SAINT GOBAIN GLASS PVT LTD,

CHENNAI,
SRIPERUMBUDUR.

IM-PLANT TRAINING REPORT

Prepared by
PRASAD
(2015-2016)

Government Institute of Ceramic Technology

Gudur-524101,S.P.S.R NELLORE(dt)
Andhra Pradesh

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 ACKNOWLEDGEMENT

We would like to express our sincere gratitude to Mr. K.

SUBBARAO (HOD of Govt. institute of Ceramic Technology)
for giving opportunity to do this im-plant training.

I am really grateful to the Almighty above who paved my

way to Saint-Gobain&gave me strength throughout my training
days to complete the project within the stipulated time.
I whole heartedly thank or rather I would say I lack words
to thank Mr. PUGALANTHI (Team leader, HR) for granting
me permission to pursue a project in a distinguished
organization as this in spite of the constraint of lack of seats.
I extend my gratitude towards Mr.SK.JELANI Sir , and
ALL TEAM MEMBERS who took out time from their daily
busy schedule and gave their effective guidance and continuous
encouragement throughout our project work with safety.

I also thank the staff members of Saint Gobain India Ltd.,

who helped us to carry out this project work successfully.

FLOW SHEET FOR FLOAT PROCESS

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 (SODA LIME SILICA GLASS)
RAW MATERIALS

STORAGE (SILOS)

WEIGHING

( DRY MIXING ) MIXING (WET MIXING )

CHARGING

MELTING

REFINING

HEAT CONDITIONING(WORKING END)

HOMOGENISING(AG3)

FABRICATION (FLOAT BATH)

ANNELING LEHAR

CUTTING

SOARTING
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 PACKING

DISPATCH

RAW MATERIALS

Following are the main Basic raw materials used for Float
Glass Manufacturing in Saint Gobain Glass India Limited(soda
lime silica glass):

Basic Raw Materials:-

1. Silica Sand
2. Soda Ash
3. Dolomite
4. Calcite
5. Sodium Sulphate
6. Cullet
7. Coal or Coke

Sources and suppliers of Raw Materials:

Raw Material Source Supplier

SBP (Sand Beneficiation
Silica Sand Gudur
Plant)
Soda Ash Bulgaria, Italy Solvay
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 (Imported)
Totucorin, Gujarat
TAC,TATA
(Domestic)
DPP (Dolomite
Dolomite Bhagalkot
processing plant)
Calcite Thirunellveli Yuvasri minerals
Sodium
Harihar Grasim industries
sulphate
Coal or Coke Chennai Coramandal
Domestic SGGI
Cullet Omega, Shah agencies
External
and others

Glass Formation Oxides:

To make float glass we are using following raw materials such
as silica sand,soda ash,dolomite,calcite,sodiumsulphate.The
oxides form a network which shapes the glass structure. They
influence the network in a different way and can
correspondingly be divided into different groups namely:
 Network Formers
 Network modifiers
 Intermediate oxides.

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 1. Network formers:-
SOME NETWORK FORMERS; (Sio2,B2o3,P2o5,As2o3,Ge03.)

The basic ingredient of most industrial glasses is sand,

consisting of 95-99 % Silica (SiO2), this is a network former.
Silica makes up 75% of the earth's crust. This relatively
inexpensive element still has to meet precise specifications in
terms both of Granulometric, Chemistry and Mineralogy. A
characteristic of Silica is that it is difficult to melt and the
melting temperature of the sand is 1723 to1728oC.
The most important network-forming oxide is SiO2. Sio2 added
to the glass via the raw material sand. Glass types based on SiO 2
are called silicate glass. These form the largest share of glass
types used in terms of volume. Glass from a pure SiO 2 is called
silica glass which exhibits the following;
1) It is very difficult to melt owing to the high melting
temperature of quartz (1600 oC) and exhibits a high viscosity.
2)It has a very low thermal expansion and hence a very good
thermal shock resistance.
3)It is a poor conductor of electricity.
4)It exhibits a high mechanical strength.

CHEMICAL COMPOSITION OF SILICA SAND :

Element % Contains
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SiO2 98.5 %
K2O 0.6%
Al2O3 1.0 %
Fe2O3 0.07 %
TiO2 0.02 %
Moisture 5%

Addition of other oxides (network modifiers or intermediate

oxides) enables easier melting of the glass, but results in other
property changes which are sometimes cancelled sometimes
strengthened.

2. Network Modifiers:-

Network modifiers cannot assume a glass state alone,

but they influence the structure of the glass as they split
the SiO2 network.
 Instead of one bridging oxygen two non-bridging oxygen
molecules occur, which causes the weakening in the
network.
 The most important network modifier is sodium oxide. It
is added to glass via the soda.
 Pure silica glass does not contain any network modifiers.
It is melted from highly pure quartz in special furnaces at
temperatures of approximate 2200oC in vacuum. Even at
these temperatures, it is much more viscous than float
glass at only 1600 oC.

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  Other network modifiers are:-
CaO: added to batch via lime and dolomite.
MgO: added via dolomite.
K2O: impurity in natural raw material

3. Intermediate Oxides:-

 There are oxides which can occur both as network forming

agents and modifiers depending on the remaining glass
compositions. However they cannot form a network alone.
Aluminum oxide belongs to this group of intermediate
oxides.
 The addition of aluminum is important for glass production,
as it has a stabilizing effect on the glass structure:
1.The chemical resistance to acid, alkali and water attack
increases.
2.Aluminum reduces the tendency to crystallize and prevent
devitirification.
 It can reduce corrosion of the furnace.
 It improves all strength values in the finished product.
 In addition to Al2O3, the iron oxide is a further important
intermediate oxide. It acts similar to Al2O3, but
additionally lends the glass its characteristic green tinge.

Function and Properties of Raw Materials

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Silica Sand (SiO2):

The basic ingredient of most industrial glasses is sand,

consisting of 95-99 % Silica (SiO2), this is a network former.
Silica makes up 75% of the earth's crust. Sand also has a high
content of organic material and moisture. The iron and
aluminium content within the sand is also significant as it
effects in final batch chemistry calculation. A characteristic of
Silica is that it is difficult to melt and the melting temperature of
the sand is 1728oC. It has high viscosity at high temperatures.
“The Gudur sand containing high amount of Al2O3 and so
called Feldspathic sand.”

Following is the Granulometric and Chemical analysis

of Silica Sand
Granulometry Analysis
Mesh
% Cumulative
size in Specification
Retained %
Microns
+850 0 0 < 0.01 %
+600 0.6 0.6 < 0.75 %
+425 15.4 16
+300 38.4 54.4
+250 15.7 70.1
+150 24.2 94.3
+106 3.2 97.5
-106 2.5 100 <4%
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Soda Ash (Na2CO3):

Soda ash is Source of Na2O.Soda ash used in the glass

manufacturing to reduce the melting temperature of silica sand
as a flux. Soda ash acts as a strong flux and is one of the
network modifiers. The main property of soda ash is its
hydrophilic nature at room temperature.
The increase of Sodium oxide in the glass increases the
viscosity range, the co-efficient of expansion and reduces the
tensile strength, annealing temperature and the durability. The
maximum limit of Soda ash in Glass is 18 % and above this the
glass is liable to be detoriated by weathering and is liable to
become dull and dirty in appearance after some time.
Na2CO3 8500C Na2O +CO2
100 Kg 59 Kg+41 Kg

There are two types of Soda ash

1. Heavy or Dense Soda ash
2. Light Soda ash
“The Light Soda ash is disadvantageous in glass melting as it
is easily carried by draughts into the flues of the furnace.”
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CHEMICAL COMPOSITION OF SODA ASH
Element % Contains
Na2CO3  99
Na2O  58
NaHCO3  0.30
NaCl  0.20
Fe2O3  0.004
Na2SO4  0.035
Moisture  0.50.

The Melting temperature of Soda Ash is 851oC.

At SGGI Soda Ash is being received from four suppliers.
1. Solvay Soda Ash ( Imported from Bulgaria and Italy)
2. TSS Soda Ah (Imported from China)
3. TAC Soda Ash (Domestic from Totucorin)
4. TATA Soda Ash (Domestic from Gujarat)

DOLOMITE
Dolomite is a mixed mineral of calcium and magnesium
oxide. Magnesium oxide in small quantities in glass gives a
rapid melting rate and improves the working properties of lime
glass and prevents the tendency to devitrification and lowers the
annealing temperature.
Dolomite lumps are received from Bagalkote, Karnataka
and Pulivendala, Andrapradesh. And these lumps are processed
in DPP (Dolomite processing plant located near by SGGI).

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CHEMICAL COMPOSITION:-
Cao  31%
Mgo  21%
Co2  48%

CHEMICAL COMPOSITION OF DOLOMITE:

Element % Contains
SiO2  2.00%
Al2O3  0.50%
Fe2O3  0.30%
CaO  30.00%
MgO  19.50%
H2O  0.5%
The decomposition reaction can be written as follows……
MgCO3CaCO3 7570C MgO +Ca +CO2
100 Kg 21 Kg + 31 Kg + 48 Kg

Granulometry Analysis

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Mesh
% Cumulative
size in Specification
Retained %
Microns Calcite
+2360 0 0 0%
+2000 0.8 0.8 1% (CaCO3):
+1180 48.8 49.7
+1000 9.5 59.1
+850 5.4 64.5 Calcite is a
+600 8.3 72.8 source of
+425 5.6 78.4
CaO. Calcium
+106 8.6 87.0
-106 13 100 15% oxide imparts
a very great chemical stability to the glass. High calcium oxide
in glass tends to devitrify, and form Wollastonite. Increase of
calcium oxide increases the heat conductivity, annealing
temperature, mechanical strength, thermal endurance and the
durability of a glass and it lowers the coefficient of expansion.
Calcite is received from following suppliers.
1. Yuvasri minerals – Thirunellveli.
2. Indiana minerals – Tiruchengode

CHEMICAL COMPOSITION OF CACITE:

Element % Contains
SiO2  2.15%
Al2O3  0.25%
Fe2O3  0.125%
CaO  53.5%
MgO 1.5%
H2O  0.5%
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The decomposition reaction can be written as follows……
CaCO3 898 CaO+CO2
100 Kg 56 Kg+ 44 Kg

Following is the Granulometric and Chemical analysis

of Calcite

Granulometric Analysis

Mesh
% Cumulative
size in Specification
Retained %
Microns
+2360 0 0 0%
+2000 0 0 1%
+1180 17.1 17.1
+1000 8.5 25.6
+850 6.8 32.4
+600 13.9 46.3
+425 12.9 59.2
+106 29.4 88.6
-106 11.4 100 15%

Sodium sulphate (Na2SO4):

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 Sodium sulphate also called as Salt cake. The reaction
between salt cake and silica sand occurs at about 1500 oC. It is
found that reaction between sodium sulphate Na2SO3 and
silica takes place much readily. Hence some reducing agent
such as Coal is added to the batch containing salt cake to
reduce it to Sulphite.

Na2SO4+C Na2SO3+CO

Practically about 2.5% of Coke to the salt cake is usually

added to the batch. Salt cake readily absorbs the moisture and
forms hydrated Glaber’s Salt, Na2SO4 10H2O, which on
exposure to atmosphere forms hard lumps difficult to grind. It
should be stored in a dry place.
Salt cake acts as a fining agent as sulphur dioxide is liberated
at a later stage in the fusion.
CHEMICAL ANALYSIS OF SODIUM SULPHATE
Element % Contains
Na2SO4  99%
Na2O  43%
SO3  56%
Nacl  0.5%

Petroleum Coke:

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 Reducing agents promote the incorporation of some batch
forming oxide in a glass. Carbon as coal is employed with Salt
cake to reduce it to sulphate, so that the reaction with silicate
may take place at a lower temperature.

