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Ei i h G WEirich Group Wo

The Pioneer in Material Pro

Advanced batch preparation for better melting properties

The Pioneer in Material Pro

ldWid Copyright by: Maschinenfab

Gustav Eirich GmbH & Co K

Copyright by: Maschinenfab

Gustav Eirich GmbH & Co KorldWide

cessing®

Author: Dan Britton / Harald EirichOctober 2011Page: 1

cessing

Advanced batch preparaor better melting properor better melting proper

1 Liter

12,000 Liters,

Presented By: Dan Britton – North American S


Eirich Machines, G

ationrties Copyright by: Maschinenfab




rties

5 Liters

400 Liters

ales Manager


Gurnee, IL

Advanced batch preparaor better melting proper

P t ti S i

or better melting proper

Presentation Synopsis

About EIRICHAbout EIRICH

Glass Production

• From the raw material to the finFrom the raw material to the fin

• Energy consumption factors

• Focus batch preparation

Improvement of Batch Preparation

Historical development of the pan mixe

• Independent studies

• R&D project “EinFormGlas”

• It pays off to improve the batch

Summary






rties

nal productnal product

er technology

preparation technology


Companies in the EiricPartners for Process TechnolPartners for Process Technol

1300 Employees in 11 Countries

Hardheim

Dnepr

Mo

ChicagoDnepr

Lyon

Johannesburg

Sao Paulo


Maschinenfabrik Gustav Eirich GmbH & C

ch Groupogy Worldwide Copyright by: Maschinenfab




ogy – Worldwide

s on 4 Continents

ropetrovsk

oscow

ropetrovsk

JiangyinShanghai

Seoul

Mumbai

Beijing Tokyo


Co KG – Hardheim, Germany

Technology Supplied ByTechnology Supplied By

Eirich preparation technology is batch or continuous processes

ith th f ll i b i tiwith the following basic operatio

- MixingMixing- Dispersing- Pelletizing- Kneading- Drying- Reacting- Reacting- Fine grinding


y EirichCopyright by: Maschinenfab




y Eirich

used for

ns:


Advanced batch preparaor better melting properor better melting proper

... it depends not only p yon how you mix…






rties

There are differentways of mixing,bbut…


Glass productionFrom the raw material to thFrom the raw material to th

Consider the entire glass productiog p

Glass production does not start at the furnaceThe furnace is the most expensive “mixer” withipNumbers of different parameters influence eachto compare plants can not be generated Problems that start at the first production chainsymptomatically at a later production step

Raw Mixing Melting Sheet Materials

gForming


Picture: S

he final product Copyright by: Maschinenfab




he final product

on chain

n the production lineph production step, so benchmarks

s have not to be compensated

Cooling Quality Packagingg

g yControl

g g


Saint Gobain Oberland

Glass productionFrom the raw material to thFrom the raw material to th

Economic assessment

From GMIC A technical and Economic Assessment“ ISBN 0 9761283 0 6From GMIC „A technical and Economic Assessment , ISBN 0-9761283-0-6

Hi h t f t i l dHigh costs for raw material and eneof investment for high quality batc


he final product Copyright by: Maschinenfab



Gustav Eirich GmbH & Co Khe final product

6 August 20046, August 2004

bl f t tergy enable fast return ching equipment


Glass productionEnergy consumption factorEnergy consumption factor

Raw Melt Considerations

During the first 45-60 minutes of the first melti75%-90% of the entire melting energy is used

The heat transfer rate and the distance of diffuThe heat transfer rate and the distance of diffudetermine the reactions

Macro- and micro structure of the batch has dMacro and micro structure of the batch has dmelting process

Batch and melting segregation has to be prevg g g p


rs Copyright by: Maschinenfab



Gustav Eirich GmbH & Co Krs

ng section, more than .

usion transportusion transport

irect influence on theirect influence on the

ented



Energy

Degree of batchDegree of batchpreparation

Quality


Basic relationships of th





Specific melting rate


he melt


der R

oh-

ng

Grad de

stoffa

ufbere

itung

Qua

lität

Energie = kon

s

Qua

lity

Energy = con

WannenleistungFurnace pull






nstantnstant



HomogenisierHomogenising

Vorr

g g

Raw

Ene

rgie

Wannenleistung, Qualitä

Ene

rgy

Furnace pull, quality

Grad der RohstoffaufbereitungDegree of batch preparation






reng

reagieren

g

w materials

StrukturierenStructuring

ät = konstanty = constant


Glass production Focus on batch preparationFocus on batch preparation

Improvements of batch p

Raw Materials and Storage• Preconditioned Material

Preventing Segregation during tra• Preventing Segregation during tra

Mixing• Increase the amount of Homogeni• Sequenced mixing for better micro

Batch Transportation• Structured batches• Mixing directly in front of the furnMixing directly in front of the furn


n Copyright by: Maschinenfab



Gustav Eirich GmbH & Co Kn

preparation:

ansportation and storageansportation and storage

isationo structure

aceace


mprovement of Batch PHistorical development of the pan mHistorical development of the pan m

Mixer sold in the glass industry

Ring trough mixerRing trough mixerUp to 1906

Homogeneity of the mix:

Possible improveme

Intensive mixer with rotating mixing pan,horizontal

A f 1924 ( ith t f 1960)


As from 1924 (with rotor as from 1960)Homogeneity of the mix:

Preparationmixer technology





mixer technology

Planetary mixerPlanetary mixerUp to 1924


nt

Intensive mixer with rotating mixing pan,tilted

As from 1970



mprovement of Batch Pndependent studiesndependent studies


PreparationCopyright by: Maschinenfab





mprovement of Batch Pndependent studiesndependent studies

Homogeneity dry glass batch orbit (1kWHomogeneity dry glass batchfor different mixer types

