Glass International February 2020

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February 2020—Vol.43 No.2

LIBBEY INTERVIEW REFRACTORIES SGT AWARDS I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International February 2020 GI Cover feb.indd 1

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Contents

www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Assistant Editor: George Lewis Tel: +44 (0)1737 855154 Email: georgelewis@quartzltd.com Designer: Annie Baker

February 2020 Vol.43 No.2

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Managing Director Tony Crinion tonycrinion@quartzltd.com

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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

Official publication of Abividro the Brazilian Technical Association of Automatic Glass Industries

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Company profile: Libbey Glass Industry needs more collaboration

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Environment: Will glass packaging be around forever?

17

Decoration: Koenig&Bauer Kammann expands with larger site

21

Decoration: VlakGlas Recycling Collecting and recycling flat glass

25

Furnaces: Ametek In-furnace thermal surveys to increase energy efficiency

29

SGT news: Celebrating the best of glass research

32

Refractories: Remivac: A technically advanced forehearth control system

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Refractories: AGC Ceramics Energy saving designs

41

Refractories: Refel Quality assessment of a fused cast AZS refractory

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Refractories: Fused Cast Technologist AZS fused cast has plenty of unrecognised potential

50

Events review: MOOC course 2000 take part in glass training

51

History

Member of British Glass Manufacturers’ Confederation

China National Association for Glass Industry

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Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.

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Editor’s Comment + International news

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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

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International News

2020 DIARY

GREG MORRIS, EDITOR

February 2020

FRONT COVER IMAGE: www.appliedglass.com

25 - 26 Glassman Asia A conference on the latest trends and issues in the industry.

Seoul, South Korea https://glassmanevents.com/ asia

March 2020

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Stronger together

The take away from this issue’s feature interview is that the glass industry will only thrive if it forges closer collaboration with other sector players.

The interviewee, Chandra Mangalagiri, is Libbey’s Vice President of Engineering, and has 25 years experience in the glass industry.

In short, he is a man who knows what he is talking about. He warns that traditional glassmakers are at risk of stagnation unless they collaborate with their peers from other sectors.

The traditional glassmaker is already suffering from the twin risk of excess capacity and increased global competition.

He suggests a container glassmaker could benefit from a partnership with a glass tableware or speciality glass manufature, or vice versa.

Each company would share the costs and risks.

This partnership could lead to product and process innovation and help differentiate a company from its competitors.

Such collaboration has prevailed in the tech industry and has propelled it forward.

Mr Mangalagiri admits that his idea is not a new one, which begs the question why has this idea not taken hold in the industry before?

Mr Mangalagiri suggests it could be that too many companies are scared of giving away trade secrets and of losing IP. But perhaps, for many glassmakers who see yearly growth of about 2-3%, they simply don’t see the need or feel enough pressure to collaborate.

Be first with the news!

VISIT: www.glass-international.com for daily news updates

NSG starts float furnace for solar glass Nippon Sheet Glass (NSG) Group has started operation of a float furnace in Vietnam.

The previously dormant float furnace at NSG Vietnam Glass Industries (VGI) located near Ho Chi Minh City was restarted earlier in January.

It will produce transparent conductive oxide (TCO) coated glass for solar panels and is one of two lines at the site.

TCO glass production at VGI has been positioned to support a long-term supply agreement with First Solar.

Nippon plant closure Nippon Electric Glass plans to close a fibreglass plant in USA. Electric Glass Fiber America based in Chester, South Carolina, will close at the end of the first quarter this year with the loss of 145 jobs.

The plant opened in 1996 as a PPG Industries facility to make fiberglass that’s used in auto parts, medical equipment and other products. It was sold to Nippon in 2017.

In a financial notice at the end of December, the owner said the closure was the result of weak demand mainly in Europe and China as a result of intense market competition.

It decided to consolidate its production facilities in America from three to two ‘in order to enhance the efficiency of management, and improve cost competitiveness as well as review production lineup.’

23 ICCG 13 The conference for advanced coatings for large-area or highvolume products.

Braunschweig, Germany https://13.iccg.eu/en/home 31 Glasstrend - raw materials A meeting focusing on raw materials hosted by Sibelco.

Sibelco HQ, Belgium https://www.glasstrend.nl/

April 2020

14-17 China Glass Exhibition for equipment for all glass types.

Shanghai, China http://www.ceramsoc.com/

May 2020

13-14 Glassman Latin America A return to Mexico focusing on container glassmaking.

Monterrey, Mexico https://glassmanevents.com/ latin-america

June 2020

03-04 Furnace Solutions Training Day & Conference The 15th training day and conference.

Stoke-on-Trent, UK http://furnacesolutions.co.uk/ 03-06 Glass South America International Exhibition for Design and Technology for the Glass Industry.

Sao Paulo, Brazil https://www.glassexpo.com. br 08-11 Mir Stekla 2020 22nd International exhibition for glass products.

Moscow, Russia https://www.mirstekla-expo. ru

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International News

European glass packaging production ‘steady’ says FEVE Production of glass packaging for food and beverage in Europe continues to grow according to figures published by the European Container Glass Federation (FEVE).

Packaging production increased by 2.0% in tonnes and 1.9% in units (representing an increase of 748 million units) in the first half year 2019.

This corresponds to the best performance over the past 4

years. From 2016-2019, half year production increased by 3.5%.

Paul Sammon, Industry Lead at Vivid Economics which reports and analyses data for FEVE, said: “The increase in growth suggests the sector remains an attractive one for customers and investors and that container glass will be central to a sustainable, circular economy.”

Michel Giannuzzi, President of FEVE added: “Growth opportunities for brands are into the ability to combine what is good for the environment with what is good for consumers.

“This increased demand for glass reflects the increasing consumer quest for a healthy and sustainable lifestyle also when it comes to packaging choice.”

NEWS IN BRIEF

Management change at LWN Lufttechnik

German air technology supplier LWN Lufttechnik has had a change of management.

The company now has two managing directors: Mr Reiner Giesbert and Mr Aleksander Pinda. Mr Dipl.

Ing. Aleksander Pinda has worked for the company as a construction manager for several years.

It has also strengthened its selling team to help it react more quickly to customer requests. It has appointed Mr Michael Nisius, who has worked in the glass industry since 1980.

Saint-Gobain completes South Korean sale

A film about a glass factory in the mid-west of America has been nominated for an Oscar.

American Factory charts the story of Chinese glassmaker Fuyao Glass’s acquisition of a plant near Dayton, Ohio in 2015 and the subsequent cul-

ture clash between American and Chinese values.

The film was nominated for an Oscar in the Best Documentary category.

The Chairman of Fuyao Glass Industry Group is Cho Tak Wong, who was named

the 2016 Phoenix Committee Glass Person of the Year award.

American Factory is available on Netflix and is the first film distributed by Barack Obama and Michelle Obama’s production company.

Vidroporto to use Fives Stein for expansion project Vidroporto has appointed Fives for an expansion project.

Vidroporto plans to increase production to 370 tpd of molten glass at its Indústria Videira do Nordeste (IVN) site in Sergipe, Estância, NorthEast Brazil.

The expansion project includes design, equipment and engineering services from Fives for upgrade of the e-boosting capacity in the furnace, and incorporation of an additional high-speed glass container production line.

Fives will supply transformers and equipment for the e-boosting system and a Prium B-HF 400 Series T-Tandem Forehearth system to distribute thermally conditioned molten glass to the two 8-section IS machines on the line.

OCMI acquires KYP Accessorios

OCMI has completed the acquisition of Spanish ampoule machine maker KYP Accesorios.

The acquisition, completed in November, marks a milestone in both companies’ growth strategy.

By joining forces OCMI OTG and KYP wish to deliver a wider range of products, better service and constant investment in R&D. Michele Gusti, Chairman of OCMI, said: “This acquisition expands OCMI OTG’s portfolio of successful businesses and mark another OCMI investment in the pharma packaging field.KYP is an excellent company with a remarkable story of innovation and dedication.”

www.glass-international.com

Oscar nomination for glass movie

Saint-Gobain has completed the sale of its construction glass activity in South Korea (Hankuk Glass Industries) to Glenwood Private Equity.

The business generated revenues of around €200 million and operating income of €10 million in 2018.

The transaction was part of Saint-Gobain’s portfolio optimisation strategy.

Saint-Gobain is continuing its divestment programme even though the initial target of over €3 billion in sales divested by the end of the year has already been met.

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International News

Flachglas to build sixth German production site

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Flat glass manufacturer Flachglas will build its sixth production site in the Weiherhammer industrial area in Germany, creating high-quality special glasses.

The groundbreaking ceremony due to take place in the summer of 2020 in the

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by the production of high-quality safety glasses in 2022.

The group is said to have invested a double-digit million Euros amount in the automated plant.

Approximately 250 new employees will be employed at the new site.

Allied Glass acquired by investment firm Container glass manufacturer Allied Glass has been bought by a global private investment advisory firm.

An affiliate of Sun European Partners has completed the acquisition of Allied Glass for an undisclosed sum.

Sun European Partners

said: “With two manufacturing facilities and a dedicated decoration centre in Yorkshire, Allied is focussed on the short and medium production run segment of the market which values flexibility, a collaborative approach to innovation and extremely

high technical standards.

“Over the last three years, the business has doubled its customer base which includes craft manufacturers and the largest blue-chip organisations in the industry and delivered sales growth of 13% per annum.”

Ghani Glass to double its production capacity Pakistan’s Ghani Glass is to nearly double its production capacity at its Model Town Extension plant from 300 tonnes a day to 500 tonnes a day.

© Air Products and Chemicals, Inc., 2019 (42615)

immediate vicinity of the float glass producer NSG Pilkington.

The first part of the building with almost 40,000m2 of production space will be built on the more than 100,000m2 site during the first phase of construction.

This will be followed

The site, in Lahore, is being renovated and expanded.

The company produces float and container glass and makes products such

as windows and doors as well as food and beverage bottles.

It is Pakistan’s largest glassmaker and exports to 26 countries.

Glass International February 2020

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International News

NEWS IN BRIEF

Embalvidro COO

Angolan greenfield container glass manufacturer Embalvidro has appointed Shiv Prasad Bandi as Chief Commercial Officer.

Mr Bandi has an extensive commercial experience of the container glass Industry in various African markets during his last 15 years, in different leadership roles at Frigoglass (Nigeria), MEG (Egypt) and AGI glaspac (India).

The glassmaker is located in the suburb of Luanda city, and is said to have the best industry machinery installations by renowned global suppliers of equipments.

Ardagh President to be GPI Chairman

The Glass Packaging Institute (GPI) has selected Bertrand Paulet, President and CEO of Ardagh Group, Glass – North America, as its Chairman.

Temeca Mitchell of Rocky Mountain Bottle Company and Nigel Dart of Gallo Glass both assumed board Trustee roles.

Ms. Mitchell and Mr. Dart join Miguel Alvarez, President, Americas, O-I, as Executive Committee members of the GPI Board.

Mr Paulet said: “It is an honour to be chosen as Chairman of the GPI and I look forward to working with our members to efficiently align our resources and add value to our mutual businesses.”

www.glass-international.com

Strategic Materials triples production

A North American glass recycler Strategic Materials has opened a new crushed glass abrasives production facility in Houston, Texas, USA. The over 30,000ft2 facility began production in early December 2019 with improved bagging technology and production line capabilities, with plans for further expansion in 2021.

The new Houston location will fully replace the company’s current Houston facility mid-year and will retain its existing employees.

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 � 1. � 2. � 3. � 4. � 5. � 6. � 7. � 8. � 9. � 10.

Oscar nomination for glass movie Allied Glass acquired by investment firm Fuyao Glass plots $46 million USA plant expansion Groot Glass confirms location of container and float glass factories Investment group takes control of Rondot Vidroporto appoints Fives for expansion project Flachglas to build sixth production site in Germany Heineken opens its largest brewing facility in Mexico Nippon Electric to close fibreglass plant O-I plots one billion sale of Asia-Pacific glass business

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Forglass designs Polish U–flame furnace The largest producer of water glass (sodium silicate) in Poland, Zakłady Chemiczne Rudniki has appointed Forglass to design and deliver a new furnace with higher pull and lower energy consumption.