RAW MATERIAL FOR VARIOUS COLOURS

Clear Green Blue/ Bronze Dark Dark

Dark grey green
blue
Sand Sand Sand Sand Sand Sand
Soda ash Soda ash Soda ash Soda ash Soda ash Soda ash
Dolomite Dolomite Dolomite Dolomite Dolomite Dolomite
Lime Lime Lime Lime Lime Lime
stone stone stone stone stone stone
Salt cake Salt cake Salt cake Salt cake Salt cake Salt cake
Iron Iron Iron Iron Iron
Oxide Oxide Oxide Oxide chromite
Cobalt Cobalt Cobalt Cobalt
oxide oxide oxide oxide
Sodium Nickel
Nitrate Oxide
Selenium

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Cullet:

Cullet is broken glassware or waste glass and is used as an

auxiliary batch ingredient in glass manufacturing. The addition
of cullet in a batch facilitates the melting and fining of the glass.
The usual amount of cullet added is 18 to 25% of the batch.

There are two types of Cullet being used:

1Domestic cullet
2.External cullet.
Domestic cullet having different type:
1. Normal cullet
2. Reflectasol cullet
3. Mirror cullet
4. Coater cullet
External cullet is being received from the dealers and suppliers.

Advantages of using Cullet:

 Energy saving. Thumb rule: 4% cullet saves 1% energy
 Cost reduction & recycling of waste.
 Increases homogeneity of the glass
 High % of cullet enables the production of higher yields
with older furnaces, as it is possible to produce with a
lower consumption of energy

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  Raw material melting time decreases considerably
 No ignition loss, results reduction in work load

RAW MATERIALS HANDLING;

SILICA SAND:

The silica sand is being received in loose condition with

dedicated trucks from Sand beneficiation plant in tada. Each
truck carries about 20 Mt .maximum&minium is 15Mt.
Hydraulic truck unloader (HTU) is used to lift the sand truck
vertically to unload the sand. The HTU is being lifted to about
40o vertically. It has one stopper called Retractor, used to stop
and hold the whole vehicle in vertical position. It supports the
rear wheel of the truck. And front wheels joint is locked by
Hook chain at the front to improve the safety of vehicle.
After unloading the sand into the hopper the material goes to the
bucket elevator through vibrating feeder, and bucket elevator
carries the material vertically to the silo top conveyors and then
goes to silo’s. One Permanent magnet and one metal detector is
arranged on the silo top conveyor to remove the metal particles.
Permanent magnet is used to remove the free iron like bolts,
nets, rods and other parts. Metal detector is used to remove the
non –ferrous material
surrounding to the metals it self containing the iron, tin,
aluminum, copper and other metals. These rejected sand falls

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down to the ground floor through the rejection chute. This
rejected sand goes back to the supplier for reprocessing.

DOLOMITE:
Dolomite is received from DPP (Dolomite processing plant) in
Bulk tanker. The dolomite material will be conveyed to silo’s
through pneumatic conveying. The dolomite bunker is having 3
compartments, in each compartment about 8 Mt materials is
filled. There will be one inlet
and one out let to each compartment. Inlet is used to give air to
pressurize the material. Once the pressure goes to 2- 4 bar inside
the compartment the out let has to be opened. One pressure
indicator is arranged to show the inside pressure of Bunker.
Once the material is conveyed to silo the pressure goes down to
zero, then operator will change the inlet and out let to other
compartments. The capacity of loading of Dolomite is 20
Mt/hour

SODA ASH:
Soda Ash is received in 1 Mt and 1.25 Mt jumbo bags. The
material carried truck comes under the Hoist and the bag is
lifted to loading hopper. Chain type hoist is used with a capacity
of 2 Mt. First the bag is lifted vertically and then moved to the
horizontally. The opening of the Bag is being done at the
bottom by the operator and the material flows to the loading

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hopper. From the hopper the material goes to the vessel.
Pneumatic conveying method is used to convey the Soda ash to
the silos. The vessel is being pressurized to Maximum 4 bar to
convey the material. When the material is being conveyed to
silo the opening from the hopper to the Vessel is being closed
automatically by the Butterfly valve to avoid material flow in
reverse order. The capacity of loading of Soda ash is 18
Mt/Hour.
Soda Ash by Solvay Process::
Soda ash is synthetically by so called solvay process This
process was discovered by “Sir Ernest solvay” in the year of
1860.In this processSodium Carbonate is obtained from cooking
salt and lime with the addition of ammonia and carbondioxide.
CALCITE:
Calcite is received in 1 Mt jumbo bags. The material carried
truck comes under the Hoist and the bag is lifted to loading
hopper. Chain type hoist is used with a capacity of 2 Mt. First
the bag is lifted vertically and then moved to the horizontally.
The opening of the bag is being done at the bottom by the
operator and the material flows to the loading hopper.
From the hopper the material goes to the vessel. Pneumatic
conveying method is used to convey the Soda ash to the silos.
The vessel is being pressurized to Maximum 1.5 bar to convey
the material. When the material is being conveyed to silo the
opening from the hopper to the Vessel is being closed

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automatically by the Butterfly valve to avoid material flow in
reverse order. The capacity of loading of Calcite is 15 Mt/Hour.

SODIUM SULPHATE:
Sodium sulphate is received in 50kg bags and then repacked in
Jumbo bags manually at SGGI for easy loading to the hopper.

COAL OR COKE:
Coal is received in 50 kg bags and is being loaded by manually
(since it is low quantity) to the loading hopper.

CULLET:
Cullet is being loaded from the cullet yard by Front end loader.
The front end loader carries the cullet and loaded to the loading
hopper. If the cullet is already crushed then it can be loaded
through hopper only.
When the Cullet is in sheet from i. e. Before
crushing, it is being loaded through crusher. The crushed
material goes to the conveyor with help of vibrator. One
permanent magnet is arranged after the hoppers
To remove the iron particles like nails, rods, bolts
and nuts and other particles. At the end of the conveyor metal
detector is being placed to remove the other metals like tin and
iron. The metal detector will reject the metal along with the

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surrounding material i.e. cullet. From this conveyor the material
goes to other two conveyors then to silos.

Quality and Inspection in Raw material

Any material will tested in two places

1. Incoming analysis
2. Silo bottom analysis

SILICA SAND:
The material is being
received based on the test certificate given by the supplier. The
incoming analysis will be done for the silica sand twice a
Week for Granulometry as well as Chemical analysis. This data
is being entered in Soft ware called as “ANTARES”.
SODA ASH:
For Soda ash, the incoming analysis is being done for chemical
and Granulometry analysis and silo bottom is being done once
in week for Granulometry analysis and once in month for
chemical analysis. It is synthetic material so that the Chemical
analysis does not change frequently.

DOLOMITE:

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For Dolomite, the incoming analysis is being done for both
chemical and Granulometric analysis. Silo bottom analysis is
being done on daily basis for chemical analysis and once in a
week for Granulometric analysis.

CALCITE:
For Calcite, the incoming analysis is being done for every truck
before unloading to the hopper. Upon conforming to the
specification for both chemical and Granulometric analysis the
material is being unloaded to the
Silo. Silo bottom analysis is being done on daily basis for
chemical analysis and once in a week for Granulometric
analysis.
SODIUM SULPHATE:
For Sodium sulphate, the in coming analysis is being done for
both chemical and Granulometric analysis. Silo bottom
analysis is being done once in a week for Granulometric
analysis and once in a month for chemical analysis. Sodium
sulphate also called as Salt cake. Salt cake is a synthetic raw
material & most important fining agent for glass
manufacturing (as a fining agent as sulphur dioxide is liberated
at a later stage in the fusion.). Melting temp of Sodium
sulphate is 885OC. Sodium sulphate is hydrophilic like soda
ash below 32.4OC. As a result the batch temperature must

Page - 23
 always be kept above this temperature in order to prevent dust
formation.
The reaction between salt cake and silica sand occurs at about
1500oC. It is found that reaction between sodium sulphate
Na2SO3 and silica takes place much readily. Hence some
reducing agent such as Coal is added to the batch containing
salt cake to reduce it to Sulphate.

Na2SO4 13000c Na2O + CO2

Na2SO4 + C Na2SO3+ CO
Practically about 2.5% of Coke to the salt cake is usually
added to the batch. Salt cake readily absorbs the moisture and
forms hydrated Gabber’s Salt, Na2SO4 10H2O, which on
exposure to atmosphere forms hard lumps difficult to grind. It
should be stored in a dry place.

PETROLEUM COKE:
For coal, the incoming analysis is being done for every 5 Mt and
there is no silo bottom analysis for coal.

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CULLET:
Cullet is being checked visually in the cullet yard. Incase of
external cullet the chemical analysis is being done. Domestic
cullet having different type
5. Normal cullet
6. Reflectasol cullet
7. Mirror cullet
8. Coater cullet
External cullet is being received from the dealers and suppliers.
Advantages of using Cullet:
1) Energy saving. Thumb rule: 4% cullet saves 1% energy
2) Cost reduction & recycling of waste.
3) Increases homogeneity of the glass
4) High % of cullet enables the production of higher yields
with older furnaces, as it is possible to produce with a lower
consumption of energy
5) Raw material melting time decreases considerably
6) No ignition loss, results reduction in work load

BATCH PLANT

Page - 25
 In the batch plant the various raw materials are used for
making glass they are received, and in stored in separate silos. It
is the place where raw materials are required to make clear or
color glass are weighed, mixed and conveyed to furnace

FLOW SHEET OF BATCH PROCESS

Silos

Vibro feeder (Screw feeder) Bin acurator

Weigh Bin

Vibro feeder (Screw feeder)

CB1M Conveyor

Dry Mixing

Wet Mixing WATER

CB2M Conveyor

CB3M Conveyor

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 Cullet Adding

Magnetic Separator

Permanent Magnetic Separator

Metal Detector

CB4M Conveyor

RRCB5M Conveyor

Batch charger Giraffe loading

Furnace

Batch plant – equipment over view

 Silos
 Conveyors
 Weighing bins
 Vibrators
 Screw feeder
 Mixer
 Dust collector

Page - 27
  Sway switch
 Idler rollers
 Local control station
 Magnetic separator
 Metal detectors
 Divertor gate
 Hoppers

Silos:
It is used to store various types of raw materials.
The silos are made of mild steel.

