““Towards a Towards a Sustainable Sustainable
Future”Future”
Environmental ImprovementsEnvironmental Improvementsinin
Glass Batch ProductionGlass Batch Production
““Towards a Towards a Sustainable Sustainable
Future”Future”
PRILOX PRILOX ®®
““Towards a Towards a Sustainable Sustainable
Future”Future”
Overview
Introduction
What is Prilox
Why Prilox
Project Aims
Proposed Concept
Practical Experience
Benefits
Conclusion and Summary
““Towards a Towards a Sustainable Sustainable
Future”Future”
Health, Safety and Environmental pressures
continue to play an important role in the decision
making process within our industry. New European
Legislation currently being considered will reduce
the existing suspension level for lead in blood to
possibly 40 microgram/decilitre.
To continually meet the proposals, and satisfy
presumed future reductions, glass manufacturers
have to consider the best solutions for
manufacturing glass, both through the “ batch
house” and the delivery of that formulae to the
melting phase
Why Prilox?
Introduction
““Towards a Towards a Sustainable Sustainable
Future”Future”
Chemson has a history in Lead chemicals of circa.
150 years, with the past 50 years supplying
masterbatch ‘one-packs’ to the Plastics Industry.
The synergy between the two industries is
remarkable, and transferring some of the
techniques and protocols developed over the past
decade it making the plastics industry a highly
advanced and automated industry, competing on
a global stage, were used to develop this project
Prilox is a masterbatch of ingredients delivered in
a desired form.
What is Prilox?
Introduction
““Towards a Towards a Sustainable Sustainable
Future”Future”
Introduction
Project Aims
• Reduce Interface with Hazardous Materials
• Automated Handling
• Reduced number of individual components
• High Quality Product
• A long term cost acceptable solution
““Towards a Towards a Sustainable Sustainable
Future”Future”
Proposed Concept
Two Component Auto Handling System
Pellet
Batch
AZO TYPEMIXER
San
d
FEED
Cullet
for hearth
““Towards a Towards a Sustainable Sustainable
Future”Future”
Trail period
The Prilox test trial by:
Inn Crystal Glass / Braunau am Inn / Austria
started 16 .Aug. 2001 and completed 15. Sept. 2001.
At three times, the TÜV – (an external international
accredited body for certification of quality
management systems) measured the emission of
dust and lead in air at three different areas:
a) in the furnace (closed room)
b) production hall – over the production units
c) with the workers
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Date / Name
MAK
• Reduced power consumption of over 5 %
• Reduced vault temperature of over 20 %
• Reduced batch mixing time of over 40 %
• Reduced water consumption of over 80 %
• Reduced total dust emissions of over 90
%
incl. reduced lead emissions.
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Results of the Prilox test trial (16.Aug.01 to 15.Sept.01) measured on by TÜV
Dust and lead in air content in the exhaust air of the furnace
first measurement: after 2 weeks production with Prilox
• reduction the dust proportion by furnace 1 over 90 %
• reduction the lead in air by furnace 1 over 90 %Second
measurement: in the last week of the trial
• confirm the first test results
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Date / Name
Dust and lead in air content in the exhaust air of the furnace 1
0
200
400
600
800
1000
1200
1400
Dust Lead Dust Lead Dust Lead
TÜV 08.08.01 TÜV 29/30.08.01 TÜV 11/12.08.01
mg
/ m³
Furnace 1 Furnace1 - near feeder
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Date / Name
Fig 1. Furnace 1• cold top• closed surface• dust free
Fig. 2. Furnace 2• hot top• open surface• dust
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Date / Name
Results of the Prilox test trial measured by TÜV
Dust and lead in air content in the exhaust air of the production hall over the machines
First measurement: after 2 weeks production with Prilox
• no reduction of the dust load, by the last comparative
measurement because only furnace 1 are working (furnice 2
started on 11/99) but
• very low workplace concentration from lead, less than 0,14
mg / m³
Second measurement: in the last week of the trial confirm the
first test results
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Dust in air content in the exhaust air of the production hall over the producing units
0
1
2
3
4
5
DustTÜV 26.4.99
dustINUS 23./24.5.00
DustTÜV 08.08.01
DustTÜV 29/30.08.01
DustTÜV 11/12.08.01
mg
/ m
³
IBS-20/I RPH-16 RPH-6 RPH-12
1) Only furnace 1 works2) Furnace 2 starts his production to 11/19993) On the measurement 11/12.08.01 - production problems
according to Inn Crystall
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Date / Name
Lead in air content in the exhaust air of the production hall over the producing units
0
0,05
0,1
0,15
0,2
Lead Lead Lead
TÜV 08.08.02 TÜV 29/30.08.02 TÜV 11/12.08.02
mg
/ m
³IBS-20/I RPH-16 RPH-6 RPH-12
Information: in accordance with the Austrian Law / BGBL 498 /1994 –the limit of the emissions of the exhaust air in glass-producing production is 5,0 mg / m³
““Towards a Towards a Sustainable Sustainable
Future”Future”
Practical Experience
Date / Name
Results of the Prilox test trial measured by TÜV
Measurement the dust and lead load at the furnace workers without protection
First measurement: after 2 weeks production with Prilox
• reduction of dust load over 50 %
• reduction of lead load over 70 %
Second measurement: in the last week of the trial
• reduction of dust load over 85 %
• reduction of lead load over 95 %
““Towards a Towards a Sustainable Sustainable
Future”Future”
Date / Name
Dust and lead load by furnace 1 workers with and without protection
0
0,5
1
1,5
2
2,5
3
Dust Lead Dust Lead Dust Lead
TÜV 10./11.7.00 TÜV 29/30.08.01 TÜV 11/12.08.01
mg
/ m³
Furnice worker with protection Furnice worker without protection
““Towards a Towards a Sustainable Sustainable
Future”Future”
Benefits
Date / Name
• Reduced number of raw materials
• Simplified Mixing Process
• Automatic Storage and Handling
• Encapsulation of hazardous refining chemical
• No moisture pick up
• Reduced energy consumption
• Reduced wastage
The easy-to-use oxide innovation enhances crystal strength and purity whilst improving the manufacturing process and gives users a more competitive edge.
““Towards a Towards a Sustainable Sustainable
Future”Future”
Summary & Conclusion
Date / Name
• The industry is seeking a permanent solution to the health, safety and environmental issues.
• The solution needs to be cost acceptable.
• Prilox provides a modern concept of material delivery, storage and handling to the melt furnaces.
• Technical and processing benefits became cost benefits.
• Modern handling concept provide a Sustainable Future.
““Towards a Towards a Sustainable Sustainable
Future”Future”