Zakłady Chemiczne Rudniki wanted to increase its competitive advantage and Forglass has the technology that will allow it to produce more volume, effectively lowering the energy cost per unit of glass.

Forglass has developed a

furnace design that provides an advantage in the heating rate of the batch when it is fed into the furnace and provides better use of the supplied energy, while guaranteeing the highest quality of the melted vitreous sodium silicate.

Groot confirms location of factories Namibia’s Groot Group has secured funding for its glass projects.

It has closed US$2 billion in private equity for the Groot projects, of which $650 million is for the two Groot Glass

factories: a float and a container glass factory.

Its financiers have asked that the two Groot Glass factories are constructed next to its silica sand factory in Oshikango, Namibia in order to

save the transportation costs of silica sand, which makes up 70% of the raw materials for making glass.

The two factories will therefore be developed on the same site as the silica factory.

Gujarat Borosil upgrades plant Indian solar glass company, Gujarat Borosil, based in Jhagadia, Bharuch increased its production capacity at the end of 2019 to 460 tonnes/day

thanks to a second furnace.

Borosil appointed EME to upgrade and expand its 180 tonnes/day batch plant.

The rebuild of dosing-, mix-

ing plant and batch distribution systems was realised under running conditions and the full operation of furnace 1 alongside the Borosil team.

6 Glass International February 2020

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International News

NEWS IN BRIEF

British Glass responds to BBC report

British Glass has responded to the report ‘Plastic Promises: What the grocery sector is really doing about packaging’ by the Green Alliance, which mentioned the environmental impacts of alternatives to plastic packaging.

They said: “The report calls for considered decisions based on evidence – which is important in the current climate crisis – as the long-term solution to the packaging.

“Research is ongoing to find alternative fuel sources for use in furnaces through Glass Futures to begin to make those plans a reality.

“Our concern is that shortterm thinking will put at risk a material that is ideally suited to a sustainable world.”

Biebuyck rebranded to become BBK

After a long transformation process, glass laser cutting machinery company Biebuyck has been rebranded to become BBK with the financial support of a new bank and partners.

It is also ensuring the maintenance and the technical support for the existing machines.

The new organisation allows BBK to collaborate with industrial partners and customers to develop and build new machines.

www.glass-international.com

Thai temple made with over one million bottles

A temple in Thailand has been created using over a million recycled glass beer bottles from Heineken and Chang beer.

The Wat Pa Maha Chedi Kaew temple is in the Khun Han district of the Sisaket province.

Collection of the bottles began in 1984 when monks used them to decorate their shelters.

The construction took two years to build the main temple. By 2009 the monks had created over 20 buildings on the site.

Fives secures repeat contract with Anchor Glass US container glass manufacturer Anchor Glass has appointed Fives for a complete forehearths system reconstruction project.

Fives was selected for the reliability of its BH-F technologies and successful previous experience at Anchor’s Elmira

facility.

The supply includes design, engineering, key equipment supply, as well as supervision of installation and commissioning for a complete Prium BH-F Forehearths System at Anchor’s Lawrenceburg facility, Indiana.

Anchor selected Fives for the first time in 2018, to design and supply a Prium BH-F Forehearths System for its Elmira facility, New York state.

The system was installed and commissioned fulfilling all the requirements of the plant.

Schott to invest record amounts in 2019/20 Schott has seen its sales rise by 5.1% to €2.2 billion for fiscal year 2018/19 and has confirmed plans to invest €320 million over the next year, the highest amount in the company’s history.

Investments in property, plant and equipment amounted to €257 million in the fiscal year, an increase of 38% over the previous year.

Among other projects, the expansion of the Glass-Ceramic Competence Centre at the plant in Mainz was completed to meet the high demand for Zerodur glass-ceramic.

The expansion of the production capacity of an existing plant in India and the construction of a new plant in China were the largest foreign investments.

The main focus for 2019/20 will be on capacity expansions in the pharmaceutical packaging business in China and India.

In Germany, Schott plans to invest in its pharmaceutical packaging business in Müllheim, among other sites, as well as in its manufacturing capacities for speciality glass in Mainz and Jena.

Investment group acquires Rondot French glassmaking equipment supplier Rondot has been taken over by private equity investment group Siparex.

Siparex acquired a majority 51% share in the glass technology supplier, which is based in Champagne au Mont D’or, near Lyon, France.

The investment company

said it wanted the hollow glass industry supplier to extend its range of products and to widen its markets geographically.

Rondot owns the Graphoidal, Sheppee and Groupe Rondot companies in the UK as well as Sonicam in France and Specialty Rondot in USA as well as Gla.Mo.Ro in Italy.

It acquired the Noxaxion group based in Paluds de Noves, France, in July 2019.

Louis Rondot will reprise his duties as president of the Rondot group. The organisation was formed by his grandfather in 1936. It has a €40 million turnover and has 180 employees. Approximatley 90% of its output is exported.

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Company profile: Libbey Glass

Libbey: Industry needs more collaboration

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MR

Chandra Mangalagiri is a true glass industry veteran. He started in his current role with tableware industry specialist Libbey Inc. at the beginning of 2019 after a 25- year career in the industry.

He has worked in a variety of glass sectors, and been employed by notable companies such as Owens Corning, Corelle Brands (formerly known as World Kitchen) and Corning Inc. His roles have included process engineering, operations management, project management, and roles in product and process R&D. He has also worked with a variety of glasses such as LCD glass substrates, Valor Glass in pharma packaging, Gorilla Glass in speciality, Corelle, Pyrex and ClearFire in tableware.

“I’ve been fortunate to have been exposed to several different glassmaking sectors and learned the specific challenges and opportunities in each of them.”

Libbey is a familiar name in the glass industry.

It celebrated its 200th anniversary in 2018 and

� Chandra Mangalagiri.

has grown globally in the last three decades. The tableware manufacturer is headquartered in Toledo, Ohio, USA and manufactures glass from six locations. It has two facilities in the US (Toledo and Shreveport), two in Europe (Leerdam, The Netherlands and Marinha Grande, Portugal) as well as facilities in Langfang, China, and Monterrey, Mexico. The Monterrey facility is the group’s largest with half of the workforce.

In 2018 the group sold about 1.2 billion pieces of tableware around the globe, with more than 70% of its sales concentrated in North America. The group supplies tabletop products through three sales channels: foodservice, retail, and businessto-business. Libbey is also in the food service business, with products being the largest share of its sales and customers. This sector includes restaurants, bars, hotels, cruise lines, resorts and healthcare facilities. Its retail channel sells to traditional brick and mortar establishments as well as direct to customers through its strong

10 Glass International February 2020

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Libbey Vice President of Global Engineering, Chandra Mangalagiri believes the various glass sectors should collaborate.

He tells Greg Morris such partnerships would drive the industry forward.

online e-commerce presence.

Libbey’s strengths include its global reach with customers in more than 100 countries around the world, outstanding customer service and history of innovation. Its focus on new product development was reflected at a national restaurant show (NRA) last year where it launched 295 new items.

“This demonstrates that we really put product innovation at the forefront,” states Mr. Mangalagiri commenting on the volume of new products.

“When you think of Libbey, you think of best in class products and service. We believe innovation is critical for sustaining momentum with customers and our superior service drives repeat customers.”

Challenges The glass industry faces challenges in the upcoming years in terms of emissions regulations.

On top of that, as any glassmaker knows, there is the ongoing challenge of working in a capital and energy intensive industry.

“In addition to the regulatory challenges, a

� Libbey is headquartered in Toledo, USA.

glassmaker must make furnace rebuild decisions 2-3 years in advance for an asset that will operate for over ten years. I consider this to be an inflexible process. We are investing a large amount of capital for an asset that will supply glass for much longer than the near term that we can forecast market trends. For example, the restaurant industry trend has moved from ‘dine-in’ to ‘take-out’ to ‘delivery’.

Although you can see some macro trends, it is hard to pinpoint a forecast of what the product demand will be.”

Three quarters of the total global glass production comes from four large segments – container, flat glass, tableware and fibre. The majority of these products have existed for more than a century, with glass manufacturers still making the same type of glass.

Some glass products such as TV picture tube has seen disruptive replacements like LCD glass substrates which allowed considerable ongoing growth and profitability because of product innovations, but this is not the case in other sectors. On top of this, there is an excess of capacity and too much competition in the market resulting in commoditisation, lower prices and profits.

Mr. Mangalagiri believes this will force players in the industry to ask themselves ‘how are we differentiating and what product extensions are we introducing so that we can continue to survive in this market where demand for volume exists but the margins do not.’

He believes this is why innovation in the glass industry is critical.

“Step change innovation is needed in both the product space and process technology. Industry has seen process optimisation and automation in the last 2-3 decades but has seen very little product development.”

While speciality glass companies like Schott, Asahi and Corning invest heavily in R&D and show continued product innovation in the glass and materials industry, the traditional glassmakers cannot afford to do so.

What can traditional glassmakers do to sustain profitability and grow markets?

“Different glass companies need to come together to collaborate and conduct joint product/process development where there is no competition. This is almost non-existent today and is a significant opportunity,” states Mr. Mangalagiri.

He believes the glass industry can learn from the tech sector where there is more collaboration which has propelled that industry forward.

There has been a reluctance to collaborate in the past because of intellectual property (IP) protection concerns.

Continued>>

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Company profile: Libbey Glass

11 Glass International February 2020

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www.glass-international.com

“People are more conservative with sharing in the glass industry because they are concerned about giving away trade secrets and a fear of losing IP. Joint development which is not new, would help share costs, risks and propel advancements much faster than any one company’s investment.”

On top of this, “glass manufacturing decision makers need to be more prominent at industry events,” Mr. Mangalagiri suggests.

While glass scientists, technical managers and operations managers are usually prominent at conferences, the people who decide on capital investments are noticably absent.

“You always see the same people at conferences!

The decision makers in the glassmaking industry don’t attend conferences where we talk about problems. We need to educate the decision makers (typically executives of companies) about why these collaborations are necessary in the industry.

“If decision makers are in the room, the true challenges will come out, and a real discussion, with action, will occur. That doesn’t happen today.”

While there have been technology advances – sometimes in part to equipment supplier innovations – the industry will advance forward if there was more participation from the decision makers. These decision makers tend to work in isolation and push their technical teams to figure out solutions for challenges, and reduce costs and capital argues Mr. Mangalagiri.

“We have to learn from the tech world and change our perspectives.

� Libbey has six plants globally and manufactures a variety of tableware glass.

“Libbey is willing to work with other noncompeting glass companies, industry suppliers, and with academia to drive innovation.”

Customer push He believes more innovation will occur in future thanks in part to customer and end consumer push for novel and environmentally friendly products.

Years from now people will still be drinking beverages and eating food from glass - its intrinsic health and environmental qualities will ensure this. But to drive innovation the glass industry must change its way of thinking to drive future technology improvements.

“Innovations will come from what consumers want to see,” he states.

He cites Libbey’s innovations, such as its ClearFire glass which digitised the forming process and its OptiMelt process which, in partnership with Praxair, has reduced energy in the glassmaking process as examples of this. In addition the company has transformed itself from a US centric to a global glassmaker.

In 2017 it also launched an E-commerce retail business which can sell direct through Amazon and other online retail platforms in a bid to capture a larger online audience.

“These are examples of how we are staying ahead of the game. The glass industry must come together to do the same.” �

Libbey Glass, Toledo, Ohio, USA www.libbey.com

12 Glass International February 2020

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From raw material intake to batch charging Benefit from more than 100 years of experience.

• Batch plants • Batch charging technology • Upgrades and modernization • After sales service • Cullet treatment & recycling systems

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Environment

Will glass packaging be around forever?

Richard van Breda and Emma Bowers highlight why glass has what it takes to thrive in a green future environment.

E

veryday we are bombarded with the shocking realities of climate change.