Tolerence
SILO MATERIAL CAPASITY (kg)
1 Sand 650T 3.0
2 Sand 650T 3.0
3 Soda ash 550T 1.5
4 Soda ash 550T 1.5
5 Dolomite 800T 1.5
6 Dolomite 800T 1.5
7 Spare 800T

8 Lime stone 800T 0.6

9 Soda +NiO 50T 0.20
10 Salt cake 50T 0.08
11 Iron oxide 130T 0.002
12 Cullet 280T 5.0
13 Cullet 280T 5.0
Page - 28
 14 Cullet 280T 5.0
15 Cullet 280T 5.0
HB15 Cobalt oxide 100KG 0.004
CB16 Cobalt oxide 100KG 0.004
HB17 Selenium 100KG 0.004
SB19 Colorants 100KG 0.004
SB20 Sodium nitrate 100KG 0.05
SB21 coal 100KG 0.003
SB22 Bad batch 100KG 0.033

Conveyors:
Conveyors are used to transport the materials from one
place to another place.
This company was following in conveyors to be:

 E- SERIES ( Cullet from cutting line)

 C-SERIES ( Cullet from yard)
 S-SERIES (Sand series)
 M-SERIES ( Batch mixing)

E –series belt conveyor:

CB1E - Collects Cullet from Cutting line and send to CB2E

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C - Series belt conveyor:

CB1C - Receives Cullet from CB2E and send to hoppers

Here Direction Changes and Elevation rises.
 Three Hoppers (H1C, H2C, and H3C) were
provided to feed cullet from YARD using FEL.
 Out of three hoppers only H3C is having
Crusher (CRH3C) to reduce Cullet size.
 Magnetic Separator ( MSCB1C) is provided to
take out Iron Particles ( like Nails / Steel
Straps)
 Metal Detector (MD1CB1C) is provided to
detect other metal Particles.

 When MD1CB1C Senses metal automatically

PD1CB1C diverts that portion of cullet to
PD2CB1C.
 PD2CB1C diverts either to EH1C hopper or
Outside rejection

CB2C - Receives Cullet from CB1C and sends to RRCB3C

 Elevation rises to Cullet Silo Top.
RRCB3C - Receives Cullet from CB2C and sends to any one
Cullet Silos S-12, S-13, S-14, and S-14 at a time.

Page - 30
  Filters are provided on the top of silos to
collect cullet dust.

M - Series belt conveyor:-

CB1M - Premixing Conveyor

 Receives weighed quantity of raw materials
from Bins and sends to Mixer.
CB2M - Receives Mixed Batch from Mixer and sends to
CB3M
 Here Direction Changes
CB3M - Receives Mixed Batch from CB2M and Weighed
quantity of Cullet from Bins and Sends to either CB4M or
PD1CB3M.
 Here Direction Changes and Elevation rises.
 Magnetic Separator (MSCB3M) is provided to
take out Iron Particles.
CB4M –
It receives the batch from CB3M and send to
CB5M
RCB5M- Shuttle conveyer-
This conveyer moves forward & backward to fill the Batch
charger compartments. After this conveyor batch material
reaches to batch charger hopper.
.

Page - 31
S - Series belt conveyor:

BE1S – It’s a Bucket conveyor to transport sand from sand

unloading hopper to CB2S at he silo top.
CB2S – Bucket conveyor delivers the sand in this conveyor
here it get pass thorough a Metal detector then it pass to
RRCB3S or to the rejected bin.
CB3S – Checked good sand goes to RCB4S.
CB4S -- It sends the good sand to the silo.
CB5S – From sand unloading hopper the sand pass thorough a
Metal separator to BE6S.
BE6S -- It’s a Bucket conveyor to transport sand from CB5S to
CB7S.
CB7S – In CB7S the sand pass thorough a metal detector
then it pass to CB8S or to the rejected bin.
RCB8S – It sends the good sand to the silo
F - Series Drag Chain & belt conveyor:

The F-series conveyors are used during the 2mm thickness

glass production. This is to maintain the glass pull rate and the
glass level in the furnace.
CB1F conveyor receives the hot feeder cullet. It is the drag
chain conveyor and the hot feeder cullet is quenched directly by
using water in

Page - 32
the drag chain conveyor box. It receives the material from both
sides of the furnace.
CB2F – receives the feeder cullet from drag chain conveyor. It
is the belt conveyor.
CB3F – receives the cullet from the CB2F and dumps in the
feeder cullet dump yard. Here the direction changes

Weighing bin:

The weighing bins are used to weighing the various raw

materials. 3 load cells are present in each weighing bin. The
weighing precisions ensure the correct proportion of each
material added to each batch.

Vibrators:

They are two types of vibrators:

 Mechanical vibrator
 Electro magnetic vibrator
These vibrators are used to dispensing the granular type of raw
material.

Vibro feeder& screw feeder:

Page - 33
 The vibro feeder is used to conveying the sand & cullet.
Because they are highly corrosive material. And other raw
materials are conveying by screw feeder. Because they are fine
and powdery material.
Mixer:
The main role of mixer is used to mix the raw
materials except cullet by adding water. The capacity of mixer
is 5tons.Threr is two mixers are there. Every 15 days change the
mixer. One mixer is in line another one is stand by.The aim to
achieve a homogeneous mixture with optimum moisture
(4–4.5%)and temperature ( 40-45degrees) celsius values.The
raw materials are physically rotated and mixed in the
mixers.The mixer arms with the spatulas rotate and the vertical
axis.The spatulas are moved from each other in order to achieve
optimum mixing during the mixer movement.The mixing
process is a compromise between the required homogeneity of
the batch and as short as cycle time as possible.The mixing is
helps to humidifies and heat the batch material. Mixer ensures
batch homogeneity. In mixer arms are using for mixing the
batch.
The tank is standard, only the internal paddles are rotates in the
opposite direction.The mixing process is divided into two
phases.Dry mixing and Wet mixing.Dry mixing: first mixing
and mainly mix the raw materials properly for maintaining the
equal moisture % in total batch and to avoid lumps because

Page - 34
soda ash below 40 degrees will form into lumps wich is
uncrushable.in order to not form lumps we should maintain
temperature inside the mixer.Wet Mixing: for homogenization
of the batch.
The purpose of adding water:
 To avoid segregation.
 To have homogenous mixture.
 To avoid carryover losses.
 To avoid dust..

Dust collectors:-
To minimize lose of material during transport and prevent a dust
local atmosphere there is a dust collector positioned in each
conveyor belt. Each unit consists of a fan that extract dust from
the running belts into a number of vertical filters. This is the
dust collector function.
Metal Detectors:
The metal detectors detects the foreign particles (metals) present
in the batch and reject that particular portion of the batch from
reaching the batch charger .The metal detector has the capacity
to sense the foreign particles of millions level and the sensitivity
can be changed based on our requirement.The rejection portion
of the batch is of collected through rejection chute.These bags
should be emptied ince get filled.

Page - 35
Hoppers:
It is used to temporary storage of materials.
Bin Accurator:
When loading raw materials into storage a segregation of the
batch various sizes occur in the batch : 1) The coarse partickles
gets collected in the core. 2) the fine particles gets collected on
the sides. The natural flow is not consistent.The coarse particles
flow directly through and the fine particles flow in irregular
waves.The Bin Accurator interrups the core flow and forces the
raw material to flow over the sides.The coarse and fine particles
are therefore mixed and a constant raw material is discharged.
Magnetic separator:
Magnets are provided over Raw Material and Batch
Conveyors to eliminate Iron Contamination. Permanent and Belt
type magnets are used for this purpose. Also there are metal
detectors which will detect and operate the Diverter gate to
throw away the batch
Rollers:
Rollers play very important role in the conveyors and depending
on the length of the conveyor. Various idlers in belt conveyors
are: Carrying idlers, impact idlers, self aligning carrying idlers,
return idlers, sled aligning return idlers, guide idlers.
Pulleys:
Various pulleys provided in the belt conveyors are Tail pulley,
drive pulley, take up pulley, bend pulley.
Page - 36
Safety switches:
Three types of safety switches provided in belt conveyor is Pull
Chord switch, Belt sway switch and Zero speed switch.
Feed back about Qty of raw material to
Load cell
DCS
Material sensor Detect flow material in the conveyor
Level Switch Indicate the level of the RM in silo
Its sense the belt sway then inform the
Belt Sway switch
DCS
Emergency Stop Push button to stop the entire system
Zero Speed
Its sense the belt in running condition
Sensor
Moisture
Detect the moisture in RM & batch
Analyzer
Variable Speed
Balance the speed with other variable
Motors
Metal Detectors Detect the ferrous component in RM
Limit Switch Act upon the set point
DCS Distributed control system
Elect& inst equipment in batch plant:
.

COLOUR ADJUSTEMENTs::
Here different differents glasses are produced.Mainly, Green
glass,Blue glass,bronze colour,Dark grey glass.

Green Glass:
Specification:

Page - 37
Reference thickness: 3.85mm
Illuminant: D65
Light transmission :: 80 +/- 2 %
Energy Transmission : 60 +/- 2%
Fe2O3 , CoO, Redox-0.22-0.23

BLUE GLASS:
Specification:
Reference thickness :6mm
Illuminant: D65
Light transmission : 56 +/- 2 %
Energy Transmission : 45 +/- 2 %
Fe2O3, CoO, Redox;0.21-0.23

BRONZE COLOUR:
Specification:
Reference thickness : 6mm
Illuminant: D65
Light transmission : 48..9 +/- 2 %
Energy Transmission < 50
Fe2O3, CoO, Se, Redox; 0.17

DARK GREY GLASS:

Page - 38
Specification:
Refernce thickness: 6mm
Illuminant:: D65
Light Transmission : 13.5 +/- 1%
Energy transmission te :: 27 +/- 1%
Fe2O3, CoO, NiO Redox; 0.30

Giraffe Conveyor:
The Giraffe conveyor feeds the batch charger during emergency
condition. The conveyor has the movable platform, rail, hopper
and the belt conveyor. The hopper is filled with the extra batch
material prepared. It is filled in the batch charger by placing
over the required compartment and by moving the belt conveyor

Batch charger:
The batch material from the RRCB5M is feed in to
Batch Charger Hooper which feeds the batch material to the
Furnace using two reversible spades. Batch charger consists of
6 compartments having the total holding capacity of 39m 3. The
Batch charger compartments are equipped with High and Low
level probes. The Spade is moved by the help of two VSD
motors, one in line and other in standby operation. Once in 15
days changed to mortar1 to mortar2. Angle of the Spade is 7*.
Page - 39
 The amount of batch material feed to the Furnace is controlled
by the Gate present in front of the Batch charger and also by the
speed of the Batch charger drive. Pile separator also helps the
batch material to be fed in different piles in to the furnace.
Batch charger spade is cooled by means of the cooling air
blowers. Batch material is discharged during the reverse stoke
by the action of wipers. The clearance between the batch
charger spade and the soldier blocks of furnace is constantly
maintained at 80mm. The spade speed varies with the glass
level. If the glass level is low the batch charger spade’s speed
increases.The Hoppers are equipped with a thermocouple which
lets us check the temperature of the batch.The batch must be
delivered the furnace above 37 degree Celsius.

