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Overview of Glass Industries

Glass is a rigid, brittle, transparent material produced by the vitrification of sand and other raw materials at high temperatures. The history of glass dates back thousands of years, with early production in Egypt and developments in blown glass and plate glass over time. The main types of glass are soda-lime glass, borosilicate glass, and special glasses. Glass is produced through melting raw materials in furnaces, shaping the molten glass through processes like floating and blowing, annealing to relieve stresses, and finishing steps. Glass production poses thermal, cutting, and respiratory hazards. Major glass manufacturers include the Flat Glass Alliance of the Philippines.

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144 views48 pages

Overview of Glass Industries

Glass is a rigid, brittle, transparent material produced by the vitrification of sand and other raw materials at high temperatures. The history of glass dates back thousands of years, with early production in Egypt and developments in blown glass and plate glass over time. The main types of glass are soda-lime glass, borosilicate glass, and special glasses. Glass is produced through melting raw materials in furnaces, shaping the molten glass through processes like floating and blowing, annealing to relieve stresses, and finishing steps. Glass production poses thermal, cutting, and respiratory hazards. Major glass manufacturers include the Flat Glass Alliance of the Philippines.

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GLASS INDUSTRIES

Presented by: Joule Renniel F. Bellosillo


OVERVIEW
 What is glass?
 History of glass
 Types of glass
 How glass is made
 Manufacturers of glass
 Hazards
WHAT IS GLASS?
What is glass?
Glass is . . .
 rigid
 a brittle material
 a completely vitrified product
Vitrification
 transformation of a substance into glass
What is glass?
Glass is . . .
 neither a solid or liquid
 an amorphous solid
Amorphous solid
 somewhere in between solid and liquid
What is glass?
Glass has . . .
 very high viscosity
 no definite melting point
 transparency
 high resistance to chemical attack
 has the ability to contain a vacuum
HISTORY OF GLASS
History of glass
 Its discovery is very uncertain
 Earliest reference of glass is made by Pliny
 6000 or 5000 B.C.- Egyptians making sham
jewels of glass
 290 A.D. – hand blown window glass cylinder
was invented
History of glass
 1608 and 1639 – Glassworks was founded in
Jamestown, Va., and Salem, Mass
 1688 – plate glass appeared as rolled product in
France
 1914 – Fourcault process was developed in Belgium
 1960s – research group in England perfected the
Float glass process
TYPES OF GLASS
Types of glass
 There are 7 types
of glass  Borosilicate glass
 Fused silica  Special glasses
 Alkali silicates  Glass fibers
 Soda-lime glass
 Lead glass
Fused Silica
 Also known as Vitreous silica
 Erroneously referred to as quartz glass
 Made by high-temp pyrolysis of SiCl4
 Transparent to Ultraviolet Radiation
 It has high thermal resistance
Alkali silicates
 sand and soda ash is simply melted together
 Its products have a range of composition from Na2O•SiO2 to
Na2O•4SiO2
 Used as fireproofing.
 Higher-alkaline variety is used in laundering as detergent and
soap builders
Sodium silicate
 Soluble glass, used as adhesive
Soda-lime glass
 Constitutes to 95% of all manufactured glass
 Composed of 70-74% SiO2, 8-13% CaO, 13-18% Na2O
 Used for flat glass, containers, automobiles, window,
tumblers, and tableware
Lead glass
 PbO instead of CaO
 Has high index of refraction and dispersion
 Has high electrical resistance
 Used for light bulbs, neon-sign tubing, and radiotrons
 Suitable for shielding from nuclear radiation
Borosilicate glass
 Composed of 10-20% B2O3, 80-87% Silica, less than
10%Na2O
 Low expansion coefficient
 High resistance to shock
 Excellent chemical stability
 High electrical resistance
Special glasses
 Colored and coated  Photochromic glasses
 Opal  Glass ceramics
 Translucent
 Safety
 Optical
Glass fibers
 Produced from special glass compositions that are resistant to
weather conditions
 Contains about 55% silica and low on alkali
 Vulnerable to moisture in the air
 Used as reinforcement
HOW GLASS IS MADE
Raw materials
 Sand (SiO2)  Cullet
must be almost pure quartz  Crushed glass from waste
 Soda (Na2O) – to oxidize Fe glass
 Feldspars  Salt cake
(R2O•Al2O3•6SiO2)  To remove scum on tank
furnace
 Borax(Na2B4O7•10H2O)
supplies Na2O and boric acid  Refractory blocks
Chemical reaction
Methods of Manufacturing