Activists like Greta Thunberg, have captured the world’s attention in demanding a change. Some of this change has started taking the form of the mounting pressure on the wholesale use of non-recyclable, single use, packaging.

There are some tangible examples of this change. Tesco’s CEO went public and said the company would ‘reserve the right not to list’ products with too much non-recyclable packaging.

Much of the pressure has been directed mainly on the plastic world. Radical measures have been implemented in markets such as Kenya and Rwanda which have banned the use of plastic bags outright. China in January 2020 introduced measures to drastically cut the amount of disposable plastics.

Broadening debate is correctly highlighting the need for a much more comprehensive approach to the multiple inter-relating challenges. Wide reaching solutions need to be sought that do more than addresses singular issues in their ‘silos’ such as littering, waste management, recyclability, circular economy and total carbon impact.

1. … infinite recyclability

... totally insert packaging

Glass is the only packaging substrate which is infinitely recyclable with 100% recycled content, without losing any of its mechanical or physical properties. It therefore provides true bottle to bottle closed loop recycling in the purest circular form. Additionally, recycling of cullet also delivers on significantly reduced energy consumption as well as reduced carbon emissions.

By nature glass is inert and is not prone to leaching out any undesirable substances, like BPA. In today’s increasingly aware and wellness conscious society, this characteristic will likely continue to be more important to consumers.

2.

5.

… among packaging’s lowest carbon footprints When used in a returnable system, glass bottles can be reused multiple times and as a result, a returnable (refillable) bottle system offers the user one of the most economic and lowest carbon impact packaging forms available.

� Young consumers such as Greta Thunberg, pictured, demand environmentally conscious packaging.

4.

3. … exceptional product protection Glass provides exceptional product barrier protection – with exceptional carbonation retention and oxygen ingress barrier properties. At the same time coloured glass provides the required beverage light strike protection for many sensitive products. It also is able to withstand hot fill and tunnel pasteurisation.

Typically, product packaged in glass enjoys increased shelf life, which improves customer supply chains.

… premiumisation character Glass has a premium character about it and is perfectly suited to supporting the premium attributes that many products stand for and represent.

6. … robust long-term local businesses, investments and jobs Glass investments are long term and significant. It is not unusual to find a glass plant that has been on the same site for decades. These largescale investments provide catalysts for other supporting industries to develop around the glass plants. In sum, these investments create longterm sustainable jobs and thriving economic communities. With a future that will seek to address total carbon impact of packaging solutions and supply chains, it is likely that local business solutions will increase in importance.

14 0

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Environment

The above doesn’t just effect plastics. It is a call to action for all packaging materials. It can therefore be expected that pressure also be directed to glass. However, glass has intrinsic properties which allows it to adequately respond to the pressures.

Two questions arise: “Will glass be around forever?” and “Does glass packaging have what it takes to survive the pressure lobby?” When one considers the real advantages that glass packaging offers the consumer and the world, one cannot but feel confident that glass has what it takes to survive and importantly thrive in a green future environment.

Some of the noble features that sets glass apart and establishes it as a suitable and sustainable survivor are unpacked overleaf (Glass provides ... 1 to 6).

The glass industry has already identified the carbon impact associated with it manufacture as one of the biggest challenges to its industry. Significant progress continues to be made reducing the carbon emissions and impact that the industry has, however the end goal must be carbon neutrality. This is a tough ambition but a necessary one for this energy intensive substrate.

With confidence that the carbon challenge will be overcome, the glass industry needs to be more vocal on promoting the virtues and the true, pure, and sustainable characteristics of glass packaging. These are the properties, which will ultimately ensure that glass packaging will be around forever. �

SUPPLY CHAIN CONFIDENCE

5 LOCATIONS ACCROSS UK AND IRELAND • Soda Ash • Sodium Sulphate • • Feldspars • Chrome • Barium Sulphate • Sodium Nitrate

SPECIALISTS IN THE GLASS INDUSTRY

About the Authors Emma Bowers and Richard van Breda both have extensive experience in packaging and glass particularly. Their specific experience in large global FMCG businesses allows them to provide a fresh perspective to glass manufacturing from both sides of the supply relationship.

In a series of articles, a number of industry relevant topics will be discussed and unpacked. The topics will provide another perspective the industry often reflecting the opinion of the glass customer or consumer. In doing so, we will discuss some opportunities we see for the industry and hope to spark some debate in the process.

www.glass-international.com

We’d love to hear from you with any comments, questions or other topics you would like us to cover in upcoming publications.

Co-Authors: Richard van Breda Richard van Breda Consulting richard@richardvanbreda.com Emma Bowers Managing Partner, Green Puffin Consulting Limited emma@greenpuffinconsulting.com www.greenpuffinconsulting.com

Contact us: +44 (0)20 8332 2519

+44 (0)20 8940 6691

sales@newport-industries.com

15 Glass International February 2020

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WHEN QUALITY MATTERS www.parkinson-spencer.co.uk

Decoration

� The new building was officially opened in December 2019.

Koenig&Bauer Kammann expands with larger site T

he new factory has 6000m2 production and 3000m2 office space and is built on a 27,000m2 plot with sufficient space for future extension. The building has the latest infrastructure, such as: � More than 65% more storage space of parts and components, � Automated high rack warehouse, � Computerised immediate ‘on demand delivery’ on short distances from warehouse to assembly line, � Assembly space to build 12 machines simultaneously; and � 10 new work stations for engineering and administration.

20, 2019 and all business units are now operating out of the new building. It is located 3 kilometres from the previous location.

It is designed to meet the exact needs for building fully automatic screen and digital printing machines for the glass industry. The relocation was completed just before Christmas on December

Coinciding with the inauguration of the new building is the presentation of Kammann’s latest new development, a new machine type, targeting the beer and soft drink market.

Demo and development centre With several permanently installed machines, the new demo and development centre is the perfect showroom to present various machine models and latest machine features. It also will allow Kammann to print samples, test new screen and digital inks and to further develop digital printing with its team of process engineers.

Machine type HS300

The new HS300 line of equipment offers speeds up to 300ppm and up to eight printing stations for thermoplastic inks, more than 50% more output than any other machine on the market. The first delivery is scheduled for February 2020.

A double speed machine for 600ppm is scheduled to be ready at the end of 2021.

Besides speed and productivity, the HS300 offers new features such as: � Contactless camera pre-orientation to the bottle seam. This allows glass manufacturers to reduces the thickness of the base and reduce bottle weight. � Freely selectable use of each printing station: each printing station can be used to print either on the body or neck. Any combination is possible. � Print Image inspection system to identify any misprint or colour variation.

Continued>>

www.glass-international.com

Koenig&Bauer Kammann has relocated to an expanded, larger factory due to continuous growth in all markets in recent years. The site has more space and customised facilities.

17 Glass International February 2020

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� Digital printing on glass has contributed to Kammann’s massive recent growth.

combination with a foil transfer unit.

This allows changed foiled images without changing screens.

Standard range

� Machine type HS300 offers speeds up to 300ppm.

Digital printing Digital printing on glass has in the past 24 months also contributed to Kammann’s massive growth. The demand for machines with the capability to print high resolution images with up to 720dpi using the half tone process has resulted in more than 20 machines sold. This machine type has become the industry standard for printing high quality beverage bottles (spirits), drinkware and cosmetic containers with the digital process. High resolution print images, realising of small order sizes and individualisation is now possible with this new technology.

Another interesting feature of digital printing is the possibility to imitate embossed glass by printing multiple

passes of clear digital ink, thus achieving any thickness desired.

The results are astonishing and have drawn attention from industry experts. For small runs or exclusive designs, this process eliminates the need to build special moulds.

Process combinations Digital printing is also offering new possibilities in combination with other processes, such as foil transfer. The recently introduced process offers the possibility to use a digital primer in

The most versatile ware transfer in the market

Half of Kammann’s global sales are still obtained from the best selling K15 screen printing machine, which offers an unrivaled amount of features for printing on all kind of glassware. From printing on simple round bottles with thermoplastic inks to nine-colour screen printing on difficult shapes with UV or LED curing inks.

Another recently-developed feature is the LED Pinning, which allows printing 360% wrap around the article, which is only possible, if the beginning of the print image is touch dry (overprintable). �

Koenig&Bauer Kammann, Bad Oeynhausen, Germany https://www.kammann.de/en/

See us at Glassman Asia, Seoul 25-26 February 2020 stand A4

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We print your world

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Recycling

� A total of 7.3% of sheet glass was reused in sheet glass production in 2018.

Collecting and recycling flat glass Cor Wittekoek* highlights how the collection and subsequent recycling of flat glass contributes towards a circular economy.

What is Vlakglas Recycling Nederland?

In 2000, Dutch sheet glass manufacturers launched an initiative to set up a voluntary recycling scheme to meet their responsibilities as producers of sheet glass. Vlakglas Recycling Nederland was founded in 2002.

The non-profit organisation coordinates all the activities associated with recycling and collecting waste glass in an efficient, environmentally friendly manner and at the lowest possible cost.

The government has demonstrated its commitment to this process by legislating for the sheet glass recycling levy for double-glazing.

Vlakglas Recycling Nederland is financed by means of a recycling fee.

This amounts to €0.30 for every m2 of insulated glass that is produced in or imported into the Netherlands. The Ministry has declared that the agreement on the recycling fee is legally binding.

This decision was published in the Staatscourant of 28 June 2016.

Vlakglas Recycling Nederland is responsible for collecting the recycling fee. The recycling fee is collected on a quarterly basis. Figures can be submitted using a secure website. After payment for the relevant year has been received,

each participant receives a certificate of participation.

Cradle-to-cradle The idea behind the separate collection and recycling of sheet glass is the ‘cradleto-cradle’ philosophy: the principle that after use, materials should be fully recyclable for use in other products.

Recycling glass is one case where the cradle-to-cradle principle can be implemented with relative ease. There are three reasons for this: glass is completely reusable, recycling glass does not result in any loss of quality, and there is little waste. This creates a loop or cycle known as ‘waste equals food’. But for this cycle to work properly, there is a need to separate biological and technical ‘nutrients’ (such as glass, metals and plastics) properly. This is the logic behind a nationwide system of collecting and recycling glass waste.

What happened to the waste glass fragments in 2018 ? � Sheet-glass industry - 7,30% � Insulation products - 35,40% � Packaging glass industry - 47,30% � Others - 1,90%

Continued>>

www.glass-international.com

R

ecycling is not a choice, but a necessity. After all, the depletion of the earth’s raw materials has been a growing problem for many years.

Our supplies of oil, gas, minerals and metals are being depleted so fast that it is uncertain how much more we can extract from the earth. Recycling is part of the solution to this issue.

Sheet glass is an umbrella term for the types of glass used in residential and utility buildings.

It is used in items such as windows and doors. But actually sheet glass has endless applications.

The range of properties that glass can be given during the manufacturing process makes it an extremely versatile material.

Glass can be used to improve both the interior and exterior appearance of buildings.

The construction sector generates thousands of tonnes of waste glass every year.

Sustainable demolition and renovation techniques mean more used sheet glass is now being separated at source for recycling.

Vlakglas Recycling Nederland, is committed to ensuring that the collection and recycling of waste sheet glass occurs consistently and systematically.

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� The construction sector generates many

� Vlakglas Recycling Nederland collected 73,637 tonnes of waste sheet glass in 2018,

thousands of tonnes of waste glass every year.

saving the equivalent of 8,541,892 kilos of CO2.

One of the aims of Vlakglas Recycling Nederland is to achieve 20% of collected waste sheet glass to be used in sheet glass production.

Advantages of recycling sheet glass The system of collection is intended for all those who work with waste glass: painters, glaziers, demolition companies, contractors, glass suppliers, glass processors, glass manufacturers and so on. Because the organisation is nationwide, it brings together all parties to cooperate effectively: companies involved in supplying glass, the collection network and the recycling companies. This saves money.

Dumping sheet glass in landfill as ‘normal’ waste actually costs the ‘dumper’ money. Plus, reusing waste glass reduces the amount of waste that has to be processed by landfill sites. In addition, recycling glass reduces the burden on our environment by reducing the need for ‘fresh’ raw materials to produce new glass.