FURNACE

REGENERATOR
4 5
1 2 3 6

HOT SPOT
FEEDER

WORKING END
CANAL
NECK
MELTER

Page - 40
 FEEDER

5 7
1 2 3 4
REGENERATOR 6

FURNACE SPECIFICATIONS;

Name - F350FF
Type - Cross fired regenerative
type Furnace fuel - Heavy Furnace Oil
No. of ports - 7
Reversal cycle - 20 minutes
Depth of glass in Melter - 1424 mm
Total holding capacity - 1710 MT

FLOAT-2 FURNACE SPECIFICATIONS

Name - F 470fl
Type - Cross fired regenerative
type Furnace fuel - Heavy Furnace Oil
No. of ports - 7
Reversal cycle - 20 minutes
Depth of glass in Melter - 1450 mm
Total holding capacity - 2100 MT

Page - 41
GENERAL DESCRIPTION;
Furnace is a closed chamber made up of different types of
refractory.Here the furnace has 7 ports and firing will be done in
cross section So, This furnace is called 7PORTS
REGENERATIVE TYPE OIL FURNACE.Having capacity 650
tons.The fuel used in the furnace is HFO ( Heavy Fuel or
Furnace Oil). Heat is produced inside by the combustion of
fuels which is utilized to melt the batch. In a glass melting
furnace different sections and their functions are as given below

SECTION FUNCTION
MELTER Batch gets melted and volatile gases escapes.
Narrow section with a physical partition
NECK
through which glass enters next scteion.
Glass temperature brought down.
WORKING
Homogenization of glass takes place by
END
convectional currents.
CANAL Glass temperature lowered in a controlled
(SG and PB manner before formation to avoid thermal
canals) distortion
PROJECT REPORT

Page - 42
FURNACE COMPONENTS
The furnace is divided into five regions. They are
 Dog House
 Melter
 Neck
 Working End
 Canal

1. DOG HOUSE:-
The dog house is a part of the furnace infrastructure that allows
the recipe of the batch coming from the batch charger.The dog
house is part of the main furnace tank,located at the head of the
furnace.The filling pocket is in the open section of the dog
house that has no super structure.This dog house is covered with
the batch and is in area free from direct flame,consequently,it
represents a cold section of the fusion tank.Because the dog
house is a cold section , convenction currents are created in this
part,carrying the batch logs into the furnace.The batch logs from
a protective barrier against the radiant heat of the furnace.It
receives the raw materials from the batch charger. Entrance of
the Furnace is Dog house. In Dog house two coolers are
arranged for the purpose of to avoid the fines flying and to
avoid the over heating of Spade.
Page - 43
Reactions in Dog House:-
As the temperature of the material constituting the glass
batch increases, moisture contained in the batch evaporates.
Heating the batch from room temperature to around 600 O C
can be treated as the first stage in melting process.
Na2CO3.H2O à Na2CO3 + H2O @ 105OC
Further heating causes decomposition:
CaCO3.MgCO3 à CaO + MgO + 2CO2 @ 740OC
CaCO3 à CaO + CO2 @ 880OC

BACK WALL:-
It protects the batch charger from the radiation of the
furnace and prevents the passage of the flames. Back wall is
made up of silica refractories which are suspended from the
steel structure. Metallic shield enclosure is provided over the
back wall and cooling air is circulated at seven inlet ducts to
prevent the heat loss and also to prevent the damage of the back
wall. Back wall is situated in 22 deg.angle.This 22 degrees
angle creates a radiant zone allowing the radiation of the
furnace to help melt the batch and thus limit the raw material
carry oveer.There is a thermocouple in the centre and one on
either sside.Also,there is a baack up cooling fan in case of the

Page - 44
praimary ventilation.To ensure the seating of the charging
area,the back wall has:
Curtains (2rows):
Front curtain is made of VRC Silica (non baked)),the rear
curtain is madde of VMA Silica.Both are suspended,the height
is regulated dduring construction to be close to the glass
line.Water Jacket:The water jacket seals the dog house area
with the top of the tank,preventing flame eturns.Its height can be
easily adjusted to ba able to lower it as possible .It needs to be
replaced regularly (nearly 6 months to 1 year) due to batch
corrosion.

The Purpose of the Back wall:-

 It Holds the furnace pressure
 Prevents the hot flue gases from escaping out from the
Melter

1.MELTER:-
The Melter is 33.5 m long, 10.7m broad and its height is
4.236m. It melts the raw powder materials to molten glass. Dam
wall is present at dog house. It is made of AZS. Dam wall
separates the current M2 & M3. It prevents the impurities from
carry over in to the Working end and acts as a physical barrier.
Melter is the region where the crystalline solid batch
materials melts and forms the molten glass. For melting this
Page - 45
batch materials two sources of energy are employed, one is the
fuel oil and the other is the Electrode Boosting. Heat transfer
from the fuel oil is by radiation and from the electrode is by
convection. The Melter constitutes seven ports on each side and
holds the flame above the molten glass. The 4th and 5th port
experiences the highest temperature.The Melter constitutes
seven ports on each side and holds the flame above the molten
mass. All the Ports have five burner slots. From the 1st to 6th port
firing is done on 1st, 3rd and 5th position and in 7th port firing is
done in 1st position. For first twenty minutes firing is done from
right side port and flue gases move to chimney through left side
regenerator. For the next fourty seven seconds no firing is done.
Again for twenty minutes firing is done from left side and flue
gases move to chimney through right side regenerator.
Secondary air picks up heat from the regenerator blocks and is
used for the combustion of the fuel oil. The oil at 15 bar
pressure is charged through a nozzle. Gets atomized
mechanically and mixes with the primary air at 1 to 0.5 bars
before it gets fired. Swirler is a small circular metal plate having
small slots in an inclined manner and it pushes the fuel oil flow
in to the furnace to help in easy and better atomization.

Solid State Reactions:-

Page - 46
This liquid phase (Na2CO3.CaCO3) developed reacts rapidly w
Typical eutectic mixtures for Soda-Lime-Silica glasses are those
ith silica (SiO
between Sodium Carbonate (Soda ash) and Calcium Carbonates
(Lime stone). (Na2CO3.CaCO3) which forms at 775OC and that
between Sodium di Silicate and Silica at about 800 OC
(Na2O.2SiO2 eutectic @800OC)
Na2CO3 +CaCO3 à Na2CO3.CaCO3 (Eutectic) @ 600 – 810
O
C

nSiO2 + Na2Ca(CO3)2 à Na2O.3CaO.6SiO2 + CO2à

Na2O.2CaO.3SiO2 + CO2 @ 850 O C
Reaction between Soda ash (Na2CO3) and Silica (SiO2)
commences at 560OC
Na2CO3 + SiO2 à Na2SiO3 (Sod. di silicate) + CO2
The coating of Sodium Silicate thus formed on sand grains
reacts further with silica at or around 700 O C
Na2SiO3(Sod. di silicate) + SiO2(Silica) à Na2O.2SiO2 (eutectic
@800 O C)

S CHEMICAL
NO NAME MELTING POINT
1 SIO2 1728

Page - 47
 2 AL2O3 2072
3 Cao 2613
4 Mgo 2852
5 Fe2o3 1566
6 So3
7 Na2o 1132
8 K2o 350
9 Tio2 1843
10 Mno 1945

Injector:
Mixing of FUEL and AIR is done by Atomization with the
help of BURNERS.Injects the pressurized fuel along with the
atomizing air. The fuel is preheated and pressurized in the fuel
preparation room before coming to the injector. Preheating is
done by steam heat exchangers. The air is coming with the 1 bar
pressure to the burner. In firing time this air is used as atomizing
air and in non firing it is continuously given to burner.
Because to cool the burner tip (Tip cooling). These both will
mix in the nozzle. In nozzle one swiller is present; this is used
to swill the air and fuel through nozzle.
PORT NO BURNNER ANGLE NO OF BUR
1 11.5 3
2 11.5 3
Page - 48
 3 11.5 3
4 12.0 3
5 12.0 3
6 12.5 2
7 12.5 1

1st & 2nd port is 11.5* because it is easily melt the heap of the
batch. 3rd, 4th &5th ports it is 12* because it is a Melter zone it
will melt the glass completely. 6th & 7th ports are 12.5* because
it is a refining zone, if it touches the glass means it will create
some defects in glass.The nozzle diameter varies with the oil
flow.The pulverization air flow rate stabilizes the flame length
and the oil drops ssize.The oil rate adjusts the flame volume and
energy.The angle of the injector helps too generate the ideal
formation air/oil mixtures and flame shape.

TEMI ROOM:-
In the temi room we are preparing oil for firing. In this room
we maintain the oil pressure and temperature.
PROSESS STEPS :
1. Coarse filter filter
2. Boosting Pump
3. Steam heat exchanger
4. Electrical heater

Page - 49
 5. Fine filter
6. Reversal on /off valve
7. Mass Flow Meter and Flow control system
8. Primary Air Pressure Control system.
9. Fuel / Primary Air / Cooling Air Reversal Valve

HFO unloading through tanks in tank. Heating HFO

from 40 C to 65 c. Pumping HFO to Fuel TEMI ROOM (Fuel
preparation room) at 3 bars pressure.
From HFO tank the oil comes with 3bar pressure and 80
degrees temperature the oil goes to pressure release valve. In
that it will show the Pressure of oil and sends to return line after
that the oil goes to coarse filter. In the coarse filter it having a
mesh and it send the oil upto 450microns to next stage. We have
two coarse filters one will work upto 15days after that it will
change. Then after it will go to boosting pump.In boosting
pump the oil pressure is increased upto 15 bar. After that it will
go to steam heator.In steam heater the oil temperature is raised
to 120oc.But currently it is not working. Then the oil passes to
electric heater. In this the oil temparature is raised to 126*c.
now we are using this to give oil temperature upto 126*c.After
that it will sent to fine filter because if we filter the oil without
high temp,due to high viscosity its chemical particles are also
filter. So that we sent oil to fine filter after firing. Then that oil

Page - 50
goes to mass flow meter. This distributes the oil to individual
ports.
Primary air:- Primary air is used to ignite the fuel. It is
coming from utilities with 1bar pressure.

Secondary air:-Theoretically for Complete combustion

One kg of HFO requires 10.83 Nm3 of Air.

But practically to achieve complete combustion 10 to 20%
Excess Air is required.

FURNACE CURRENTS:-

BACK WALL

FRONT WALL
1 2 3 4 5 6 7

SIDE WALL
M1
M2 M3

DAM WALL
MELTING
REFINING
HOMOGENIZATION
CONDITIONING

TRANSVERSE CONVECTION CURRENT (M1):

The current direction is from furnace towards walls. These
currents promote batch melting in melting zone and

Page - 51
homogenizing in refining zone. It is observed in the V of the
batch charging zone.
LONGITUDINAL CONVECTION CURRENT (M2):
The current direction is from batch charging to canal. The
denser cold glass flows towards the bottom, then towards the
hot point, thus facilitating the melting process.
1. Batch charging to hot point
2. Hot point to Canal.These currents promote better
homogenizing, correct refining and conditioning.

SURFACE CURRENT (M3):

The current flows across the whole furnace length from Batch
charging zone to Canal. The objective is to prevent unmelted
glass flowing from the Batch charging zone directly in to the
Working end and Canal, as this would cause defects or ribbon
breaking in Float.Positive pressure of ±1Pa above atmospheric
pressure is maintained in the Melter section to avoid the
ambient air coming inside. The back wall prevents the escape of
flue gases from the furnace to the surroundings. The working
end pressure is more than the Melter pressure (3Pa) to avoid the
gas flow from the Melter to the W.E., the shadow wall in the
neck also helps in this function. The working end pressure is
maintained by controlling the air flow through the blowers and

Page - 52
the gas flow through the WE stack. . The dam wall at the bottom
of the Melter helps in the formation of currents in the furnace.

Regenerators:
Regenerators Present on both sides of furnace.
Function of the regenerator is to recover the waste heat from the
hot flue gases and to preheat the secondary air. The flue gas
generated during combustion process leave chimney via
Regenerators thereby transferring heat to the checker blocks.
This heat is recovered by the Secondary air after every reversal.
The temperature of the Flue gas decreases from 1350 oC to 350
o
C. Regenerators are made up of AZS Cruciform Checker
blocks, Corrugated and plain surface blocks. In Ports 1, 2, 3 &
4, three layers of checker blocks are available
1) Corrugated Cruciform ER5312 and ER1682, ER1682 (plain
cruciform)). ER5312 is recommended where the temperature
level, Carry over level and fume velocity is high. Ports 5, 6, and
7 have two layers of checker blocks (corrugated and plain
cruciform).

