HELLO EVERYONE 1

Glass Manufacturing

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Prepared By:-

Harish Balout

Ceramic Engineering

Roll No. 12ECTCR020

Submitted To:-

Mr. Narayan Dutt Joshi

Training Project Coordinator

3Introduction To CDGI

• Centre for the development of glass (CDGI) has been setup as a

joint venture

Project of Govt. of India, United Nation Development Program

(UNDP)/United Nation Industrial Development organization

(UNIDO), AND Govt. of Utter Pradesh as a register society on 06

1992 at Firozabad (U.P.)

• Objective of CDGI1. Creation of new job opportunities and improvement of skill and working

condition for worker/artist engaged in small scale glass industries

2. Efficient utilization of country’s energy and resource

3. Development and adoption of new technologies and product

4. Protection of environment

Department In CDGI 4

1. Laboratory Service• Physical Laboratory• Chemical laboratory1. Pollution control division2. Combustion Engineering3. Product and technology development unit4. Pot development unit5. Consultancy &Troubleshooting service6. Design and decoration unit7. Training

5GLASS

• Glass is amorphous solid = non crystalline, lacking of periodic

atomic arrangement and long range order

• Glass is super cooled = Liquid cool to a stage where its

viscosity is so great that the molecule do not move free

enough to form a crystal

• Any material, inorganic, organic, metallic form by any

technique which exhibit time dependent glass transformation

behavior is glass

6Raw material used for Glass

Manufacturing

• Network Former ( Glass making oxide)

1. 𝑆𝑖𝑂2

2. P2O5

• Network Modifier ( Flux)

1. Na2O

2. PbO

3. Li2OResult in serious degradation in many properties

• Network Strengthening (Stabilizer)

1. Cao

2. MgoDegradation properties can be counter by addition of alkali earth or transition metal oxide

• Refining Agent

1. As2O5

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17280C

• SiO2 Glass ( High Quality)

• SiO2 + Flux Glass (Less Strength)

• SiO2 + Flux+ Strengthening Good Strength ( Not refined)

• SiO2 + Flux + Strengthening + Refining Glass ( Refined)

Glass Manufacturing Process 8

a

9Flow Chart

Raw Materials

Cullet Silica Feldspar CalciteDolomite

Proportioning of Raw Materials

Mixture

Chamber

Silos

Dog House

Tank Furnace

Throat

Working end

Feeder

Shaping

MeltingCombustion

10Melting Process

• Aim = Is to get defect free glass at working temperature

• Raw material in proper proportion is mixed along with the cullet. It is fine powder

and the mixture called Batch is fused in Furnace at high temperature results in

formation of homogeneous viscous fluid.

• CaCO3/Na2CO3/MgCO3 CO2 + Oxide

(source of air bubble)

• During melting, cullet will form high viscous layer on the surface of the carbonate

and flux

• Flux start react with the solid grain along with the formation of air bubble and liquid

melt.

• Practically all the reaction must be complete by 2/3 of furnace and then refining 1/3

furnace.

• The air bubble present in the melt comes on the surface and start bursting due to

the temperature and glass pressure

11Individual Section Machine

• Melt from feeder is pushed by the plunger assembly which cut the melt into molten mass.

• Molten mass of glass called gob is transfer to the IS machine.

• IS machine forming process based on the Blow and Blow Process

• The machine consist of 19 mechanism to form a bottle by compressed air ( HP

=3.2 bar and LP =2.8 bar)

• IS machine part: Scoop, Trump, Deflector, Mold, Neck Ring, Take Out Arm.

12Blow and Blow Process

• Blow and Blow process take place in IS machine where a gob released during

plastic stage and move along to mould.• The gob is forced into the blank mould using compressed air to push the gob into

place.

• The gob, now a parsion is then flipped into a corresponding final mould where it is blow again to form interior container.

13Annealing

• Annealing is process of controlled cooling of glass ware after shaping.

• In this process the hot glassware is transfer to annealing lehr where it is subjected to prescribed cooling rate in different zone of the lehr. Combination of above

cooling rate is called ‘Annealing schedule’.

• Factor governing the cooling rate in different zone are:1. Thickness of glass

2. Coefficient of linear expansion of glass

3. Tensile strength of glass.

• Most important factor to be kept in mind

1. Annealing schedule must be set according to the maximum thickness of any portion of any ware to be annealed together.

2. Annealing temperature is an intrinsic property of glass and it has not at all related

to thickness of glass.3. Even momentary slighter faster cooling rate in any zone result in self breaking of

ware, may be after very long time.

ZONE 1 – 550 degree centigradeZONE 2 – 400-450 degree centigrade

ZONE 3 – 300 TO RT

4. Cooling rate is inversely proportional to square of thickness of ware.

14Viscosity of Glass melt

•Viscosity of Glass melt should be uniform otherwise inhomogeneous melt result in chord and stone.

•Viscosity varies with change in temperature:

1. Strain point ( 10^14.6 p)– Temp(490Ċ). at which the internal stress is reduce and the glass become

rigid.

2. Annealing Point (10^13 p) – Temp (500-550Ċ) Above this point there is no stress.

3. Softening Point( 10^7.6 p) – Temp. (710-720Ċ) Glass will deform under its own weight.

4. Working point (10^4 p ) – Temp. (1250-1300Ċ)

Viscosity of glass at different part in glass melting

1. Melting – 10^2 poise

2. Feeder - 10^4 poise

3. Mold - 10^4.5 Poise

4. Remove from Mold – 10^7 Poise

5. Annealing - 10^13 Poise

Devices And Equipment Used In

Glass Industry

1. High temperature equipment

2. Pyrometer

3. Thermocouple

• Heat Saving Device

1. Regenerator ( matrix type)-

2. Recuperator

• Equipment

1. Cullet crusher

2. Magnetic separator

3. Vibrating sieve

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Testing

1 Impact Testing ( 90° suspend bob)

It is used to determine the impact resistance, strength and breakage resistance characteristic in order to ensure that they are fit.

2 Thermal shock resistance

Glass article that may be subjected to significant difference in temperature during their normal used should be tested for TSR to ensure the product is fit.

3 Physical inspection

4 Stress Testing by Polaroid glass

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Production Chart 17

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ANY QUESTIONS?

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Thank You