The system of collection Waste glass can be collected in various ways: � Ad hoc (projects): Vlakglas Recycling Nederland can provide temporary containers for renovation or demolition projects. A small contribution towards the cost of these containers is required for this. � Storage and transfer stations: A company can deposit waste sheet glass at one of Vlakglas Recycling Nederland’s affiliated storage and transfer stations. A processing fee is charged. � Collection points: Small amounts of sheet glass can be deposited free of charge at Vlakglas Recycling Nederland’s collection points. These collection points can be found at selected glass resellers and

producers, but also at a number of major waste recycling centres. � Container rental: Companies can also hire a container for their own use on site. � Waste parks: Containers can be rented by waste parks so that small amounts of sheet glass waste can be deposited by consumers.

Clearly, it is important that the waste glass is clean when it is delivered to the collection points. Contaminated sheet glass is not recyclable and has to be disposed of as standard waste.

The glass cycle After collection, the waste sheet glass is transported by boat or truck to specialist recycling plants. As there are no recycling facilities in The Netherlands, the cullet is shipped to recycle companies in Belgium and Germany. There, the dirt is removed from the glass and it is processed into cullet, which is made up of small pieces of cleaned recycled glass. This cullet can then be re-used in the glass industry.

All kinds of sheet glass are collected, including wire glass, laminated glass, coloured glass and double-glazing. The recycling company processes all these types of glass into a final product that is made of 100% pure glass. The incoming waste sheet glass is stripped of any foil, iron or other contaminants. Then it is crushed to pieces of the right size. The pieces are then mixed to the specifications of the purchaser and delivered to glass industry as a high-quality, consistent, homogenous and reliable product.

Finally, the glass cullet is delivered to customers who reuse it.

Highest rate of reuse…

The flat glass waste that is collected is for 90% post-consumer and almost always polluted with other (attached) material.

This means that this cullet cannot be used for the production of new flatglass, but only for packaging glass and isolation products.

Vlak’s aim is to reach a higher rate of recycling of cullet in the flatglass industry.

It started a project with AGC Belgium and Maltha. For this project it received Life+ funding from the European Commission.

This project aims to develop and validate an innovative method for recycling and up-cycling glass and other waste materials in the production of flat glass. This aim will be achieved through an innovative grinding technology that allows the content of recycled materials of the final flat glass to be raised to 25%, and the use of up to 55% of glass cullet. https://www. agc-flattoflat.eu/

Recycling in figures � If sheet glass is not collected separately, but disposed of as regular construction and demolition waste, this means a CO2 burden of 620 kilos. � If 10% cullet is added to the mix of raw materials for glass production, 5% less CO2 is emitted. � If 10% cullet is added to the mix of raw materials for glass production, 2.5% less energy is used. � One kilo of cullet can replace about 1.2 kilos of ‘fresh’ raw materials in glass production. � Recycling 20 cm2 of glass saves energy equivalent to lighting a 60-watt light bulb for four hours. � In 2018, Vlakglas Recycling Nederland collected 73,637 tonnes of waste sheet glass. This saves the equivalent of 8,541,892 kilos of CO2. �

*Director, VlakGlas Recycling, The Netherlands www.vlakglasrecycling.nl

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We are changing the world of glass melting for good, with a new super-efficient furnace offering lower emissions, lower heat losses and lower energy consumption.

Furnaces

In-furnace thermal surveys to increase energy efficiency Neil G Simpson* looks at how to increase energy efficiency using in-furnace thermal glass surveys.

T

hermal images from static permanently mounted near infrared borescope thermal imagers can be used to trouble-shoot and optimise furnaces in terms of glass quality and yield, furnace pull, asset protection, and energy and emission reduction.

Ametek Land’s NIR-B Glass thermal imaging cameras have been operating continuously since 2014 with more than 50 reference installations in glass melting furnaces globally, more recently, transportable instruments are being used to perform dedicated in-furnace thermal surveys of glass melt tanks.

The potential scope of a survey is significant, and the challenge is to decide the priority of what to look at. With more than 324,000 thermal data points in one image, the analysis and interpretation of the data can take longer than the time taken to take the actual measurements.

The amount of data measured and recorded is contingent on the customer site in terms of access, preparation and quality of utilities. The equipment used is almost the same as used in the fixed system but without the automatic

retraction mechanism, however, for extended surveys or regenerator repairs, a retraction system may be utilised to protect the instrument.

The in-furnace thermal glass survey is not an alternative to a conventional traditional refractory inspection but a supplementary service.

The thermal imager design is straight and does not have the potential for a 90-degree angle as in conventional endoscopic photographs. The imager can generate equivalent colour and black and white (B&W) images, however, also shows the actual temperature of the refractory when the flame is off.

This can provide data to show when there is either too much or insufficient cooling at the metal line and in extreme cases where there is a hole.

By utilising a negative image, the lighter points show where there may be too much cooling, which leads to increased energy and resulting emissions, but also increased wear of the refractory as the batch piles drag along the refractory. This is of specific interest for container glass furnaces. Similarly, holes and cold spots

can frequently be seen at the skew.

By utilising an isotherm function, it is possible to highlight refractory areas which are below 1388 and where NaOH can condense and corrode silica refractory. This is of specific interest in float glass applications in the fining area.

These are two examples of how a survey can help reduce energy while also monitoring and protecting the furnace asset. A temporary installation of a thermal imager with automatic retraction system has also been used as part of hot regenerator repairs during the oxy fuel operation. The regenerator repair has the attraction of recovering the energy efficiency back to being comparable with the furnace when new, and results in an improvement in specific energy consumption.

Thermal surveys of regenerative furnaces highlight the sources of parasitic air ingress. When these are sealed/ addressed then energy savings of 3-5% have been realised. As with the images from the fixed thermal imager the most powerful image is the thermal profile or isotherms which are seen when the

ďż˝ Fig 2. Negative image shows over-cooling at the metal line and batch piles ďż˝ Fig 1. Zoomed image of damage/wear to the tuck stone.

dragging along the refractory.

www.glass-international.com

Continued>>

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Furnaces

� Fig 3. Zoomed

� Fig 4. Addition of isotherms shows in-balance

image shows the detail

of flows to regenerator ports and areas of

of the crown and

over-heating.

damage at the skew.

� Fig 5. The NOx Palette indicates parts of the flame which are at risk of forming thermal NOx and enable optimisation/ reduction.

furnace’s firing stops and reverses. The measurement of the thermal profile frequently identifies that the thermal profile is not optimised for the furnace.

Typically, the flames are too short but sometimes they are too long. A conventional thermal profile would take roughly four hours for an end-fired furnace and six hours for a cross-fired regenerative furnace assuming 20-minute firing cycles.

The imager creates an instantaneous image with 324,000 optical temperature measurements. The net result is that it can identify when the thermal profile is skewed.

An example is shown where at the end of firing from the Right-Hand Side glass flow (Left Hand Side of Fig. 5) the hot spot is at Port 4 however is at Port 2 on the opposite side.

Clearly, the thermal profile is skewed and not optimised.

If the profile is not optimised, then the below glass recirculation currents cannot

be optimised with the risk of shortcircuiting. As soon as a pull is limited due to quality it negatively impacts the energy efficiency and of course financial profitability. Improving the convection currents improves furnace quality and yield. Once the quality and yield have increased above specification then there is an option to lower the equivalent throat temperature.

By referring to conference technical papers and customer case studies by Ametek Land and Simpson Combustion and Energy, the thermal imager can be used to establish which flames have a higher intensity and therefore potential to generate higher thermal NOx. Before a customer makes any changes to the flame it is critical that the furnace thermal profile is measured and optimised first, since making good glass is the priority. In most cases adjusting the flame to get the hot spot closer to its design has the effect of lowering the energy which in turn automatically lowers the emissions.

Once the hotspot has been optimised, the flame, which is generating the most NOx, can be identified and adjusted by the furnace operator. One burner at the wrong angle can negatively impact the adjacent burner which is perfectly aligned.

Finally, a thermal survey can be used to validate a CFD model specifically when used as part of troubleshooting.

Ametek Land in-furnace thermal surveys include service, equipment rental and reporting conducted by experienced engineers. Each survey includes a site induction, pre-meeting, set-up and thermal survey from a specific number of furnace locations.

In partnership with Simpson Combustion and Energy consultancy, combustion analysis is also undertaken to offer additional advanced surveys.

The in-furnace thermal glass surveys use the latest near infrared borescope thermal imagers (NIR-B Glass) to return precise temperature measurements from the inside of the furnace, creating detailed and live high-resolution images for analysis, in combination with the Lancom 4 portable multi-gas analyser for measuring up to eight flue gases in combustion and emissions processes. Optimised for measuring high temperatures between 1000 – 1800°C (1832 – 3272°F), the NIR-B Glass continuously measures temperatures in HD+ resolution and the imager connects to a Windows PC running dedicated image processing software for accurate data analysis. �

*Combustion & Energy Consultant to Ametek Land, Dronfield, UK www.ametek-land.com

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FIC SGT advert 2020 AW_FIC-Society advert 2019 27/01/2020 16:29 Page 1

Society of Glass Technology Join the worldwide network of interests centred on making glass great The Society of Glass Technology exists to serve people who are interested in the production, properties or uses of glasses, whether from a commercial, aesthetic, academic or technical viewpoint.

It is a non-profit making organisation serving a worldwide membership publishing journals and text books, organising meetings and conferences on glass related topics.

You can now join the SGT by going to www.sgt.org and selecting your journal choice and appropriate package. You will also be able to see the comprehensive history and activities of the society.

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SGT news

Celebrating the best of glass research The UK’s Society of Glass Technology (SGT) highlights some of the best talent in the industry with its awards. Here is a selection of its awards and some recent winners.

Entries are being sought for the Fifth Society of Glass Technology–Alastair Pilkington Award. The award is designed to encourage and recognise excellent work in glass research or innovation achieved by someone who, like Sir Alastair, has come relatively recently into the field of glass.

This award is not restricted to hard science or engineering – it spans all dimensions of glass technology, creativity and research; glass art as well as glass science, conservation and museum studies as well as engineering.

The winning candidate will receive €1500 and support in attending the ESG Conference, in in Krakow, Poland (https://icg2020krakow.com).

The winner also receives a smaller replica of the iconic glass sculpture, which is the focus in the Award Ceremony. The award is funded by the Society of Glass Technology and the Mushroom Trust, a fund set up by Sir Alastair’s family.

The fourth winner of the award in 2018 was Dr Morten Smedskjaer of Aalborg University (Pic 1). His submission for the Pilkington Award related to pressure induced changes in interdiffusivity and compressive stress in chemically strengthened glass. Much of his work looks at improving the mechanical properties of glass: scratch and damage resistance, structural relaxation. The presentation of the prize was held at the Physics of NonCrystalline Solids/European Society of Glass Science and Technology conference held in St Malo, France.

The first award was presented at the ESG, in Maastricht, to Dr John Mauro of Corning, for his invention of an astonishingly strong thin glass suitable for use in the screens of mobile phones and tablets. In Pic 2 Dr Mauro is receiving his award from Ros Christian, Sir Alastair’s daughter.

He later gave a lecture on the research,

which led to development.

his

ground-breaking

SGT AWARDS The Society of Glass Technology has a number of Awards it presents every year or at events such as Furnace Solutions, the Annual Meeting and the ESG (European Society for Glass Science and Technology) Conference. � Pic 1.

2018 winner Dr Morten Smedskjaer.

The Memorial Lecture is held biennially and the Student prize will be awarded in the intervening year.

Candidates are being sought for the ‘ACG Glass Engineering Student Prize’.

Those interested can be of any age working full or part time in the glass industry and their work should be centered around glass engineering and technology with no limits to the size of the company or institution in which they work. There should be a continuing education aspect to potential entrants, with affiliation to an educational institute. The award is made up of a cash prize and expenses to attend the presentation.