The Rider arch present at the bottom of Regenerator bears

the load of the checker bricks. The rider arch and the equalizing
blocks above the rider arch are made up of Silimanite bricks
which have the Good load bearing capacity.

Page - 53
 The efficiency of regenerators depends on the energy
recovering capacity from the hot flue gases by the cruciforms.
The efficiency decreases because,
 Fine particles of batch materials are carried over by the
swirling action of the flue gases and settles on the
checkers of the regenerators.
 The temperature is less at the bottom portion of the
regenerators and the Sox gases present in the flue gas
condenses and forms a sulphate layer on the surfaces of
cruciform’s and it blocks the passage of flow medium
through it and decreases the energy recovering capacity of
them.
Due to this the differential pressure across the regenerator
increases resulting in poor performance of it. Service life of the
regenerator depends on the carry over of the silica fines at top
leading to bursting of cruciform’s and on the alkali attack in the
middle condensation zone. So to maintain the efficiency of the
regenerators periodical cleaning is to be done (once in six
months)
Shadow wall –
Ensures the separation of fusion zone from the
working end. Shadow wall is present just before the neck
region to prevent the flow of working end gases into the
Melter. The height of the shadow wall is 2.616m. The

Page - 54
gap between the shadow wall and glass level is
maintained approximately around 50mm.It is made of
silica brick supported by iron plate. It is cooled by air
from shadow wall blower. The Shadow wall cooling air
pressure is also maintained higher pressure when
compared to the Melter pressure.
Breast wall – refractory vertical wall which are part of furnace
super structure that closes off the space between crown tank and
port mouth. The Breast Walls are the part of the super
structure.these are insulated with insulating materials layers and
erected on tuckstones.They normally made of silica,except the
breast walls on ports from 1 to 6,in which they are made of
AZS.These have peep holes to look into the furnace.These walls
assso aiming for manual temperature reading with optical
pyrometer. “ Breast walls are aiming points for temperature
measurements”.
Electrodes:
Electrodes
Bottom of the molten glass is heated by electrodes. There
exists 19 electrodes made of molybdenum and are grouped into
F1 - 6 F2 - 6
three segments.
The electrical connectivityF1 is through
F2 glass
S itself .Fusion-1,
fusion-2 & source are inserted into the glass. Maximum energy
is transferred through the tip of the electrode. The electrodes get
consumed with time at the rate of 2mm per month. So that

Page - 55
electrodes are pushed in once in six months by 10mm. Around
electrodes, cooling and inert gas is provided because
molybdenum above 500 degrees ‘C reacts with oxygen and
forms molybdenum oxide which is powderish and breaks

Electrodes are surrounded by KANTHAL (alloy) spool.

The Electrode is surrounded by water jacket and nitrogen is
allowed in between water jacket and electrode and a positive
pressure is maintained. Ceramic gasket is put in between
water jacket and KANTHAL for sealing purpose. All electrodes
were mounted on a jack provided with wooden insulation and
the entire area is fenced.

Refining: Disappearance of all gases likes CO2, SO2, and

O2. This phenomenon occurs simultaneously with melting.
There are 17 bubblers in between 4th and 5th ports from bottom
of the furnace. We are giving nitrogen to bubblers for refining

Page - 56
.
Batch Line: More batches are melted in the centre of the
furnace compared to the sides giving a V-Shape to the batch.
This happens due to following reason.
Temperature is maximum at the centre as the flame covers
almost 3/4th of the furnace width.

Foam Line: The Line that differentiates the refining region

and region after that is the foam line, after which the glass is
completely molten.

BUBBLERS:
They are equipments used for refining of the melt. Nitrogen gas
is passed through the bottom of the Melter so that they help in
refining as it will bring the dissolved gases in the glass bottom
to the surface. There is provision for 17 bubblers and is situated
in between 4th and 5th ports. The bubbler also generates localized
currents and also its increase M2 current.

TOTAL- 16

Page - 57
Reactions In Refining Zone:-
Sulphates accelerate the glass melting reactions and
promote the refining and Homogenization of glass. It reacts
with silica as follows
2Na2So4 + 2Sio2 Na2o.Sio2 + 2So2 + O2

The rate of reaction is maximum at 11000C.The SO3 given off

creates disruption with in the melt creating a vigorous stirring
effect, which together with the available soda, speeds up the rate
at which silica is taken into solution.
However ,with increasing temperature ,solubility of sulphate
decreases The use of salt cake to accelerate melting can result in
formation of “Salt water gall” on the surface of the melt, due to
the presence of undecomposed sulphate.

Page - 58
The formation of gall can be lessened, whilst still retain the
advantage s of Sulphates, by addition of reducing agents like
carbon in the form of coke or diesel.
Na2So4+2C Na2S(Sodium Sulphate) + 2Co2 @
7000C

Sulphide (Na2S) dissolves in sulphate (Na2So4) forming a

eutectic with a melting point of 7400C.
3Na2So4 + nSiO2 + Na2S (Na2O) 4. (SiO2) n
+ 4 SO2 @11000C

The amount of sulphate and carbon added to a batch strongly

influences the Redox process and solubility of gases.
During the melting process, a large quantity of gases is evolved,
mostly CO2 from carbonates and some quantity of Sox from
sulphates.

3. NECK:-

Neck is 10.5 long and 5.6m width. It’s tapered upwards in a

slant manner to avoid deposition of defective glass at the
corners.The neck connects the fusion zone of the furnace to the
working end.The Neck is the narrowst part of the furnace to
helps the correct movement of the glass.It consists of the bottom
bearing blocks.The superstructure is composed of silicsaa,breast

Page - 59
walls aand silica crowns opposed to the fussion zone,the breast
walls and the crowns in the waist do not have any heat
insulation.
BARRAGE:
Barrage is put in the neck region from both left and right side
of the furnace. Barrage is a rectangular box whose inner sides
are cooled by cooling water. The purpose of barrage is to divert
some portion of M3 current back towards the Melter and there
by increasing the homogenization. In this way the temperature
difference between the surface and bottom of glass are reduced.
Barrage also eliminates certain surface defects. The size of
barrage employed for clear glass production. Barrage is
positioned in such a way that some distance is above the surface
of the glass. The gap between the two barrage elements is
maintained.

Homogenization:-
To make the same physical and chemical properties of the entire
melt by establishing continuous convection currents.

4. WORKING END:-

The working end is 16m long and 9m broad. In working

end the glass temperature is reduced to about 1250oC by using

Page - 60
two air ducts through which air is blown in counter direction of
flow of glass. The pressure at working end is 3.5 - 4 Pascal’s.
The Working end pressure is controlled by the chimney damper
Furnace glass level measurement both Manual and Automatic is
present in the Working end which is as important furnace
control parameter.

Conditioning:-

To bring down the temperature of the glass slowly to the

workable condition without affecting its homogeneity.

Feeder:

Feeders used to take out the molten glass in order to maintain

the furnace pull during low thickness run. Feeder drained point
is placed at the exit of working end on the both sides.
The Feeders are operated under following conditions:
 2mm glass productions
 4mm reflectasol production
 Under float shutdown emergency

Page - 61
 5. CANAL
Canal delivers the melting glass to the float bath with a
temperature as constant as possible. The canal is provided with
equipment to

Homogenize the glass. The canal has a converging end with a

Spout lip from which the glass flows on to the float bath. The
canal bottom and
Side wall is made of Zargal -M, a refractory that does not cause
any defects. The canal superstructure is closed off by crowns
separated by Curtains. The breast walls of the canal are made of
sillimanite bricks. They support the installation of Gas burners
when needed. The canal is 6.54m long and is tapered towards
the spout lip. The thermal homogenization of glass is obtained
using AG3. The AG3 are slow running agitators. The arms are
made of mullite refractory and covered with platinum sheet. The
3 curtains available above the glass level to maintain the canal
pressure. The pressure at canal is 6.5-7.5 maintained. The PB
temperature is measured above the glass level at the end of
canal and is maintained at 1100 o for clear glass

AG3 in Canal:-

Page - 62
 In canal the thermal homogenization of glass is obtained
using AG3. There are four agitators with six arms. Two of the
agitators rotate in clockwise direction while the other two rotate
in anti-clockwise direction with a maximum speed of 2.5 rpm.
The speed of the agitator should be optimized. Too much rpm of
the Ag3 will introduce seeds in the glass because of the
viscosity condition also high speed generates turbulence in the
glass. The agitators are cooled by means of cooling water
supply in

Their jackets. The arms are made of mullite refractory and

coated with platinum of 20microns thickness. This coating is
highly essential because
The mullite refractory has high seeding potential which
may lead to the formation of seeds.
The various advantages of having AG3 is that
 It reduces the variations in the spread of molten glass
in the float bath.
 Avoids variations in the PB temperature.
 The pull tonnage is maintained constant.

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CURTAINS:-
They separate the atmosphere in the working end and the
atmosphere in the canal. The curtains also limit disturbances
when homogenizing equipment is being introduced. The
curtains are made with silica refractories.

GUINAND:
The guinand is inserted into the canal.The stirring is done via a
pan inserted into an eye one the end of a water cooled and
Page - 64
insulation arm.This equipment has to be manually pushed into
place,there is no drive mechanism or rails,only wheels.The arm
moves forward and backwards in the glass at a speed by the
potentiometer located in the control panel.
BURNERS:
They provide energy boosting to avoid glass settling in the canal
during a shut down.
VENTILATION:
A system is provided to ventilate the canal bottom. The cold air
is used to cool the canal bottom

REFRACTORIES USED IN FURNACE AND ITS

PROPERTIES:-

The different refractories we are using in furnace are as follows:-

AVOID HEAT
DOGHOUSE TO
BACK WALL SILICA FLOW TO BATCH
CROWN
CHARGER EQUIPMENT

Page - 65
 WALL UPTO GLASS IS IN
SIDE WALL AZS
GLASS LEVEL CONTACT HERE ONLY
BREAST AZS (from dog
WALL house to port7) WALL ABOVE
SILICA (after TUCKSTONE TO PORT GALLERY
port7 to working SKEW BACK
end)
TO ISLOATE
SHADOW END OF
SILICA WORKING END FROM
WALL REFINING ZONE
MELTER ATMOSPHERE
COVERS PREVENTS HEAT
CROWN SILICA WHOLE FURNACE LOSS AND RADIATES
AT TOP BACK TO BOTTOM.

Page - 66
 1. AZS (alumina zirconia silica):-
 High corrosion resistance
 High temperature resistance
 High density than glass

2. Silica refractory:-
 Monolithic formation
 Dripping does not affect the glass quality
 High rul resistance
 Cost effectiveness

Regenerator – Cruciform AZS :

 Excellent Chemical resistance
 High heat Conductivity
 Does not reacts with Sulphates condensates

Canal – Zargal .M:

 Low seeding potential
 Better dimensional accuracy

BLOWERS:-

Page - 67
 The following table gives the blowers used in the furnace
area.
NO: OF
AREA LOCATION FUNCTION
BLOWERS
Batch charger 60 M Level Cooling the spades 2 (1W + 1SB)
Side wall cooling,
Side wall 55 M Level 4 (All Working)
to reduce corrosion
Conditioning of
Working end 55 M Level 2 (1W + 1SB)
glass.
Secondary air
Below Secondary air for
(combustion 8 (7W + 1SB)
Electrodes combustion
blowers)
Super Super Structure
49 M Level 2 (All Working)
Structure cooling
Hanging Shadow
Shadow wall 49 M Level 2 (1W + 1SB)
wall cooling
Placage
49 M Level Placage cooling 4
Blower
Back wall 49 M Level Cooling back wall 2 (1W + 1SB)

Side wall cooling is done just below the glass level to avoid
corrosion. Corrosion is maximum in this region due to the
following reasons.
 The cross convectional currents in the furnace
 Maximum reactivity in the solid-liquid-glass interface

Page - 68
 1. Back Wall Cooling ( for cooling the Metallic
Supports of Hanging Back wall)
2. Shadow wall cooling ( for cooling the Metallic
Supports of Hanging Shadow wall)
3. Sidewall Cooling ( for reducing the corrosion rate of
MELTER SIDE WALLS)
4. Working End Conditioning ( for reducing the Glass
temperature from Shadow wall to PB Temperature
by passing Air in counter flow direction to the glass
flow.