150.0%

(

ribbon (1k

110 0%

120.0%

130.0%

140.0%

80.0%

90.0%

100.0%

110.0%

mog

enei

ty

50.0%

60.0%

70.0%

var.

coef

f. / h

om

20.0%

30.0%

40.0%

0.0%

10.0%

0 1 2 3mixing time in minutes






W/100kg) ring pan (2kW/100kg)g) g p ( g)

kW/100 kg) Intensive (5kW/100kg)

4 5 6


mprovement of Batch Pndependent studiesMethods to Increase Specific

ndependent studiesp

Melting Rate

furnace for tubesfurnace for tubesabout 25% heat losses through the structure

(independent to the furnace pull!)

Ring trough mixer:60 kg/(m2.h), 90% melting productivity75 kg/(m2.h), 75% melting productivity

Intensive (Eirich)-mixer with rotating pan:75 kg/(m2.h), 90% melting productivity

Results:• 25% higher specific melting rate

on same product quality levelon same product quality level

Average 6% energy saving







mprovement of Batch Pndependent studies

Selective Batching

ndependent studieswt% g

raw

(by W.M.Carty)

wt% glass

wt% modifier

wt% modifier g

former raw material

A

raw material

B

raw material D

cullet C

Total weight mixed batchABCD

ABCD added to glass melt residing in furnace melt tank

Melting and FiningFining


Standard Preparation





glass former w material

wt% modifier

wt% modifier

A raw material B

raw material C

Selective Batching of Batch Components

combination material AB

forη control in

combination material AC

forsolid state rxnη control in

meltsolid state rxn

melt

pelletizeAB

pelletizeAC

Mix AB, AC and any remainingportion of A, B and/or C in a mix

hopperpp

Add mixed batch to glass meltresiding in furnace melter tank

CONTROLLED REACTIONS DUETO SELECTIVE COMBINATIONS


Structured Preparation

mprovement of Batch PR&D Project with “EinFormGlR&D Project with EinFormGl

EIRICH is an active research partner for un

Research Project with EinFormGlass

Research cooperation sponsored by the GermanResearch cooperation sponsored by the GermanProduction of lightweight containers in a single pFinal presentation at Glasstec 2010


EIRICH T

reparationas” Copyright by: Maschinenfab




asniversities and producers

n Governmentn Governmentproduction step


Test Center – Hardheim, Germany

mprovement of Batch PR&D project with “EinFormGlas“R&D project with EinFormGlasStructuring the batch by sequential

Coating of single grains

Granulating of different minerals or filter d

-All Inside the same m





Gustav Eirich GmbH & Co Kpreparation

ust up to the entire batch

mixer -


mprovement of Batch PR&D project “EinFormGlas“

Sequenced mixing

R&D project EinFormGlasStructuring the batch by sequential

Sequenced mixing(basing on an old patent Nölle/TU Frei

1st Mi i t d ith1st sequence: Mixing wet sand with so2nd sequence: Addition of the remainin

2 5% 5% 7% 8%2.5% 5% 7% 8%

Test for 1st sequence : 2/3 sand, 1/3 soda

=> Mixing mill or intensive mixer necessa=> Segregation stops at about 8-10% wat=> Improved melting with reduced melt s


=> Improved melting with reduced melt s




Gustav Eirich GmbH & Co Kpreparation

berg)

dodang raw materials

9% 10% 11%9% 10% 11%

a, different moisture addition

aryter addition

segregationAuthor: Dan Britton / Harald EirichOctober 2011Page: 21

segregation

mprovement of Batch PR&D project “EinFormGlas“R&D project EinFormGlasAdvanced batch structuring

From batch to pellets with up to 15 mm diameter

conventiomoisture 12 - 18

additional binder yes

Significant reduction of batch and melt segr

additional binder yesgrainsize 70% < 10


Significant reduction of batch and melt segr





Structured batch 1 5 mmStructured batch, 1,5 mm

onal new% 8 - 10%

no

regation as well as carry over

no00µm standard sand


regation as well as carry over

mprovement of Batch PR&D project “EinFormGlas“

(1) (2) (3)

R&D project EinFormGlasComparison by primary melting test

h

h

h






(4)ts

(1) standard batch2,5% moisture

(2) transport segregated(2) transport segregatedstandard batch2,5% moisture

(3) Sequenced mixedb t h ith li ht dbatch with light soda4,25% moisture

(4) Pelletized batch with fine raw materials11,75% moisture

green line = batch free time


mprovement of Batch PR&D project “EinFormGlas“R&D project EinFormGlasComparison at a small melting furna

a.) Standard batch (3,5% moisture)

compared to

b ) St t d b t h ( t d d d tb.) Structured batch (standard sand etc.,light soda, fine dolomite and lime, 8% moisture when fed into the furnace)

(1.370°C, 140 min)

a.) b.)

M lt t d ili


Melt-segregated silica




Gustav Eirich GmbH & Co Kace (TU Freiberg)


mprovement of Batch Pt pays off to improve the batch prept pays off to improve the batch prep


Preparationparation technology





paration technology


Thank you for your attenThank you for your atten

In case of any further

questio

Eirich Machines, Inc.

Division of Machinenfabrik Gustav Eir

Dan Britton – North American Sales M

Tel.: (847) 406-1359

Mail to: [email protected]

Internet: www.eirichusa.com


ntion!Copyright by: Maschinenfab




ntion!

ons or comments:

rich Hardheim, Germany

Manager


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