DAVID MARTLEW MEMORIAL PRIZE

The awards are either judged by the Board of Fellows, the Basic Science and Technology Technical Committee or by peers in the audience at conferences.

Professor Michael Cable The SGT has established a Memorial Lecture and a Student Prize in memory of Professor Michael Cable of the University of Sheffield recognising his contributions to practical glassmaking. AGC Inc. sponsors both the Student Prize and the Memorial Lecture.

Dr Richard Hulme of Guardian Industries presented the first Michael Cable Memorial Lecture at the International Congress on Glass in Boston in June 2019. The Society is now seeking candidates for the Student prize.

The David Martlew Memorial Prize is sponsored by the Martlew Family and the Society of Glass Technology. David Martlew Hon FSGT was President of the Society in 1993–94 and 2006–08, an active member of the North West Section, a great and enthusiastic speaker on many glass subjects and the instigator and general impresario of the Heritage and History Special Interest Group and the many related activities it generated.

It takes the form of a bursary to enable a Student in the fields of study normally covered by the History and Heritage part of the Annual Conference of the Society of Glass Technology to attend and present a paper at the Conference.

The award is for students, undergraduate, post-graduate or mature who may, or may not necessarily be in full or part-time education.

LUCY OLDFIELD AWARD The Oldfield Award is open to UK and international students. There are cash prizes for first, second and third. It is presented for research projects carried out by either undergraduate or taught masters Continued>>

www.glass-international.com

SGT–ALASTAIR PILKINGTON AWARD 2020

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SGT news

� Pic 2 . Dr John Munro won the first Alastair Pilkington award.

students. The subject of the project can be any experimental, theoretical or practical work related to amorphous solids, glasses, glass-ceramics or sol-gel materials, glass history and archaeology or glass arts, technology or design.

Reports not dealing entirely with glass should spell out the relevance of the subject to the science, technology or arts of glass. This can include fundamental science, applied science, arts, technology and engineering.

It should be work completed within the 12 months prior to the June submission and presented in English. Entries are judged by a panel made up of members of the Basic Science and Technology Technical Committee.

Joint first winners in 2019 were Jessica Rigby (Sheffield Hallam University) on Development of Novel Glass Formulations for Treatment of PostOperative Clean-Out (POCO) Wastes for Decommissioning of the Sellafield Site; and Francesca Lewins (University of Birmingham) on Electrospun Bio Active Glass Fibres as a Novel Haemostatic Agent; and third place went to Quentin Bollaert (UPMC Paris) on Study of the Conditions of Formation of two Tektites using Spectroscopy and Chemical Mapping.

Basic Science and Technology Technical Committee members in the audience at the Society of Glass Technology annual conference. The award is £250 + free student SGT membership for the year.

The 2019 winner was Katrina Love of Sheffield Hallam University who spoke on phosphate solubility and impacts on properties of radioactive waste glasses for the Hanford site, USA (Pic 3).

THE MICHAEL GARVEY AWARD The award is presented every year at Furnace Solutions for the best paper.

It is presented in memory of Michael Garvey who worked for Guardian Glass in Goole and was a graduate of the University of Sheffield.

Michael died in a climbing accident in 2008. He was 27 years old. He initially joined Guardian as a summer intern at the DeWitt, Iowa plant where he got what can only be described as ‘rave reviews’ from the team there.

After he completed his Masters he joined the Carleton, Michigan facility and then moved to work in the Glass Technology Group in Carleton. Michael worked on a range of projects and with all levels of the company.

He was an extremely motivated, dedicated and technically gifted glass technologist. He moved back to the UK and was a key member of the Goole process team and quickly earned their respect.

Michael presented a paper at Furnace Solutions-3 and made a very good impression on the audience and members of the Melting Technology Committee.

The award is sponsored by Guardian, but it originated thanks to Chris Windle, Geoff Evans and the other members of the MTC and shows the ‘people matter’ side of the SGT. The Michael Garvey award 2019 went to Ms Burcin Gul of Sisecam for her paper Improving Furnace Performance by Design and Operation. �

Society of Glass Technology, Chapeltown, Sheffield, UK www.sgt.org

� Pic 3. Katrina Love won the Paul award in 2019.

PAUL AWARD The Paul Award prize is for the best presentation (clarity, technical content) by a new researcher as voted by the

30 0 Glass International February 2020

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Refractories

A technically advanced forehearth control system G

lass conditioning depends on the quality of the forehearth and a reliable and technically advanced control system such as the power-packed Revimac Forehearth Control System (FCS) combined with a high performance forehearth produced by Fusiontec.

The forehearth control system has been developed with the cooperation of Fusiontec that is the designer and manufacturer of the complete refractory package.

The design, evaluation of structure and development of forehearths and working ends, is performed by Fusiontec through the use of the FEM software package.

The FCS control system includes: � Equipment and instruments installed in the forehearth. � Supervisor system based on proprietary software package, equipped to also be managed in remote control.

Instruments and electronic devices installed in the forehearths are the key points of the control system.

Forehearth is constituted by different zones, each equipped with temperature detection instruments such as optical pyrometers and/or one and three-levels thermocouples.

By means of those, the temperature of the glass is measured in different layers inside the conditioning channel.

According to the temperature profile

defined by the technologist and to the temperature registered in the zones, the automation system provide heating by means of the burners installed or cooling by means of the fans.

Each forehearth is equipped with a neatly designed gas-feeding ramp with individual air & gas mixing units and two centrifugal air fans, one operating and the second in stand-by, are supplying the required quantity of combustion air.

The FCS control is in housed into one cabinet featuring twin CPU and dual Can-Bus channel for data transmission, to ensure complete reliability and enable the automatic switch-over in case of failure.

A user-friendly touch screen operator interface is available for technologist and operators to control all the data and process information of the forehearth.

The software installed is a proprietary Revimac/Fusiontec development and enables to control each zone of the forehearth, left and right side firing independently.

Production recipes and process information are stored in the memory of the system to be recalled by the operator when necessary.

Alarms and logs provide and effective trouble-shooting to the operator. �

*Gianfranco Tempesta, Export Manager, Revimac, Italy www.revimac.com 32 0 Glass International February 2020

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TRADITION ADVANCED Leading Refractory Concepts for Crystal Clear Results

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ADVERTORIAL - LWN

LWN Lufttechnik GmbH: A New Momentum

L-R: Mr Reiner Giesbert , Mr Jörg Günther and Mr Aleksander Pinda.

The selling team of LWN-Lufttechnik consists of : L-R: Mr Dipl. Wirt.-Ing. Johann Keyserlingk, Mr Dr Ing. Frank Lohbach, Mr Dipl.-Ing. Wieland Wittig and Mr Michael Nisius

Dear Business Partners, We are happy to announce some operational changes which currently took place in our company.

In 2012 a breakthrough for LWN Lufttechnik was the takeover of Mr Reiner Giesbert and Mr Wieland Wittig as sole owners of the company.

The former shareholder Mr Ralph Lauer withdrew in that moment and has since then not been acting again for the company.

(With the withdrawal of shareholder - Mr Ralph Lauer in 2012, who since then, has not been active within our company, Mr Reiner Giesbert and Mr Wieland Wittig became the sole owners of LWN Lufttechnik.)

Mr Giesbert and Mr Wittig conducted essential restructurings of the company and repositioned it for the market. The further, constant development of the products enabled to gain new customers in the global market. The last years have been characterized for us by steady growth.

Like many of our customers, we are also facing the new requirements of the hollow and flat glass industry.

Since 01.10.2019, the company LWN – Lufttechnik is held by two managing directors: Mr Reiner Giesbert and Mr Aleksander Pinda.

Mr Dipl. Ing. Aleksander Pinda has already been working in the company as a construction manager for many years.

To satisfy the rising demands of production and quality, we have strengthened our personnel in the area of operational management: On October 1st, 2019 Mr Dipl. Ing. Jörg Günther embraced the management in our production manufactory in Wilsdruff.

To be able to react more quickly to customer requests, we have lately strengthened the selling team with Mr Michael Nisius.

Mr Nisius works in the glass industry since 1980.

This group of persons is the sole selling team of LWN - Lufttechnik and is looking forward to your requests.

We have expanded our product portfolio in other areas.

The piping of compressed air, water and vacuum as well as the complete electrical wiring have already been carried out in the glass industry very successfully. Embracing all the consecutive phases of realisation - starting from the planning to the complete assembly.

We aim to be a reliable partner and keep moving ahead with you on this pathway. We are looking forward to continuing good cooperation.

Sincerely, The team of LWN-Lufttechnik

34 0 Glass International February 2020

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21/10/2019 14:51

Refractories

Energy saving designs Kenji Matano* discusses how refractories can save energy based on their designs.

Insulating materials such as blankets and boards are widely used for glass melting furnaces because of their low thermal conductivity and high usability. They contain Refractory Ceramics Fibre (RCF).

It is reported that RCF shrinks even under the service temperature because of crystallisation.

Bio Soluble Fiber (BSF) that doesn’t contain RCF is also used; however it has the same behaviour as RCF at a high temperature. As a result, heat loss from furnaces increases during operation because crystallisation gives the insulating material a dense structure therefore leading to increased thermal conductivity. RCF is categorised as Probable Human Carcinogen in several countries. This means it has restricted use.

AGCC’s approach AGC Ceramics (AGCC) developed an insulating material named Thermotect.

It is a monolithic refractory which achieved high thermal resistance and glass vapour resistance without using RCF, meanwhile since they are flexible monolithic materials, it can be applied easily to complex parts.

In addition, it consists of AGCC’s originally developed fused ceramics particle, using recycled materials generated from its plant, meaning it

grade shrank 6% at 1200˚C, the BSF 1200˚C grade shrank more than 10% at 1200˚C .

The Thermotect 1600 and 1300 grade had little or no shrinkage up to its maximum service temperatures.

Meanwhile, mineralogical compositions of these samples were analysed to determine the chemical reaction that caused the shrinkage. Before heating, RCF and BSF consisted mostly of non-crystal.

After the test, mullite was formed in the RCF samples, and Cristobalite, Tridymite, Wollastonite and Enstatite was formed in the BSF samples respectively. On the other hand, the Thermotect 1600 and 1300 grade had no change in its mineralogical composition.

Continued>>

Stability Heating up tests were performed to evaluate the stability of insulating materials at a high temperature (Fig.1).

The insulating materials were kept for 100 hours at each temperature, and after cooling, the linear shrinkage rate was measured. As a result, the RCF 1260˚C

Service Temperature [°C]

1600°C Grade

Installation Quantity [ton/m3]

1300°C Grade

1.00

1000°C Grade

0.95

0.45

SiO2

<1 13

39

Chemical Composition [%]

83 69

39

6 4

-

Al2O3

ZrO2

110°C×24h 2.5 4.5

Cold Crushing Strength [MPa] 1000°C×3h

1.0

2.1

1600°C×3h 2.5 -

1.1 0.9 -

Thermal Conductivity [W/m-K]

at 500°C

0.48

0.46

0.16

at 1000°C

0.54

0.50

0.31

� Table 1. Property of Thermotect series.

30% BSF 1200°C grade 25% BSF 1250°C grade 20%

THERMOTECT 1300°C grade

15%

THERMOTECT 1600°C grade

www.glass-international.com

Conventional insulating materials

contributes to reduced emission.

The Thermotect series has three types of products according to service temperatures (Table 1). To obtain the optimal insulating wall, it is necessary to choose the most suitable materials depending on operating temperature and subsequent design multilayer insulating wall.

Linear shrinkage rate (%)

E

nergy efficiency has a big impact on glass manufacturing costs and has been of major interest for a long time.

There is also a strong desire to reduce environmental load such as carbon dioxide emissions. For glass melting furnaces, insulating materials can be a key solution.

Improvements to the insulating structure may cause serious damage such as accelerated corrosion or melt down of refractories located on the inside of the furnace, therefore insulating design should be done carefully using tools such as heat calculation by computer simulation.

10%

5%

� Fig. 1. Heating up test of insulating materials.

