Glass Production
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Transcript of Glass Production
Glass ProcessesCaroline Hsia, Jackie Allen, Althea Rosen, James Davis
Overview
● The Many Uses of Glass● Equipment & Technology● Advantages & Disadvantages● Economics● The Future of Glass● Case study: CFLs
○ Equipment & Technology○ Advantages○ Economics○ The future
● Conclusion
The Uses of GlassFour main types of glass:
● Glass packaging○ Bottles, jars, and other containers
● Fiberglass○ Insulation for buildings and OEM applications○ Textile fibers used as reinforcements for plastics
● Flat glass○ Windows, automobile windshields, mirrors, tabletops
● Specialty glass○ Table- and ovenware○ Flat panel display glass○ Light bulbs○ Television tubes○ Fiber optics○ Scientific and medical equipment.
Glass Processes● Rolled
○ Patterned Flat Glass○ Wired Glass
● Float○ Flat Glass
■ Buildings & Vehicles● Blown
○ Bottles○ Jars○ Bowls/Chinaware
● Spun ○ Specialty Products
■ Figurines, Christmas Ornaments, etc.
Equipment & Technology
General Types of Equipment● Furnace
○ Molten glass formed● Forming
○ Individual Section (IS) Machine● Annealing Oven
○ Lehr ● Coating
○ Usually two coatings● Cutting
○ After glass is processed, it is then cut to desired size
Advantages of Glass
● 100% recycling capability● Environmentally friendly manufacturing processes and
products ● Exceptional chemical durability● Multi-faceted optical properties● Many diverse, unique applications● Least expensive form of packaging in food industry● Does not diffuse into contents of packaging, like polymers
Disadvantages of Glass
● Long distance distribution is hard due to the weight of glass● Some specialty glass such as TV tubes does not justify
recycling due to insufficient volume○ Causes environmental problems primarily in 3rd world
countries● Manufacturing facilities are specialized
○ Facilities for one type of glass cannot be easily adapted to produce other types
● Brittle● Glass production is energy intensive and often expensive● Unlike polymers, it is hard to enhance or incorporate new
properties in glass
Advantages of Different Glass Processes
● Rolling○ The only way to mass produce wired glass
● Float glass○ Can range in thicknesses between .4mm and 25mm○ Can produce clear, tinted, and coated glass
● Blown glass○ Best way to form hollow work pieces○ Automated production can produce 600 containers/min.
● Spun glass○ The best way to use glass as an insulator○ Can be used to fortify other materials
Disadvantages of Glass Processes
Glass processes are very specific and rarely interchangeable
● Rolling○ Very limited variety of glass products can be made○ Not the preferred method to produce flat sheets of glass
● Float glass○ Propensity to shatter○ All specifications and additional work must be done
before toughening process● Blown glass
○ Limited to hollow parts○ Wall thickness hard to control
● Spun glass○ Poses health hazards: irritation of eyes, skin, lungs
Economics
Economics
Economics
Economics
- 4 main segments = $1.6 billion in energy per year
- ~ 14% total production costs
- ~ 38% production costs = heating process
- Improvements: - Heat generation - Heat containment - Heat transfer - Waste heat recovery
The Future of Glass
Where is The Money? 1. 7% batch preparation2. 54% refining3. 25% forming4. 14% finishing
What New Technology is Here? 1. Rain bed preparation2. Oxy-fuel melting 3. Material Based Ion Exchange
Rain Bed Preparation
● Glass particles fall● Hot gass rises● Higher surface area/
volume ● Reusing hot gas from
furnace● saves 0.5 MMBtu/ton
Oxy-fuel Improvements
● Direction of heat● Penetration● Improved efficiency ● Consistency in heating● Water saturation
Ion Exchange
● Create glass, then heat treat
● Create glass and change composition
● More energy savings○ 1MMBtu/ton
Case Study: Compact Florescent Lights
Advantages of CFLs:● CFLs use 1/5th the
energy of incandescent light bulbs
● CFLs last 6 to 10 times longer than incandescent bulbs
● CFLs produce 75% less heat than incandescent bulbs
CFLs: Economics
CFLs: Process, Equipment & Technology
Process● Spun Glass
Equipment used in CFL Process● Bending● Annealing● Cleaning● Coating ● Sealing
CFLs: How It's Made
The Future of CFLs
Rain Bed Technology● Reducing the Cost of CFLs● More Green
Oxy-fuel Improvements● Further reduce cost● Better for the Environment
Questions?
References1. "Glass - Industry of The Future" NREL, Office of Industrial
Technologies2. http://eelndom1.ee.doe.gov/OIT/oitpdf.
nsf/Files/ionexchange.pdf/$file/ionexchange.pdf3. http://www.osti.gov/glas/Glass%20R&D%20Project%
20Factsheets/Cullet%20Preheater.pdf4. http://www.ceramicindustry.
com/Articles/Feature_Article/0d1a52c7f1ac7010VgnVCM100000f932a8c0____
5. http://www.energystar.gov/index.cfm?fuseaction=find_a_product.showProductGroup&pgw_code=LB