MEASUREMENTS IN THE FURNACE:

Thermocouples:
The thermocouples continuously measure the temperature in
mosst zones of the furnace,sendingthe data to the control system
of survailence.
There are two types of thermocouples installation in the furnace.
 Through thermocouples,in direct contact with the molten
glass.
 Blind thermocouples:,inserted into the refractory but not to
in direct contact with the glass.
When a measuring instrument is defective,a drift is a by
comppating it witth the other instruments.These devices have a
service life of about 1 to 3 years for most exposed ones.

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PRESSURE MEASUREMENT:-
It is essential for furnace control and to make quality glass.The
pressure measurement system measures and control all the
pressure in the furnace that are relevant to the glass making
process.Pressure is measured in quiet zones to avoid subjecting
measurements to variations. The atmospheric pressure is
measured and taken as reference. The pressures in the furnace
are then compared to this reference pressure. The objective is to
maintain the pressure in the canal at a higher level than
atmospheric pressure.Pressures are measured on either side of
the furnace. The DCS calculates an average value to minimize
variations. The canal pressure does not have a specific control.
However, the canal pressure is related to the working end
pressure which is controlled. When a measuring apparatus is
Defective, this can be detected by the drift in its results
compared with other measuring devices. Pressures are measured
on either side sof the furnace,which are then averaged to
minimize the variations caused by flames.

TEMPERATURE MEASUREMENTS

To control the flowing glass temperature, the canal is

equipped with an
1) Optical Pyrometer and a PB Thermocouple

Page - 70
 2) Blind thermocouples on the bottom
Fixed optical pyrometer::
The fixed optical pyrometer remotely measure the glass
temperature before it flows into the float,without any direct
contact with it.One fixed parameter is installed at the end of
working end and canal to measure before it flows into the
flat.The fixed optical pyrometer is continuously water cooled.

Hand held optical pyrometer:The hand held optical

pyrometer remotely measures refractory temperature in the
furnace.The optical pyrometer operates with batteries.It has a
display to show the measured temperature the emissivity.
IMPORTANT PARAMETERS:
 Dog house temperature - 1380-1390 C
 Hot spot temperature -1589-1592 C
 Shadow wall temperature -1475-1485 C
 Working end temperature -1139-1155 C
 Crown temperature -1550-1555 C
 PB temperature -1084-1085 C
 Furnace glass level
 Furnace, Working end, and canal pressures

Automatic glass level measurement:

Page - 71
The automatic glass level measurement system measures
continuously the depth of the molten glass inside the furnace
and several tthis measure to the main control system..The
automatic glass level measurement probe is located on the left
side of the working end.The glass level is measured in a quiet
zone in the working end to avoid the faulty readings to
swirling.The probe continuously water cooled,ssincee it is
directly inside the furnace.Description:The probe automatically
sends an electrical signal down to the glass for every 8
seconds.Thee electrical signal is reflected back up by the glass
and is received by the probe.this time taken by the signal to
return to the probe is sent to the transmitter.The transmitter
uuses the delays time to calculate the estimation of glass
level.The glass level is calculated by the transmitter is sent to
the main control system.
MANUAL GLASS LEVEL MEASUREMENT:
Manual glass level measurement of the glass level is performed
to check thhe aauttommaatic measurement.The manual
mmeasurement is performed by meanns of a gauge on the end
of water cooled probe located at the left side of the furnace aat
the skimming pocket.The equipment is entirely water cooled to
the withstand the furnace temperature.
Oxygen Probes:
The oxygen probes measure the amount of oxygen O2 left in the
waste gas when entering the regenarators.This measures allows

Page - 72
the precise adjustment of the amount of combustion air injected
into the furnace,thus lining the amount of noxious emissions in
the waste gas.The percentage of oxygen in the waste gas is of
measured during the waste gas phase for the regenarators.The
measured value are automatically recorded by the DCS.To resist
the temperature,the probes are called with compressed air.The
general compressed air inlet for the probes is located at the
exterior corner to the first regenerator at each side of the
furnace.This inlet must always kept open.

FIRING REVERSAL SYSTEM:

During every 20 minutes reversal of firing takes place. During
this time secondary air comes through the firing side and the
flue gases goes to the chimney through the other side of the
regenerator. Checker blocks in the regenerator absorb the heat
in the flue gases and supplies it to the secondary air during the
next reversal.

ESP (Electro static precipitator)

FDC (FORCED DRAFT COOLER):-

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 FDC is used for reducing the temperature of the flue gas
before entering the fan. The waste gas is directed to FDC
through damper 2.
Flue gas enters FDC at the bottom of the first bank and
travels upwards and enters the second bank from the top
through transfer duct. When the flue gas passes through the
tubes, it is cooled by the atmospheric air and air from axial flow
fans acting on the outer surface of the tube.In forced draft
cooling the flue gas temperature is reduced from 350-550*c to
250*c. FDC outlet temperature should not exceed 262*c.
The collected heavy dust particles in the FDC are removed
through rotary feeder.

FGD (flue gas desulphurizer):-

In flue gas, it contains acidic sulphur (Sox) in it .FGD
reduces the Sox before letting out flue gas through chimney.
The outlet of FDC is connected to FGD unit. The FGD is used
to desulphurization the flue gas by using soda ash.First this soda
ash is milled and then this milled soda ash is sent inside the
FGD by pneumatic process.From the FGD pipes the flue gas is
sent inside the FGD,Here the flue gas is sent inside the FGD and
soda ash is sent through pipes wen this both weill mix chemical
reaction will takes place and the salt cake will comes out from
the bottom of the FGD. scrubbing action using soda ash and
lime slurry. Lime and soda ash slurry is atomized and sprayed

Page - 74
on the flue gas depending upon the incoming Sox and targeted
Sox at the outlet. The flow rate and the concentration of lime
slurry varied.
The FGD type is spray drier absorber type. And FGD
decreases the Sox and the temperature also upto 250*c to 100*c.

ESP (Electro static precipitator):-

The electro static precipitator is used to control the suspended
particulate matter in the flue gas to the acceptable form before
going to the atmosphere.
The desulphurized flue gas enters into the ESP. In ESP there
is 2400 emitting & 416 collecting electrodes are made ground.
Hence electric field is produced in between them. The flue gas
is passed through the electric field between emitting and
collecting electrodes. In the electric
Field the dust particles in the flue gas gets charged. The
charged particles stick to the electrodes and the clear gas is
carried in its passage through the Induced draught fan and then
through the stack. The collected dust is discharged from
electrodes using rapping mechanism.

Stack or Chimney :

Page - 75
(the stack effect inchimneys: the gauges represent
absolute air pressure and the air flow is indicated
with light grey arrows the gauge dials move clock
wise with increasing pressure )

Chimney is a structure which provides ventilation for hot flue

gases from a furnace or fire place to the out side atmosphere .
chimneies are typically vertical to ensure that the gases flow
smoothly, drawing air in to the conmbustion in what is
known as the stack, or chimney, effect the space in side a
Page - 76
chimney is called a flue.the height of the chimney influences
it ebility to transfer flue gases to the external environment via
as stack effect.

When coal,oil,natural gas,wood or any other

fuel is combusted in industriel furnace,the hot combustion
product gases that are formed are called flue gases.
The higher pressure outside the chimney is the
driving force that moves the required combustion air in to the
combustion zone and also moves the flue gas up and out of
the chimney. That movement or flow of combustion air and
flue gas is called chimney effect or stack effect.

Special jobs

1. Placage:-

Page - 77
  Over coating in side wall is done when original side
wall is corroded to minimum thickness.
 Over coating can be also done if side wall is having
multiple cracks and chances for glass leak.placage is
also named as patching.

Tools used for Placage:-

1. Placage blocks
2. Mesh support
Page - 78
3. T-support
4. 75mm channel
5. M 24 studs for pushing purpose
6. Cooling ducts
7. F-clamp
8. Temporary cooling ducts
9. 1 inch pipe for clamp purpose

1. Placage blocks:-
Over coating on the side wall blocks are done using AZS
blocks when side wall or previous Placage block corroded to
maximum level
2..Mesh support:-
Each support mesh will support a block completely which
subsequently by a support channel. The mesh is used to hold
the crack pieces of old blocks and it will not come outside
3. T-support:-This support is given to the blocks as well as
new blocks temporarily during support channel removal and
replacement.

4. Placage block support channel:-A channel that supports all

the support meshes over the blocks all the time and it holds
this support rod by using block support in a F-clamp

Page - 79
 5. M 24 studs:-
These studs hold the channel for supporting purpose through
F-clamps.

6. Cooling ducts:-
Placage block cooling will done by these cooling ducts.

7. F-clamp:-
The rods that hold the channel supports are tighten to this
clamp.

8. Metal plates:-
These plates are used at the bottom of Placage blocks to
adjust position over the support stand.

Other Tools used for Placage:-

1. 36 double end spanner

2. 24 socket for F-clamp

Page - 80
 3. 0.5mm shim plate
4. Compressed air line
5. Light
6. welding machinery
7. Jar cutting machine
8. grinding machinery
9. Placage bottom support
10. Placage cooling ducts

Safety precautions:-
1. Use goggles
2. Use fleece top
3. Hand gloves
4. Hot gloves
5. Face hood
6. Shoes

Procedure for doing Placage;-

While doing Placage first we have to reduce the glass level.

After reducing the glass we have to remove the cooling ducts.
Then we have to weld the T-support for support the mesh. Then

Page - 81
after that we have to loosen the bolts of F-clamps and we have
to remove it. After removal the C-channel also is removed.
Then slowly we remove the mesh and place a new block
immediately. Then after we put mesh frames to support the
blocks. For each block we have to put one mesh frame to
support. Then weld the T-support for mesh for temporary
support. After that we have to place C-channel and put F-clamps
and bolted it slowly. Then we remove the T-support after
keeping C-channel. Then we put the cooling ducts. After that
we have to visualize the place where we done
Placage manually. Then the Placage job is finished. Then we
have to raise the glass gradually to our required pull.

2. Flue gas analysis;-

Flue gas analysis is essential to ensure the good combustion
in the furnace. This operation is required to carry as per the
schedule.

Procedure:-
 Flue gas sampling probe is to be checked for the
cooling water flow and to be ensure that all connections
are properly connected
 Connect the flue sampling tube to the probe and
establish the connection to the flue gas analyzer.