0% 1000

1100

1200

1300

1400

Temperature (C°) Dwell time 100 hrs

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Refractories

THERMOTEC 1600°C GRADE METHOD Temperature Time: 2 days 1500 [C°] Temperature: depending on samples

1300°C GRADE 1250

Test sample Platinum crucible

Before => After

Soda lime silicate glass

Reaction face

�Fig. 2 Glass vapour corrosion test.

Conventional design

Material

Thickness(mm)

Seal material

Insulating structure

New design

TMT-1600

210

TMT-1000S

150

Bonding bricks

65

Insulating bricks

130

Blanket (RCF)

100

Total

Melter crown

Material Thickness(mm)

40

335

Total 360

Temperature on outer face (°C)

109

101

Diffused heat loss (W/m2) 1442

1264

Decreasing rate

12%

-

Total weight of insulating materials Kg/m2) 438

280

Decreasing rate

36%

-

� Table 2. Crown insulating design of oxy-combustion furnace. Crown material: fused cast AZS, Temperature inside: 1600°C ambient: 30°C

In addition, a glass vapour corrosion test was performed (Fig. 2) because corrosion resistance against glass vapour is one of the main development targets of the new materials. As a result, there was no change in appearance, bulk density and mineralogical composition

therefore they were expected to keep good insulating performance during furnace life.

Installation in actual furnaces Optimal insulating design depends on the operating condition of each furnace.

�Fig. 3 - Installation records of the Thermotect series.

Crown Port

Reg. wall

AGCC proposes the design with the Thermotect series for each furnace by using heat calculation in advance. It is possible to reduce energy consumption by 2% to 3% in comparison with conventional ones. Furthermore, in the case that took account of deterioration on conventional insulating materials, the margin will expand more because the Thermotect series is expected to keep good insulating performance over the long operation.

The Thermotect series was installed in various parts of actual glass melting furnaces such as melter crowns, breast wall, ports and regenerator wall (Fig. 3).

Hybrid structure of breast wall

As the result of the heat calculation for oxy-combustion melter crown with a fused cast refractory blocks, the new insulating design was decided (Table 2).

Although thickness is almost the same, the weight of new design was lighter, and diffused heat loss from the outer surface of the crown was less than a conventional one. The new design was installed in several live furnaces.

It was carried out by means of the precast block method for quick installation, on the other hand it is also possible to install through casting and troweling methods. The pre-cast blocks, casted and dried in advance, were installed on the fused cast blocks. Subsequently, clearances between the pre-cast blocks were casted by monolithic materials of Thermotect. This meant that heat loss from joint gaps could be reduced compared with the conventional design which had much joint gaps of insulating bricks. After four years from the start of operation of the furnace, the new insulating wall didn’t have any deterioration and kept good insulating performance.

AGCC also developed the new insulating design for air-combustion melter crown with silica bricks and installed it in the actual crown. As a result, it was confirmed that the insulating performance kept as it was designed in the long term.

Therefore, the new insulating designs are expected to keep the insulating performance during the whole life of these furnaces. �

* Manager, Material Development Group, Development Center, AGC Ceramics, Japan https://www.agcc.jp/

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We build your furnace.

You enjoy peace of mind.

https://www.agcc.jp/en/core/glass/tabid/160/Default.aspx

Glass Industry Division +81-3-5442-9177 Mita NN Building Floor 6, 4-1-23, Shiba, Minato-ku, Tokyo 1080014, Japan

Refractories

Quality assessment of a fused cast AZS refractory Dr.-Ing. Roland Heidrich provides an overview for the evaluation of refractory materials for glass melting furnaces, particularly for fused cast aluminazirconia-silica (AZS).

Particularities The raw mineral batch is fused and cast into individually made moulds, with the target of obtaining a dense block structure without open porosity and therefore with excellent corrosion resistance against glass melts, dusts and gases.

This property justifies the complex manufacturing process. However, the block structure is also inhomogeneous due to natural factors that occur during production, such as phase segregation and temperature profile: the block’s cross and longitudinal sections show gradients in density, chemistry and crystal structure.

For the quality assessment, it is therefore recommended to evaluate the entire block, not just individual fragments or small samples.

The presence of voids is a particular characteristic of fused cast block production. After casting and melt solidification, voids occur inside the block (also termed ‘cavities’ in the case of larger sizes) due to the volumetric shrinkage during cooling (Figs 1 and 2).

The formation of voids can be influenced by the manufacturing technology, melt chemical composition, as well as block size and shape. Furthermore, special casting techniques affect the location and size of voids or can even eliminate them, though additional casting headers of sufficient volume are required to supply extra melt and compensate the void.

External characteristics The first step in quality assessment is to evaluate external characteristics.

For the single block, these include compliance with nominal dimensions and perpendicularity. The surface protrusions and flatness of mating surfaces is measured. With pre-assembled blocks, the fit of joints the dimensions of the overall construction must be verified.

The damaged edges and cracks are also assessed. Particular attention should be paid to cracks of more than 1mm in width, long cracks or cracks that go beyond edges.

The block’s bulk colour can be evaluated on cut surfaces. It should be as bright as possible, as a grey color indicates reduction products. The block’s subsurface layer may contain small pores, which are exposed during the grinding process.

In the case of regular cast formats (e.g. for the glass furnace superstructure), the shrinkage cavity is an integral part of the block. The cavity is visible on the casting face of the block and can be closed with refractory mortar. In case of glass contact blocks, the cavity containing section is partially or completely sawn off. The control and visualisation of the cavity’s spatial extent inside the block can be performed with non-destructive test equipment.

Internal characteristics The following characteristics are determined by destructive test methods.

These methods are used to make comparative statements about different refractory materials. A modern test laboratory is required.

Chemical composition The chemical composition is a base characteristic. A key quality feature is the consistency of the same, even over a longer production period. Due to the discontinuous melting and casting process, a modern laboratory with X-ray fluorescence (XRF) is required to

� Fig 1. The longitudinal section of this regular cast block shows an unfavourably dispersed

Continued>>

shrinkage cavity.

www.glass-international.com

B

ecause their manufacturing process and properties differ widely from those of conventional ceramic products, we will use the term fused cast ‘blocks’ to better distinguish them from other materials. The blocks can be up to 2 metres tall and weigh more than 1000 kilograms. They are produced using a combined melting and pouring process similar to metallurgy.

� Fig 2. With sophisticated casting technology this longitudinal section shows a concentrated cavity that only extends over a third of the block height.

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Refractories

of glassy phase should be spread between the corundum crystals (Fig 3). In the case of the perfect fused cast material, the main part of the block profile consists of this ideal structure with minimal fluctuations.

a

b

� Fig 3. Fused cast AZS petrography. (a) scanning electron micrograph and (b) its pseudo-color image with coprecipitated zirconia (red) and corundum (yellow), surrounded by glassy phase (blue). Image width 400 µm.

analyse every casting in real time (online chemistry). Only complete control can guarantee a consistent composition of all blocks. If, however, only one block should be available for quality assessment, it is recommended to analyse several samples at different locations on the block.

The evaluation depends on the amounts of the main components (alumina, zirconia, silica) present and the content of accompanying oxides and impurities, which should be as low as possible.

The content of dissolved gases, which are determined by carrier gas hot extraction, could be of special interest, but requires high experimental effort.

The lower the gas content, the better the block quality.

Bulk and true density A simple but useful test for an immediate evaluation of the compactness of the block is the determination of its density.

The overall structure of a fused cast block consists of: a) a dense portion with few small noncommunicating pores, b) a portion with larger, closed pores and intercrystalline cavities, c) and a shrinkage cavity. To assess the density, the following properties must be distinguished: The bulk density of a block can be calculated using its external characteristics, such as dimensions and weight (including voids and porosity).

This corresponds to the catalogue values measured in kg/dm³.

The proportion of dispersed porosity is determined through the bulk density in g/cm³. This is investigated using a pycnometer on some fragments that have been removed from the dense parts of the block, i.e. at distance from the cavity, but not just below the block surface.

Finally, the true density in g/cm³ serves as a reference, which can also provide information about deviations in the

chemical composition and structure. It is determined with a pycnometer and a powder sample, with sampling at various block positions and by grinding smaller than the size of closed pores.

Porosity The determination of the apparent porosity by means of water absorption or permeability is not effective since the pores in the fused cast material do not communicate with each other. The determined values of water absorption are insignificant and correspond mainly to the pores under the casting skin (also known as ‘subsurface porosity’).

Petrography The proportion and arrangement of glass and mineral phases in the fused cast material influence important properties: the glassy phase exudation, the corrosion resistance, and the thermo-technical properties. Investigations with an optical microscope and in a scanning electron microscope show that the most resistant AZS materials have a dense network of corundum plates with a so-called sieve structure. This structure is formed by coprecipitated baddeleyite crystals oriented perpendicularly to the base surface of the corundum. A small amount

Thermo-technical characteristics The measurement of some thermotechnical properties requests an experimental effort so high that they are investigated only from time to time.

The values change insignificantly with constant chemistry, so that catalogue values should be sufficient for quality assessment. These properties include e.g. refractoriness under load, thermal expansion, thermal conductivity, crushing strength, thermal shock resistance, and electrical conductivity.

Application related properties In addition to manufacturing quality, application-related properties are of great practical and fundamental importance for the glassmaker. These properties can only be tested in specialised laboratories.

Sampling should be carried out carefully according to a defined scheme to obtain representative test results.

Since the homogeneity of the individual samples also influences the results, samples from the vicinity of the surface are the most suitable. Sampling in the vicinity of the cavity results in nonreproducible test results.

For comparative statements it must be noted that the results only apply to the test method used, i.e. a specific property (e.g. exudation) tested with different methods (e.g. wafer test, ASTM, ICGTC11) gives different test results. For reasons of comparability, therefore, the chosen test method should always be

� Fig 4. Referring to fig 2, the principle sketch illustrates the presence and spatial extent of the zonal structure of a regular cast block, including the most corrosion resistant zone, the “shell” (1) with homogeneous and very compact crystalline structure, the “working zone” (2) with fine grained structure, the “central zone” (3), coarse grained with intercrystalline pores, and the shrinkage cavity zone (4).

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Refractories

indicated together with catalogue values. NB: the higher effort with the ICG-TC11 methods pays off through the reliability and reproducibility of the measured values.

Corrosion resistance Resistance to corrosion by molten glass is one of the most important properties of fused cast refractory. Different static and dynamic methods are used to test the corrosion resistance. The usual methods are those in which small samples are immersed in the glass melt (finger test).

Glassy phase exudation During furnace service the expulsion of part of the AZS glassy phase at the fused cast refractory surface may occur, resulting in glass defects known as knots and cords.

Also in this case, various test procedures with contrasting results are available. The samples should be large enough for reliable statements on the exudation property.

Test results show that the relatively low exudation values for porous samples correlate with a low corrosion resistance.

Blistering An unpleasant property of refractory materials is their tendency to form bubbles in contact with the glass melt.

These bubbles represent a defect in the glass melt and increase the corrosion rate of the refractory blocks.

There are various test methods that differ in terms of sample geometry, test parameters and, ultimately, the reproducibility of the results. Their common feature is the heating of the refractory material together with the glass melt with subsequent evaluation of the bubbles that occur.

*

*R&D, Refel, San Vito al Tagliamento Italy. roland.heidrich@refel.com www.refel.com

www.glass-international.com

For a detailed evaluation of external characteristics, refractory manufacturers have corresponding technical specifications for standard formats. In the case of complex blocks or special shapes, larger tolerances may need to be discussed.

In principle, all superficial imperfections like cracks or bulging can be eliminated by cutting and grinding. The later optical appearance is a white, smooth block. However, with the removal of the block’s skin, also the most dense and homogeneous structure (the ‘shell’, fig 4) gets eliminated.

Heavily ground block faces, therefore, can lead to badly performing blocks. As a consequence, deep grinding of surfaces is neither economical nor practical.

The quality of certain refractory brands can only be assessed on the basis of the examination of several blocks, if possible over a longer period. Therefore, complete blocks of standard dimensions should be used for complex evaluation, as flakes or small samples are not sufficient. The sampling position must always be documented.

