污染物的碎玻璃，也称之为 适于熔化的碎玻璃。 即便是最干净的碎玻璃仍然可能严重导 致玻璃工艺的不稳定，因为会有LOI变化，

76 0

*作者研究员，

**联名作者：实验室总监， ***联名作者：研究员

Stazione Sperimentale del Vetro (SSV), Murano, Venezia, Italy www.spevetro.it

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Cullet SsV 73 74 76.indd 3

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06/03/2018 14:58:48

公司简介：肇庆通产

投资改善肇庆通产市场概况 中国瓶罐玻璃制造商肇庆通产为Heineken和Carlsberg等全球多

个饮料品牌供应产品，其工厂位于广东省。 公司目前在厂址进行一

项大型投资，多个欧洲技术供应商参与其中，比如Vertech、Horn、

Heye、Iris、MSK、AGR和Antonini。 其副厂长翁建忠与我们交流有关 公司的情况。

▲

这家中国瓶罐玻璃制造商是在近期一次大规模投资中安装的

▲

SIL系统广泛覆盖生产工

艺，符合玻璃制造商的实际 需求。

贵公司产品有哪些，哪款是最受欢迎的

您是否可以简单的介绍一下贵公司？

目前，就设备与分厂产量而言，肇庆通产玻璃

肇庆通产玻璃技术有限公司是深圳通产集团投资建

技 术 有 限 公 司 可 以 在 中 国 公 司 里 排 在 前 10。 我

立的一家现代玻璃瓶制造商，总投资达6.9亿人民币

们主要生产中端和高端啤酒瓶，主要客户包括

（1.035亿美元），目前有近500名员工，属于深圳国

Heineken、Carlsberg、Budweiser、珠江和青岛。

有资产监督管理委员会管辖的国有独资公司。

产品？

公司位于广东省肇庆市高要区金利镇金淘工业园。

继续>>

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Vertech SIL系统。

77

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Company profile Zhaoqing Tongchan 77 78 79.indd 1

07/03/2018 11:15:27

公司简介：肇庆通产

▲

近期投资也包括来自

Heye International的IS机器。

贵公司有多少个熔炉，日产量为多少？

目前我们有一家工厂，两个熔炉。日产量在125-164 万瓶。

技术优势和多个独立知识产权：

肇庆通产玻璃技术有限公司 总部

“我们的优

势也在于玻

www.glass-international.com

a.

熔炉设计与改良；

b.

玻璃行业设备改良；

c.

配料成分

d.

碎玻璃加工

e.

循环经济技术

我们的优势也在于玻璃制造设备，整条线都配备从 海外供应商进口的先进设备。我们聘请了Horn Glass 负责熔炉、前炉和工作端的设计工作，并请他们监督 安装。我们有从Heye International购入的10-段三滴料

璃制造设备

IS机器和10-段双滴料IS机器，还有从Antonini进口的

备从海外供

检查设备来自Agr Inernational。码垛机和热收缩包装

先进设备

1月分别通过ISO9001、ISO2200和ISO1400认证，公

整条线都配 应商进口的

”

璃市场？

目前中国瓶罐玻璃市场是买方市场，出现了混乱竞争

贵公司的优势在哪里？ 反面：

您觉得应该如何形容中国目前的瓶罐玻

退火窑。检查机器是Iris Inspection Machines供应的， 线上的多功能检查机器来自Heye Inernational而线下

机来自德国的MSK。 我们的管理体系在2011年6月、2013年2月、2016年

司也严格执行精益管理。

从地理角度看，主要客户集中在哪里？

的情况。啤酒瓶消费量逐年降低，也越来越多地使用 回收瓶和易拉罐。与此同时，食品业对玻璃包装的需 求日渐增加，在一定程度上弥补了啤酒业对玻璃产品 需求降低的缺口。 国家环保监管力度加大对具有竞争力的企业而言是 个好消息。综合不同因素，与欧洲市场相似的大型生 产集团可能出现在中国。

贵公司近期在五条线上安装了Vertech的 SIL系统。 为什么选择SIL系统？

公司大量投入资金，如果不生产中端和高端产品，就 根本无法盈利。所以，我们只有关注生产管理才能保 证效率。纸质版质控反馈显然无法跟上公司的发展速 度。我们一致认为充分利用真实的生产信息会对产量 有重要影响。在生产线上安装信息系统自然也成为公 司的共同需求，这同样也是供客户稽核的一个基本方 面。 作为玻璃行业信息系统的专业制造商，Vertech 的开发团队始终致力于完善系统，满足客户需 求。Vertech是公司的首选，因为SIL系统广泛覆盖生 产工艺，符合我们的实际需求。

主要客户集中在广东、海南、云南、江苏和浙江省， 当然也有多个亚洲国家。大概有四分之一的产品会出 口到海外市场，包括印度尼西亚、泰国、马来西亚、 越南、老挝和缅甸。

78

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Company profile Zhaoqing Tongchan 77 78 79.indd 2

07/03/2018 11:15:31

公司简介：肇庆通产 SIL系统将为贵公司带来哪些好处？ 随着公司员工使用SIL系统的熟练度提高，过去冷端 经常无法向热端反馈在冷端发现的问题，进而解决的 问题所导致的损失就可以降低。因而采取纠正措施所 耗费的时间就可以缩短，达到提高产量百分比的目 标。

与此同时工厂是否也有其他投资？

我们也借此机会冷修熔炉，聘请Horn为我们重新设 计熔炉、前炉和工作端。我们还与Iris Inspection讨论 过检查机器升级的问题。

投资会对客户有何益处？

2. 性价比高：应该可以为我们带来可观的经济利

从ISO9001中提及的管理就可以看出，对SIL的投资

益，也有助于我们减少人力；以及

可以进一步完善产品的可追溯性，也是客户确信产品

3. 操作效率高：低故障率以及维修成本低。

质量的可靠工具。

您希望公司未来五年会怎样发展？

您的机器和生产设备供应商应该有哪些 品质，您才会考虑采用？

只要我们可以摆脱今年的困局，充分利用作为国有公 司的优势，结合所有通产人的努力，抓住机会投资3

面对目前市场残酷混乱的竞争，个人觉得机器和设备

号炉，让公司进一步做大做强。■

应该具备下列关键要素：

肇庆通产玻璃技术有限公司，广东，中国

1. 紧密配合生产需求；易掌握和操作；

新扬（深圳）炉窑热修服务有限公司 新扬（NOSCO ASIA ）是2010年成立以来快速崛起的团队之一，也 是亚洲玻璃窑炉热修行业领先公司。提供先进的窑炉热修技 术、令客户满意的优质服务是我们公司的宗旨。 维修之前

维修之后

新扬（NOSCO ASIA ）已经为很多国家（如马来西亚、印度尼西 亚、泰国、菲律宾、越南、中国、韩国、日本、巴 基斯坦、阿 联酋、阿曼、印度、沙地阿拉伯等）提供各种玻璃窑炉的陶瓷 焊补热修服务。

Tel: +60 127110788 (MY) Tel: +86 13923111639 (CHN)



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

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疏通蓄热室格子砖

www.noscoasia.com

www.glass-international.com

新扬（NOSCO ASIA）的主要服务 :

Nosco Asia Hot repair specialist

soonlee.ng@noscoasia.com

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