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  Start the flue gas analysis and allow calibration.
 After calibration insert the sampling probe to the
regenerator through the top peep hole.
 Sampling probe has to be inserted on the non-firing
side.
 Flue gas analyzer will analyze the flue and parameters
will be displayed in the LCD.
 Every two minutes o2% has to be recorded in the data
sheet provided.
 And the recorded parameters print out has to be taken.
 This process has to be continued for 20 minutes.
 Then sampling probe has to be removed carefully and
keep it ready for next port analysis.
 Adjustments to be done as per the requirements.
 The same process as to be made for next port also.
 Analysis has to be carried out for the confirmation.
 Disconnect the sampling probe tube from the sampling
probe.

2. Regenerator cleaning:-

Regenerators cleaning done to clean the deposits which were

settled on the regenerator checkers. This operation will be done

Page - 83
as per schedule i.e... Twice in a year. This will improve the
regenerator performance.

Procedure:-
 Move the regenerator cleaning table and tools to the area.
 Establish the connections to the regenerator burner; those
are LPG and compressed air.
 Ensure that all the connections are leak free.
 Inform to control room to maintain the LPG pressure as
per the consumption and for taking the furnace pressure
control in to manual mode.
 Remove the regenerator cleaning peep hole plugs.
 Cleaning has to be done through the firing side of the
regenerator.
 Adjust the LPG pressure to 1 bar.
 Start the burner and adjust the flame to touch the
refractory and ensure proper consumption.
 Keep the burner at one particular section of the one
particular checker.
 Ensure the cleaning by inspecting through the mirror
provided.
 Each one has to be cleaned as per requirement.
 Cleaning has to be stopped as soon as reversal starts and
the opposite side cleaning have to be started immediately
after firing starts.

Page - 84
  Cleaning has to be done alternately both the side of the
regenerators.
 Same procedure has to be removed for all the sections of
checkers.
 All the materials which is cleaned will fall to the
regenerators bottom.
 Regenerators bottom doors as to be kept open for cleaning
the materials.
 After cleaning the regenerator remove the material
through the non firing side with the help of tools.
 Collect total material in metallic tray and transfer to the
jumbo bags after cooling down to room temperature.
 During cleaning regenerator pressure has to be taken into
manual and controlling to be done.
 Close the regenerator bottom door after completing the
each side of cleaning.
 After cleaning establish the furnace pressure control in
auto mode.

Batch charger hopper cleaning:-

Page - 85
 Batch Charger compartment Cleaning is essential to
remove the scaling part and improve the life of charger as well
as to avoid excess heating.

Procedure:-
 .Batch Charger compartment Cleaning has to be done in
sequence of combination.
 .First combination is sixth and first
 .Second combination is second and fifth compartments.
 .Third combination is third and fourth.
 .Cleaning has to start with first combination.
 .First lowers the level in the batch charger sixth
compartment.
 Ensure no loading done while cleaning the compartment
this will lead to accident.
 .Then cleans the compartment with hammering the sides.

 .Remove Scaling material from the compartment; avoid

scaling material contamination to the batch.
 .Ensure all the time batch is there in the compartment.
 .Then proceeds to the next compartment and continue the
same procedure to the remaining compartments in the
sequence explained.

Page - 86
AG3 removal and insertion:-

AG3 is used for homogenizing the glass going to the float bath
for formation. The equipment consists of a motor, four speed
reduction gears, and water cooled arms covered with ceramic
rope & platinised fingers of mullite refractory. The motion of
fingers is in rotating mode in transversal direction of glass flow.

Removal:-
 General cleaning to be done before starting the job. No
metal pieces should be present on the AG3 platform.
 Ensure all the fingers stopped and in the direction of glass
flow i.e., 3&4 float and 2&1 towards left side.
 Disconnect all the coupling to the fingers and keep ready
for removal.
 Rotate the cover block for finger no.1 and replace with
ceramic fibre.
 Start lifting the first AG3 finger in order of no.1, 2, 3,
&4.While lifting the direction of finger arm to be across the
glass flow. After removal of each arm, place ceramic board
below it to cover the canal crown.

Page - 87
 Lifting of Ag3 finger to be done with chain pulley block
slowly which was mounted already to the EOT crane.
 Shifting movement to be done with EOT crane carefully
without touching to the structure.
 Placement to be done carefully after removing the circular
plate of the each finger.
 Lower the finger and place it in specified position

Insertion:-
 General cleaning to be done before starting the job. No
metal pieces should be present on the AG3 platform.
 Start lifting the first AG3 finger in order of no.4, 3, 2&1.
 During insertion into the canal the finger must be
positioned as follow I.e... Two fingers towards RHS and
two towards LHS.
 The agitator to be in place just above the glass level
inside the canal for 30 for preheating. Each agitator arm
to be kept hanging from the chain block, one by one in
order no.4, 3, 2&1 for 30 minutes and then inserted.
 After finishing the finger inserting, clamp the gear box of
each AG3 and connect the drive coupling with gearbox.
 Rotate the the motor of AG3 arm manually to check the
direction .If it is normal it will start with 0.2rpm.

Page - 88
ELECTRODE PUSHING:-
Bottom of the molten glass is heated by electrodes. These exits
19 electrodes made of molybdenum and are grouped into 3
segments:
Fusion 1 – 6
Fusion 2 -- 6
Source –7

The electrical conductivity is through glass itself. Fusion 1,

Fusion 2 & source are inserted into the glass. Maximum energy
is transferred through the tip of the electrode. The electrode gets
consumed with time at the rate of 2mm per month. So that we
are pushing electrodes into the furnace in every clear run in
which electrode boosting is not required & subsequently
extended at the bottom. Around electrodes, cooling and inert gas
is provided because molybdenum above 500*c it reacts with o2
& became molybdenum oxide which is powderish and breaks.
Electrode is surrounded by ‘Kanthal Spool’. The electrode is
surrounded by water jacket and N2 is inserted in between water
jacket and electrode is maintained positive pressure. Ceramic
gasket and Kanthal for sealing purpose. All electrodes were
mounted on a heavy duty jack provided with wooden insulation
and the entire area is fenced.

Page - 89
Tools used for Electrode pushing:-
1. Insulation block
2. Gaskets
3. Ceramic rope
4. Long and small rods
5. Chain block
6. L-supports
7. Spirit level indicator
8. Long studs
9. Jack for pushing
10. Water jacket removing stand
11. Two Tool boxes

Page - 90
ELECTRODE PUSHING:

Procedure for electrode pushing:-

Electrode pushing is done in every 6 months. This is to
compensate the corroded part of electrode inside the furnace
Melter.While doing the electrode pushing first we have to
reduce the electrode energy to zero and stop the electric feeder.
Before starting the job ensure the electric feeder is switched off
at the power plant. Open the feeder cage and arrange two

Page - 91
coolers on either side for heat reduction purpose. First remove
the security arranged 2 long studs. Then unlock the jack screw
and arrange water jacket removal stand with pipe properly.
Then rotate the hand wheel rapidly. Then we have to check the
temperature whether we have to push or not. If it is ok then we
have to push otherwise we have to put insulation block to
increase the Kanthal temperature. . If electrodes not inserting
smoothly means provide the insulation and allow it to rest for 24
hours.First we have to check the electrode is in straight
condition or not by checking it with spirit level indicator and if
not we put chain block and correct it. Then after we put marking
of 100mm. Then we have to loosen the water jacket base 3
bolts. Then we have to adjust the jack and rotate the screw with
the help of rods. Ensure that electrode is going the Melter
smoothly and do jacking at the 3 intervals. After inserting the
electrode
Inside with 100mm, tight the water jacket base nuts. And give
all water hoses and nitrogen pipe to water jacket and fix the
original jack. Lastly fix the long studs and lock the jack nut

properly. Ensure that electrical connections are not touching any

where. From this the entire job is finished

Page - 92
 FLOAT BATH

The molten glass coming from the furnace enters into the tin
bath which is a closed structure. Here molten glass floats on the
tin, so the structure is known as FLOAT BATH.

The float bath is used to transfer the glass to the next stage of
the process at the required thickness, width, temperature &
quality. Machines called TOP ROLLS manipulate the
continuous ribbon and these are used to achieve the desired
width and thickness. The bath is a sealed enclosure filled with
hydrate nitrogen reducing atmosphere and containing a tank of
molten tin on which the glass ‘floats’.

Page - 93
All Float baths throughout the world are the same basic shape
and adopts same basic principle of glass making, but vary in
size depending on the market. The bottom of the bath is a metal
casing with very tight tolerance on flatness lined with large
refractory blocks.
Large ventilators are cooling this casing, it is forced cooling by
ID fans, and (this is
Normally specified as 366 cu.m/hr per sq.mt (at 32 deg. C) of
bath bottom cooling)
A common bath casing will be split into 18 to 20 bays and each
bay has 10 sections that help in identifying the areas. (SGGI &
SGGUK has 18 bays, SGG-PORZ has 21 bays & SGG-
STOLBERG has 20 bays).
The top of the bath is entirely separate to the bottom, this upper
part is manually lowered after the blocking has been inserted
and the gap is then sealed using removable side seals. It is
totally suspended from top.
The roof has electrical Bus bars hanging down that are used for
the controlled heat up of the bath, maintaining the bath
temperature if the flow of glass stops for any reason (this is
known as a ‘shutdown’ and it can take around 24 hours to restart
the line following a shutdown) and also a small amount is used
in normal production during the forming of the ribbon- these
Bus bars can generate almost 3000 KW of power if needed. It is

Page - 94
important to know that following the start up, the high
temperature inside the float is generated from the glass.

TIN:
The glass is entirely supported by molten TIN during the
forming process; glass floats on TIN- thus the name ‘FLOAT
GLASS’. Tin is used because of its melting temperature of 232
deg. C and boiling
temperature of over 2623 deg. C and therefore remains molten
for the whole of the forming temperature range (~1000 to 600
deg. C). Tin is also used for various other reasons-

1. It is denser than glass (at 6500kg/m3) so the glass floats

on it and this gives it the fire-polished surface and the top
surface is only in
2. Contact with atmosphere and therefore this also has a fire-
polished finish.
3. It is readily available in large quantities (there is about 200
to 220 tons used in an average float bath).
4. It is not very expensive comparatively.
5. It has a low vapor pressure so therefore does not vaporize
at glass forming temperatures. Other metals with the right
melting and
boiling temperatures have been considered but they bring
other problems, for instance Thallium, Lithium and Bismuth
have too high vapor pressure and Lead cannot be used
Page - 95
 because of the condensation effect and others are not so
readily available or are too expensive
.
There are also downsides to using
tin- it is easily contaminated by oxygen or sulphur and sodium
which all give defects in glass ribbon. It needs only small levels
of oxygen or sulphur impurity in the tin to cause the formation
of stannous oxide or sulphide that migrate to the cold end of the
bath and form on the upper surface. This is then reduced to
metal by the atmosphere and drips onto the ribbon surface and
thus affects the quality of glass.

MECHANICAL EQUIPMENT IN FLOAT BATH

 WATER BOX (CUT OFF BOX)

 BACK TWEEL
 FRONT TWEEL
 SPOUT LIP

Page - 96
 FLAT ARCHES

 WET BACK TILE

 RESTRICTED TILE
 SPREAD CAMERAS
 HOT END COOLERS
 TOP ROLLS
 WATER FENCE
 CARBON FLAGES
 CARBON PUSHER
 EXIT COOLERS
 DEDROSSING POCKET
 EXIT LIP
 WASH LINE
 CURTAINS
 PYROMETERS
 LOR (lift out rollers )
 DROSS BOX

WATER BOX:-
Water box is used when ever the glass flow
has to be stopping completely. In case of spout lip change
over the water box is inserted in to the glass. The water box
is made of mild steel. It is continuously cooled by circulated

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 water system. The water box is coated by the boron nitrate;
hence it should be prevented from the contact of glass
directly.