A variety of different test methods is available, whose results largely depend on the test conditions and parameters. Catalogue values should always be compared with full awareness of the methods and test standards used to obtain them. A higher effort in sample preparation and measurement methodology pays off through the reliability and reproducibility of the measured test values. �

* latest swabbing-robot installed in July 2017 in Germany

Closing remarks

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Refractories

AZS fused cast has plenty of unrecognised potential P.Carlo Ratto* discusses the benefits and problems with using an AZS fused cast.

A

lmost a century after the initial development of fused cast refractories, the industry is still to consider the fundamental differences between fused cast and the traditional sinter refractories.

It has been a success story since its development nearly 100 years ago. Its aplication has developed to the point where it has become the principal (when not the solo) refractory applied in the glass contact and superstructure of the glass smelting furnaces.

The heavy, solid and bold aspect of fused cast blocks can lead to believe that these are stable materials against the extreme temperatures and harsh chemical attack inside a glass furnace.

The outstanding performance in operation confirms this.

But when moving from sensations to rational evaluation, most opinions will change.

Unlike traditional sinter refractories, fused-cast are manufactured through electrofusion of pure oxides and pure silicates at extremely high temperatures (among the highest in the general industry), followed by the pouring of the liquid ceramic into special moulds and a subsequent controlled cooling process.

During this cooling, a complex phenomena of crystallisation, solidification and stress release happens so as to get to the refractory body as we know it, that can undergo mechanical treatments (cutting, grinding, drilling) without major cracking and constitute the components of glass smelting furnaces.

One could infer that these refractories,

for example an AZS refractory, being treated at temperatures extremely higher than those that will be reached when in application in the glass furnaces (i.e. about 2000°C against 1600°C), they should

� Fused ceramic being poured out of an E.A.F. be thermally stable at the application temperature and that, therefore, only the chemical attack (glass contact or gases in superstructure) will have to be considered as a source of refractory degradation.

The cooling process does not happen under thermally homogeneous conditions and does not go through infinite equilibrium stages. At the

opposite the cooling goes through strong thermal gradients (the inside of the block is still liquid when the surface is well under solidification temperatures) and at the highest speed compatible with obtaining an unbroken block that can be handled and machined without cracking, having released enough thermo mechanical stress coming from expansion/shrinkage of precipitated crystalline species and the transition from plastic to elastic behaviour of the residual glassy phases.

The motivation for the fastest possible cooling process, of course, stems from process’ economic factors: it should be considered that, for the largest blocks, the cooling/ annealing stage of the process can last up to 20-25 days and that, therefore, the ‘annealing warehouse’ where blocks stay to move from liquid to a manageable solid, is by far the most ‘capital intensive’ step of manufacturing.

Hence every effort to accelerate the cooling process has a strong payback and is welcomed by manufacturers.

It is clear why an AZS fused cast block is generally an inhomogeneous body, with important differences in chemical, crystallographic textural between different zones, and why this body is far from the equilibrium that could come from the original liquid composition after an ideally slow cooling process, capable of maintaining the cooling body without internal thermal gradients.

Continued>>

44 0 Glass International February 2020

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Refractories

Alterations in AZS fused cast in a glass furnace

Arbitary unit

ASTM C1233 standard procedure

8 7 6 5 4 3 2 1 0

1

2 3

4

5

open porosity

Distance fro

6

7 mullitization

8

9

� Newly-formed Porosity and Mullite distribution starting from hot face (left) toward cold face of the AZS f.c. block (right).

Exudation: 2,53%

Exudation: 5,82%

� ASTM exudation test – Courtesy of SSV Venice.

Having pointed out this fact, the logical consequence is that fused cast refractories, and specifically the AZS to which we refer, are not at all in a chemical and physical equilibrium and that once brought at a temperature providing kinetic to the system, (because the block is now installed a working glass furnace or because a test sample is heated in a laboratory muffle), these materials will tend to re-equilibrate to a condition pertinent to the specific temperature, even if this temperature is, obviously, much lower than the temperature to which components were exposed during the fusion stage of the manufacturing process.

This peculiar condition - much less present in a sintered refractory fired at temperatures higher than the one in application - explains several behaviours observed in AZS fused cast refractories when heated at relatively high temperatures, typically above 1,0001,200°C when the fluidisation of its glassy phase permits structural rearrangements, mobility of chemical components and ultimately the reach of a new chemical and physical equilibrium and the release of thermo mechanical stresses that were residual in the refractory as produced.

In all of these alterations there is no role of any chemical interaction (commonly defined as corrosion) with the operational environment, in contact with molten glass or exposed to the combustion atmosphere of the furnace above glass level.

The well-known ‘exudation’ phenomenon of AZS fused cast blocks in a superstructure, generated by complex driving forces, is only one, although perhaps the most dramatically visible, effect of re-equilibration inside the refractory body as (at least initially) an exclusive consequence of heating above 1200°C. Other less visible alterations occur when AZS fused cast are exposed at glassmakings process temperatures, following and/or coincident to the visible exudation.

One major change, directly connected to the exudation phenomenon, is the new formation of open porosity. AZS fused cast refractory, as a virgin material and in the ‘dense zone’, typically has a minor amount of porosity, generally around 2%, of which almost all is closed porosity within the glassy phase.

This is imaginable in terms of small blisters of gas diffused in the liquid ceramic, that remain trapped into the refractory texture during cooling, precipitation and solidification.

But, when the refractory is heated to the typical temperature of a glass melting furnace, as a consequence of the development of internal gases and softening of the glassy phase, the internal pressure causes extrusion of a liquid component (with a composition very close to that of the overall glassy phase) tcalled ‘exudate’.

It is easy to understand that these gases, responsible of the exudation, once liquid

phases are partially pushed out, they leave behind voids in shape of a number of intercommunicating micro-pores, that constitute what is called ‘open porosity’.

The development of open porosity within the texture of an AZS fused cast is, therefore, the normal consequence of exudation, under exclusive action of temperature, that is somehow proportional in quantity to the amount of exudation and particularly evident within zones of dense refractory under the hot face of a block (e.g. in superstructure) in a thermo-gradient condition.

On the long term exposure of the block to high temperature in a real furnace condition, other phenomena related to the reduction of the thermal gradient and to the diffusion of foreign elements migrating from the hot face to inside the refractory structure (chemical aggression and diffusion) can reduce the open porosity since foreign liquid phases can partially fill up this open porosity and dissolve some crystalline component of the refractory (mostly Corundum).

It is to be noted that we are not talking about minor amounts of open porosity, since, for example in AZS blocks in superstructure operating at very high temperatures (more than 1600°C), in the first several months of operations, the amount of open porosity, detectable through coring of a sample and determination with Archimedes method, can account at more than 10%, while it was zero in the virgin material.

Another non-visible consequence of the re-equilibration of AZS fused cast refractories installed in a glass smelting furnace, and also exclusively consequence of the exposure to working temperatures, is the so-called ‘mullitisation’.

This term, often used to explain the new formation of mullite as a consequence of firing of natural aluminosilicates like sillimanite or kyanite, can be properly used also for this AZS alteration, as we’ll see.

Continued>>

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m hot face

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Refractories

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In spite of the presence of silica and alumina in the composition of AZS fused cast, in a virgin block we do not normally detect presence of mullite (3Al2O3•2SiO2), since all crystallised alumina is precipitated in form of alpha corundum while all silica is present in form of a hard sodium silicate glass, saturated with alumina and zirconia (that is the so-called glassy phase).

When part of the alkaline glassy phase is extruded as a consequence of the high temperature and the block (or a portion of it) lingers at temperatures favourable to the formation of mullite, part of the residual silica combines with the dissolved alumina with formation of mullite within the residual glassy phase: corundum crystals dissolve into the depleted glassy phase and this contributes to the growth of mullite (from crypto to well formed crystals) until more free silica is available.

As pointed out when talking about open porosity, the protracted exposure of the block to the furnace environment (both for superstructure and glass contact) can favour the diffusion of alien components (e.g. alkali) from outside to inside the AZS fused cast, through open porosity and through ionic diffusion within the glassy phase.

These phenomena, in a variable extent due to the particular composition of the produced glass, combustible, operating temperatures and a number of other factors, can lead to a partial dissolution of the new-formed mullite, until the refractory reaches a relatively stable equilibrium with the environment.

In all cases, it is generally observed that a spent refractory (having been in a glass furnace for a variable amount of time from months to a full campaign) when analysed for its crystallography (X-ray diffraction) shows the presence of variable but remarkable amounts of mullite.

In the past, post-mortem investigations of AZS fused cast refractories, with evident detection of open porosity and mullite, have risen doubts on the original quality of the refractory installed, until laboratory simulations utilising refractories of perfect quality (no open porosity, no mullite) simply exposed to temperatures matching those of a sodalime glass furnace, even if for a short time (several hours to days) have made evident the development of remarkable amounts of both open porosity and mullite.

This has shown that open porosity and mullitisation, as well as the accepted (since visible) effect of exudation, are a

consequence of the exposure of an AZS fused cast to high temperatures even in the absence of any external contribution of elements not being part of the refractory. Furthermore these effects are in a much-more-than-linear correlation with the operating temperature.

Thinking about the quantitative aspect of these phenomena, these depend on a long list of peculiar factors, as mentioned above and, in a real furnace application, we can invariably observe ‘zoning’ of the refractory body, generally in a function of its thermo gradient, mostly evident when the block is relatively young in application and thick in the dimension perpendicular to the hot face.

This brings about another interesting point that must be considered when comparing results of laboratory tests and actual installed materials.

Since samples tested are usually those utilised for exudation tests (ASTM C1223 or other recommendation from TC11), in all cases samples are exposed, in regular atmosphere, at testing temperature and isothermally; due to the small dimension of test samples, any thermo gradient, in fact, is rapidly eliminated and all portion of the sample are exposed to the same test temperature.

The test results are more representative of a specific zone of a refractory, thin enough to be considered isothermal, rather than of the actual situation in a furnace.

In all of these considerations, of course, the effects of chemical aggression and diffusion that inevitably interact with the thermal re-equilibration of the fused cast body are completely disregarded.

An AZS fused cast block in a glass furnace, in spite of the idea that everybody has of a refractory (stable and inert against the rise of temperature), is therefore to be considered more resembling a live body, that undergoes changes toward different equilibria, while chemically interacting with the operational environment.

Laboratory testing does not completely represent the actual conditions in a furnace but, in spite of this, not immediately intuitive effects like development of open porosity and mullitisation are assessed as a consequence of exposure to operating temperature. This represents another step toward a better understanding of AZS fused cast. �

*Owner, Fused Cast Technologist, San Vito al Tagliamento, Italy www.fusedcast.com

Glass International February 2020

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Refractories

A software to compare crowns Santiago Suarez Arango* & Manuel Alejandro Parra Rangel** provide the results of CFD software looking at four different case studies putting monolithic against traditional brick furnace crowns.

T

he need of a higher thermal efficiency in melting glass processes guides companies to look for improvements in any area. For Magneco/Metrel this topic is of a big concern too and it’s for that reason that it has continuously improved its methods and materials to offer the best option to build more efficient glass furnaces in the market.

This paper describes the results obtained in a 3D modeling and simulation by the use of a CFD software in which the heat transfer and energy losses in the crown of a glass furnace are analysed in four different configurations: 1. Case of study: Monolithic crown with insulation 2. Case of study: Monolithic crown without insulation 3. Case of study: Traditional brick crown with insulation 4. Case of study: Traditional brick crown without insulation The main objective of this study is to perform the heat transfer analysis specifically in the crown of an end port glass melting furnace by using CFD software to identify the main differences between thermal behaviours

of a monolithic crown versus a traditional one, Fig. 1 shows the furnace crown general arrangement.

Development of the study Based on the technical specifications granted to carry out the modeling, materials from different trademarks were selected; choosing those whose physical properties were public knowledge, used insulation is listed on Fig. 1 detail D, monolithic refractory used for the modeling was Metsilcast from Magneco/ Metrel and GEN-SIL blocks were used for simulating traditional construction crowns.