Melting Shaping Annealing Finishing


Melting
 Melted in Glass furnace
 Glass furnace can be classified as either Pot or Tank furnace

Pot furnace
 For small production of special glasses
 Employed in the manufacture of optical and art glass
Melting
Tank furnace
 Batch materials are charged in the “tank”
 The tank is built with refractory blocks
 Has dimensions 38x9x1.5 m
 Can be classified as day tanks and regenerative tanks
Shaping and Molding
 Fourcault process
 Pilkington process
 Glass blowing
 Danner process
Fourcault process
 Done for window glass
 Uses debiteuse
Fourcault process
 The debiteuse is slightly submerged in the glass
 The metal bait is lowered as the debiteuse is submerged,
drawing the glass upward.
 The glass is initially cooled with the adjacent water coils
 As it travels, it passes through a lehr, about 7.5 m tall
 It is cut and sent to cutting and grading
 Operates at 1500˚C
Pilkington process
Float glass
 High quality flat glass or plate glass
 Developed by Pilkington brothers in England
Pilkington process
Melting and Refining
 Raw materials are mixed to make a batch
 Flows to furnace at 1500˚C
Pilkington process
Float bath
 Glass from furnace gently flows over the refractory spout
 Passes through the mirror-like surface of molten tin
 It enters at 1100˚C and exits at 600˚C as solid ribbon
Pilkington process
Coating
 Additional process for reflective glass
 Metal coatings are added
Annealing
 It undergoes heat treatment in a lehr
Inspection
 Inspection for impurities in the glass
Pilkington process
Cutting
 Diamond wheels trim off selvedge – stressed edges – and cut
the ribbon to size dictated by computer.
Glass blowing
 One of the most ancient arts and technique
Casting operation
 Directing molten glass into a mold where it solidifies
Parisons
 Partly formed bottle or bottle blanks
Has two types
1. Suction-feed type
2. Gob-feed type
Glass blowing
Suction-feed type
 Molten glass is contained in a shallow, circular revolving tank
 Drawn up to the molds by suction
 The mold swings away from the surface, opens, and drops
away leaving the parison sustained by the neck
 Bottle mold rises into position
 Blast of compressed air causes the glass to flow in the mold
Glass blowing
 Gob-feed type
 The glass is cut into a gob by mechanical shears
 The gobs goes through troughs in which they proceed in to
the mold
Glass blowing
Gob-feed type
 Has Parison mold and Blow table
Parison mold
 Molds the neck of the glass
 Molded by the Settle blow
 Counter blow prepares the
parison for the blow mold
Glass blowing
Blow table
 the body is molded
 The Final blow molds the body of the glass
Glass Blowing
Danner process
 Used for glass tubing
 Glass flow falls onto a rotating, slightly downward pointing
mandrel
 Air is blown in the middle of the mandrel
 a pair of belts grips the tubing and draw it at uniform speed
Annealing
 It is necessary to anneal all glass products
 It relieves the stress in the glass by letting it
undergo heat treatment in a long furnace also
known as the lehr
Annealing
 Lehr
 Known as the annealing oven
 It is like a heat chamber which the rate of
cooling can be controlled to meet
foregoing requirements
Finishing
 Cleaning  Sandblasting
 Grinding  Enameling
 Polishing  Grading
 Cutting  Gaging
All annealed glasses must undergo one or
more certain finishing
Special glass manufacture
 Most common
 Colored and coated glass
 Safety glasses
Special glass manufacture
 Colored and coated glasses
 Mixed with various compounds to alter the absorption of light
frequency of the the glass
 NiO and CoO gives gray tint
 SeO gives bronze tint
 Fe2O3 gives green tint
 CoO gives blue tint
Special glass manufacture
 Safety glass
 Laminated safety glasses – 2 sheets of glass + 1 sheet of non
brittle plastic
 Tempered glasses – involves controlled annealing (non-uniform
stresses turns to controlled, uniform, low-level stresses). Strong
in compression, weak in tension
HAZARDS
Hazards
 Thermal hazards
 Cutting hazards
 Respiratory hazards
Manufacturers of glass
The Flat Glass Alliance of the Philippines Inc.
References
 Austin. G.T. (1984). Shreve's Chemical Process lndustries, 5th ed.
McGraw Hill International
Edition

 All pictures: www.google.com


 http://www.eurotherm.com/glossary-of-terms
 http://www.pilkington.com/pilkington-
information/about+pilkington/education/float+process/step+b
y+step.htm

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