BACK TWEEL:- Back tweel is made of cast iron. It is used

only in emergency purpose like front tweel change over. If
in absence of front tweel the back tweel is used and it with
stands up to 5 hrs only.

Composition of back tweel is;

Carbon - 0.2-0.3%
Nickel - 10-12%
Chromium - 24-27%
Manganese - 0.6-1%

FRONT TWEEL:-
It is made of fused silica having the 99 % of
pure sio2 (monolithic refractory). It is supported by a non
cooled metal frame. This metal frame stands upon the studs
provided on both sides. It is adjusted by the screw that extended
and provided a wheel to rotate manually. It is used for general

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production time. The flow of glass is maintained by the front
tweel. The life of front tweel is 6 months that it depends upon
the MOC of front tweel and pull of the glass.

SPOUT LIP:-
Spout lip is the connection between canal
and furnace. Spout lip is made of JARGAL – M i.e. containing
of high alumina. It allows the continuous flow of glass. Since it
having high abrasion, we can maintain the quality of glass. The
life of spout lip is 4 years. The life of the spout lip is varies
upon the PB temperature, rate of pull and number of transitions.
The spout lip is seated on the metal frame which is cooled by
the circulated water system. It is to notify that the glass surface
which is

touching the floor of the furnace and lip flows towards the edges
of the glass ribbon, due to density of the defective particle.
Where as this edges are cutting in the edge trimming.

FLAT ARCHES:-
The arches which are covered upon the
spout lip are known as flat arches. It is made of silica
refractories. These flat arches are having the metal frame to pick
and remove easy. It is seated upon the spout lip to reduce the
heat loss from the float bath. There are 5 flat

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Arches, in those 2 are non removable and 3 are removable.
During changing the spout lip or front tweel these are easy
removable.

WET BACK TILE:-

Wet back tile is used to maintain the
reversal flow of glass from the lip. It is made of Siliminite
refractory. Here the glass flow comes towards the wet back tile,
due to the surface tension, viscosity of the glass. In other case
the hot glass always attracts the back tile which is cold.
It is situated at the back side of metal frame which is cooling the
spout lip. The life of wet back tile is 3 years. It is supported by
the restricted tiles on both sides.

RESTRICTED TILE:-

The tile by its name restricts the glass flowing in to

bath without contact of casing on both sides of the bath. It is
made of Siliminite refractory. It is supported by the metal T
block made stainless steel.

LINTEL CURTAIN:-
Lintel curtain is the wall of bricks in float bath
to maintain the pressure. It does not allow the pressure from
Bay1 to Bay0.

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The pressure in the bath is N2H2 where as in the Bay0 is only
N2. If H2 enters in to the Bay0 it reacts with NA2SO4 present
in the glass and forms the bubbles. To avoid this lintel curtain is
necessary

TOP ROLLS:-
The top rolls are used to form the ribbon
mechanically. These will maintain the thickness, width, spread
of the glass at the head of bath. This equipment is water cooled.
The top roll shaft having a knurl disc made of graphite. The
diameter of disc is 220 mm. It has the knurls to hold the ribbon.
The number of top rolls is depending upon construction of the
float bath. Top rolls having a camera to watch its function. It is
supported on fixed chassis. It is also having the canon which is
holding the top roll shaft. Top having 4 motors with individual
parameters, they are as follows;
 penetration
 bite or height
 angle
 speed

PENETRATION:

The length from the top roll knurl to the casing of the bath is
known as penetration. The limit of the penetration is
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 Maximum – 2800 mm
Minimum - 0 mm

It is used to maintain the width of the ribbon. If the penetration

goes to high, there will be an effect on speed and angle of the
top roll. It should
be balanced on both sides; hence in an error there is an ability to
deform the ribbon.
BITE:
The insertion of top roll knurl into the ribbon is known
as bite or height. It is used for stability of the ribbon in the bath
and limits of the height are as follows.
Maximum - +55mm
Minimum - -55mm
It is also shows the effect upon the angle and speed of the top
roll.

ANGLE:-
The direction of top roll towards the ribbon in the bath
is known as angle. The limits of the angle are as follows
Maximum - +15 (+ve angle)
Minimum - -15 (-ve angle)

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 If the angle is positive, then the width is
increased and thickness is decreased. Where as the angle is
negative, then the width is decreased and thickness is increased.
Increasing in 10 of angle, there will be 2mm decreased.
SPEED:-
The number rotations of top roll knurl to itself is
defined as speed
The limits of the speed is as follows
Maximum - 17 mt/min
Minimum - 1.2 mt/min

If the top roll speed increases, the gross width will decrease and
thickness will increase. Similarly decreasing in top roll speed,
the gross width will
Increase and thickness will decrease. Increases in 1m/min of
speed, 6-7 mm of gross width will decrease.

WATER FENCE:-
The water fence is used to maintain the
position of the ribbon. It contains a vertical cylinder made of
graphite supporting from a water cooled tubes. It is
continuously cooled with circulated water system. It is
immersed in the tin. According to universal truth the hot always
attracts the cold; hence the hot glass is attracted towards the
water fence. The water fence touches the glass and guides its

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position and direction of the glass in the bath. During edge
trimming it is easy to cut the glass in the cutting end. It is also
having a camera as like the top roll to watch the position and
function of the water fence. There are two water fences present
on both sides of the bath. But only one water fence will guides
the ribbon. It is controlled by DCS. If it is having the high
pressure the distortion may occur.

CARBON FLAGS
The carbon flags are used to maintain the
stability of the ribbon. It is made of the graphite. It is immersed
in the tin. It also maintains the tin (convention) currents in the
bath. In float bath the
Upstream currents should not mix with the down stream
currents, incase the total bath contains the same temperature the
glass may cools with the tin and there is a possibility to increase
the wash line and the exit break

May occur. It is adjusted only by manually. Three flags are

present on each side of the bath.

CARBON PUSHER:-
The carbon pusher is used to hold the
ribbon to prevent it from the sides of the bath in emergency

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cases. It contains a graphite body connected by the shaft which
is cooled by the circulated water cooling system. It is located
on both sides of the bath near by the shoulder. But only one
side pusher is suggested to use and another side is water is used.
It is also immersed in the tin. It is controlled by the DCS or
locally.
It also contains the camera to watch the function of the carbon
pusher. The camera is continuously cooled by water system and
the camera lens is cooled by the N2 gas.

EXIT END COOLERS:-

Exit end coolers are used to maintain
the exit temperature of the bath. It is made of stainless steel
having the 5 fingers to the each cooler on both sides of the bath.
In those 3 are non movable and 2 are movable. One set of
coolers is known as Car. It is continuously cooled by the water
system. The exit temperature should not be more than 625 0C, to
maintain this temperature the exit end coolers plays the main
role in the bath exit.

DEDROSSING POCKET:-

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 Dedrossing pocket is used to
remove the dross from tin i.e. tin oxides and tin sulphides. It
contains the two wheels,

One is rotating in the tin made of graphite which collects the

dross and sent to the fixed plate present in the Dedrossing
pocket. To the bottom of
it a box is provided to collect the dross like as dust collector.
From there it is cleaned manually. It located on both sides of the
bath in the exit area.

EXIT LIP:-
Exit lip is located in the exit of the bath to
restrict the tin from the bath. It having the plate, it is cooled by
N2 gas because the temperature of the plate should not be more
than 1800C. Incase if it is more the plate of the lip is deformed
and tin may come in lehr.

WASH LINE:
Wash line is defined as the length between where the glass
leaving the tin to the point where the glass touches the lip. Wash
line is depends upon the exit temperature, thus the temperature
is maintained by the exit end coolers and exit heaters.

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The temperature is inversely proportional to the wash line and
the wash line is directly proportional to the thickness.
For particular thickness suitable wash line is provided and for
particular wash line suitable temperature is provided.
Wash line is calculated by the following way
Mm in wash line = 2.5* mm in thickness.

CURTAINS:-
Curtains are used to prevent the heat loss from the float bath. It
is made of silica material. There are 5 curtains in float bath exit.
The gap between the glass and curtains is 3mm.

ANNEALING LEHR:-
From the float bath the glass ribbon is taken out by the
LOR`s and it is cooled in a controlled manner to attain a proper
stress profile. The lehr is broadly into 3 zones.
 Pre- annealing (A0&A1)
 Annealing (B1, B2 & B3)
 Cooling (C, D1, D2, D3, F1, F2, &F3)
The first 12 rollers of the lehr rise up gradually. There are
332 rollers in the annealing zone are smooth with 305mm
diameter in A0, A1, B1,B2, and B3 zones. The rollers have
channels with 216mm diameter in

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 C, D1, D2, &D3 zones. The rollers have ring with 216mm
Dia in F1, F2, & F3 zones.
The motor M1 or M2 drives the lehr rollers one in master
and the other is slave. The slave runs at 95٪ speed of the master.
Bonny drive runs at a maximum speed of 5m/min when both
master and slave fail.
SO2 Cushioning is given in A1, B1, B2 and B3 zones. Since the
glass in soft in this zone the rollers may cause scratch marks on
the bottom surface of the ribbon. Zones A0, A1, B1, B2, and B3
are permanent stress zone. The zones C, D, D2, D3, F1, F2,
&F3 are temporary stress zones. A Lehr is a long chamber that
controls the cooling of the ribbon.
(Controlled cooling). The ribbon is cooled in a controlled
manner from around 600 deg, C to a cutting temperature of
about 60 deg. C. The cooling chamber also induces stresses in
the ribbon that are ‘permanent’
In nature for the downstream customers cutting quality at
ambient temperatures and ‘temporary’- so that the glass can be
cut safely at the end of the production line.

Cold End

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In cold end the glass coming from annealing lehr is cutted into
required sizes. In cold end different sections are present those
are as follows:

1. Break detect sensor: - It will detect the breaks in ribbon.

2. Scan tech:- It will scan the ribbon & defects in glass.
3. Ribbon trapper: - This is used to crush the glass ribbon.
4. Water pad: - It applies water to the edges of glass ribbon
for smooth cutting of edges.
5. ISRA: - It will detect the defects which are present in
glass ribbon.
6. Biosilnge: - It is used to calculate the stress profile in glass
ribbon.
7. Manual inspection booth: - In reflectasol production
quality people will inspect the glass in this booth.
8. Zinc citrate: - It is sprayed on glass ribbon to avoid the
weathering effect.
9. Cross cutting machines: - It will cut the glass according
to the dimension.
10. Error marking system: - In ISRA it detects the
defects, that defects are marked in this system. So this is
called Error marking system.
11. Dynamic snapper: - After giving the cutting mark,
this will move up to break the glass.

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12. Edge trimmer: - In this the edges of glass ribbon
will cut with the help of a wheel present above the ribbon.
13. Optimum trapper: - After cutting the ribbon
according to dimensions, if optimum defects occur means
the ribbon is crushed in this trapper.

14. Interleaving powder: - This powder is sprinkled on

the glass sheet to avoid the sticking of glasses in pile.
15. TRA 1 & TRA 6: - It is used to lift the glass sheet
and load the glass sheets in piles and to dispatching.
16. Ware house: - It is a place to store the glass sheet
piles.3

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THANK YOU

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