The parameter established as border conditions for carrying out the study of heat transfer in the four study cases were: � Ambient temperature: 40°C � Crown convection coefficient: 9 W/m2K � Gas flow at the entrance: 10 m3/s � Pre-heated air flow: 6.6 m3/s � Gas temperature at entrance:

1726.85°C � Pre-heated air temperature: 1250°C These values were determined from the scientific literature consultation due to the difficulty of getting complete technical information first hand. A temperature of 1726.85°C (2000°K) corresponds to

the maximum flame temperature which decreases longitudinally and transfers heat to the glass surface and furnace structure (O.H. Díaz, 2011).

Temperatures of 1250°C correspond to the pre-heated air of the regenerative chamber, by combining these, an average temperature of 1500°C is obtained inside the furnace.

For analysis purposes, in the simulation are only considered near-reality values and results for the crown case, walls may not correspond to values close to reality due to they are not considered in the border conditions in this specific case of study.

Results comparison Once the results of both case studies were obtained, a comparative analysis of one with respect to the other was carried out with the purpose of identifying the main differences between the thermal and energy behaviour of a traditional crown constructed with blocks and a monolithic one, Fig. 2 shows the different temperature scenarios in the cold face of the crown with insulation.

Case study one shows that temperature distribution on the cold face of the crown is homogeneous for most of the surface and that the only area where a Continued>>

� Fig 1.

� Fig 2.

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Refractories

� Fig 3.

two and four, Fig. 4 shows the thermal profile of furnace crown in configuration monolithic versus traditional but this time without insulation (note that higher temperature observed on the surface to the crown corresponds to the expansion joint).

In the case of study two, the heat distribution on the external surface of the crown is not homogeneous since it has higher temperature zones located at the lateral and front ends of the crown corresponding to the flue gas flow inside the combustion chamber.

For the case of study four the images show that the temperature distribution is not homogeneous as spots of a different colouration are seen in different areas of the crown, sections with a red coloration indicates hot spot which are result of heat leakage through the spaces between blocks. Note that the union of the crown with the back wall shows a colder area attributing this effect to the location/ proximity of the ports where the start/end of the flame is held (lower temperature).

After analysis of thermal behavior, the following observations and differences were defined: � Although no homogeneous distribution was observed in either case, it is important to emphasize that a smaller number of hot spots were identified in the monolithic crown � Average temperature observed in the monolithic crown is 390°C and 420°C in the traditional one, this confirms that the traditional crown has more heat losses and in turn negatively affects the thermal efficiency of the furnace � Traditional crown has hot spots up to 512°C in the central zone (expansion joint), this means, 80°C above the average temperature which indicates that in real conditions this zone would have an

accelerated refractory wear � The un-insulated monolithic crown holds better the heat inside the furnace due to the inexistence of joints in comparison with the traditional crown (case study four) Fig. 5 show the comparison between energy profiles results of cases two and four (monolithic versus traditional crown without insulation).

An additional analysis was carried out when making the modeling regarding temperature and flow behavior of the gases inside the furnace. Fig. 6 observes a higher thermal efficiency and a more laminated flow of gases can be granted in the case 1 corresponding to the Magneco/ Metrel’s Metsilcast monolithic crown with insulation and the crown with bigger energy losses thus like more turbulent flow corresponds to the traditional blocks crown, this last arrangement also means a risk of condensation, accelerated wear of the refractory and a higher energetics consumption.

Conclusion From the mentioned comparisons it can be concluded that: � A monolithic crown has a higher thermal efficiency than a traditional crown. � A traditional crown without insulation has a large number of hot spots which in turn can become critical hotspots due to the high temperatures reached in these areas. � A monolithic crown with insulation contains better the heat inside the furnace obtaining a temperature in cold face from 40 to 50°C lower than the temperature on a traditional crown.

Continued>>

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considerable difference in coloration is seen in the corners where temperature is lower than that of the rest of the crown.

Case study three shows temperature profile on the cold face of the traditional crown where is observed that temperature distribution is relatively homogeneous, however, lines can be appreciated in a different hue that indicate an increase in temperature in these areas, due to the leakage of heat through spaces/joints between blocks.

On the other hand, a higher temperature in the cold face of a surface means energy losses. Fig. 3 shows it is possible to appreciate the heat flow outside the furnace crown in both scenarios (Monolithic vs traditional configuration) with insulation, an interesting difference is noticed.

From the analysis of both thermal profiles it can be defined the next observations and differences: � Monolithic crown has a relatively homogeneous temperature distribution on the cold side, unlike the traditional crown that has higher temperature points which coincide with the joint areas. � Average temperature in the monolithic crown is 140°C while the traditional crown is 195°C, it means a difference of 45°C which indicates there is a greater heat loss in the traditional crown as a result of the existence of joints. � Traditional crown has more hot spots which in real conditions generates accelerated wear of the working refractory and, in turn, a deterioration of the installed insulation.

Comparison of results between case studies two and four In the same way as the comparison of cases one and three, a comparative analysis was carried out between the thermal and energy profile results of case of studies

� Fig 4.

49 Glass International February 2020

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Refractories

� Fig 6.

� Fig 5.

� In a practical case, a monolithic crown requires lower insulation thickness in order to get the same temperature in the cold face that a traditional crown (higher thermal efficiency). � It was found that a traditional crown has an average heat flow (energy losses) to the exterior of 4651.35 W/m^2, this means a 535% above the monolithic crown with insulation (869.84 W/m^2); this is attributed mainly to the losses observed on the expansion joints thus

like in joints between blocks. � If removing the sampling points corresponding to the expansion joint, would be observed an average heat flow in the traditional crown with insulation of 3839.84 W/m^2, this means a 429%above the average heat flow of the monolithic crown with insulation (893.48 W/m^2).

More information regarding the complete analysis (temperature, energy losses, gas flow, gas temperature, temperature gradients along cross

sections, energy savings percentages, dynamic simulations, and others) can be gained by contacting Magneco/Metrel Inc. where a professional specialist can assist to get a specific technical/ commercial proposal which suits your process. �

*Vice President Sales, Latin America, Magneco/Metrel Inc ** Operations Manager, IPM de Tlaxcala S.A.S.

Events review: MOOC course

2000 take part in glass training M ore than 2000 people took part in an online course that explored glassmaking.

The aim of the open course was to raise awareness about a career in glass to as many people as possible. French glass technological centre Cerfav offered the programme in the form of a Massive Online Open Course (MOOC).

The training was held in collaboration with 12 French glassmakers, which were contacted to help raise awareness of glass as a profession among potential candidates.

Topics studied during the five-week programme included history, different types of packaging glass, colouring and decoration and glazing.

Cerfav’s Fanny Guenzi said it was a new initiative, which aimed to integrate digital technology into training in glass professions.

“French industries and glass federations

have told us of their difficulties in recruiting in the glass sector, due to a lack of knowledge of the industry’s trades, and a lack of qualified manpower.

“Cerfav has chosen to offer an innovative training course, giving access to as many people as possible and free of charge to first-level educational content, developed in collaboration with glass manufacturers and specialised institutions.”

After successful feedback, a further initiative is planned later this year.

The 12 glassmaking companies which participated were Arc France, Cookware International, Eurofloat, Everglass, Ferro, Guardian, Saint-Gobain, SGD Pharma, Solover, Somobresle, Stoelzle Masnières and Verrissima.

The industrial partners unveiled their latest innovations and projects.

The involvement of companies which specialise in glass waste recycling also

allowed everyone to understand more about the ecology of glass.

Ms Guenzi added: “This MOOC session is over, but given its success, a new session will be organised at the end of 2020 which will be open to the English-speaking public.” �

Cerfav Prover, Vannes-le-Châtel, France moocvitra@cerfav.fr www.cerfav.fr

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History

Prof. John Parker

Under stress Prof John Parker discusses quantitative measurement of stresses in glass. looking through a toughened window sees stresses that are equal in the x and y directions perpendicular to the viewing direction. Consequently, no retardation occurs – that requires different stresses in the two directions.

Now cooling involves many individual nozzles and the cooling rates vary across the surface according to whether the area of glass is directly ‘beneath’ a nozzle or in a zone between them. So different stresses are induced across the sheet but are much smaller than the ‘toughening’ stresses.

The patterns reported on the internet correspond to the nozzle arrangement and the small retardations seen are consistent with low stresses across the sheet (as opposed to through it); black corresponds to zero stress while low stresses give shades of grey.

Similarly, inadequate temperature control across a glass ribbon in the annealing lehr during flat glass manufacture generates balanced compressive and tensile stresses along the ribbon axis which can cause failure during cutting. A particular issue occurs if centre line stresses are compressive.

The release of such stresses on cutting, generates tensile stresses along the cut surface and can cause a so-called lehr split which runs back along the ribbon into the lehr where it continues to grow as more ribbon is created. The crack cannot easily be eliminated until a proper temperature distribution is restored. Now optical devices, a polarised light source and a detector on the opposite side, scan across the sheet in seconds after annealing to measure the stress distribution and have dramatically reduced the incidence of such issues.

But is it possible to solve the issue that retardation depends not on the absolute or maximum stress but on the differences in stress in two directions perpendicular to the travelling beam summed over the whole beam length?

A similar problem arises for mechanical

engineers using transparent models of engineering artefacts to analyse stresses in use. Not long after Maxwell was making his childhood observations, Brewster was already considering glass plates for modelling complex stress problems although later he used jelly, which could be poured into a mould to create the required profile.

In recent decades Aben and co-workers in Tallinn have researched extensively this issue. One approach uses optical devices combined with basic principles and mathematical modelling to deconvolute the observations into stress distributions.

These methods work well for residual stress measurement in axisymmetric glass articles and are widely used. For non-axisymmetric glass articles of complex shape, photoelastic tomography is also available. For automotive and architectural glass panels, surface stress can be determined from the refractive indices of the two rays vibrating parallel (surface stress) and perpendicular to the surface (zero stress) measured using a prism and total internal reflection; this is most effective on the tin-enriched, high refractive index surface of float glass which acts as a light-guide - hence its title of mirage effect. Stresses measured using the scattering of a laser beam also give support to analytical results. �

Bibliography Glass in Engineering Science, J A Hemsley, Volume 1 Optical Birefringence in Glass Published by the Society of Glass Technology ISBN: 13-978-0-900682-74-2 Modern Photoelasticity for Residual Stress Measurement in Glass, H. Aben, J. Anton, A. Errapart, https://doi. org/10.1111/j.1475-1305.2008.00422.x

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

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I

n September 2017 I wrote in these pages a brief history of strain viewers and how they allowed glassmakers to visualise disannealing stresses in their products.

Hemsley in his recent excellent and extensive review of photoelasticity tells how James Clerk Maxwell (1831-1879) was intrigued by the coloured patterns he saw using polarised light to view unannealed glass sheets.

He had been taken as a ‘mere’ boy by his uncle to visit Nicol, who famously developed the Nicol prism for creating polarised light. Nicol showed Maxwell examples of patterns that could be generated. Maxwell’s response was to paint in water colours what he had seen, receiving two prisms as a reward from Nicol. Later at just 19 he presented to the Royal Society of Edinburgh a theoretical paper on the elastic properties of solids, which included a photoelastic study of the stresses in unannealed glass triangles.

The colours Maxwell saw arose because polarised white light propagates through stressed glass as two polarised rays with differing velocities. The term retardation expresses how out of step these rays become; it depends on pathlength and the magnitude and orientation of the stresses present. Recombining them using a second polariser produces a colour defined by the retardation.

The patterns that piqued Maxwell’s curiosity were undoubtedly bright and strongly coloured, corresponding to large retardations and high stresses. A recent internet discussion in Physics Forums (October 2015) concerned similar effects seen in the toughened glass of a car rear window. The enquirer was puzzled though because he saw colourless, black and white patterns corresponding to small retardations and low stresses. Yet toughening involves rapid cooling to introduce steep temperature gradients and generates stresses much higher than produced by poor annealing. The reason for this apparent paradox is that the viewer

51 Glass International February 2020

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