GlassTrend-ICG seminar & workshop

INNOVATION IN GLASS PRODUCTION

10.-12. April 2013 Eindhoven, the Netherlands
Objective of the meeting: Bringing together the Technical Committees of the Cluster Glass
Production of the International Commission of Glass (TC11, TC13, TC14, TC15, TC18, TC21,
TC25: www.icglass.com) and glass industry (GlassTrend) to exchange information of TC
activities, to promote cooperation between the TCs, to address new developments in Glass
Production and to discuss the formation of new technical committees. Furthermore, analyzing
further needs and driving forces for innovation in glass production.
The meeting comprised a general session on recent innovations in glass production and specific
sessions with papers from experts of the Technical Committees of the ICG. The seminar is
closed with a panel discussion addressing the future technical/technology subjects of concern
for glass production and glass industry.

Target Group: members of TC11, TC13, TC14, TC15, TC18, TC21 and TC25 and GlassTrend
members / registration limit about 100 persons.
Official members of the ICG-Technical Committees TC11, TC13, TC14, TC15, TC18, TC21 &
TC25 and maximum 2 members from GlassTrend companies have free access to the seminar.
Venue of meeting:

Van Abbe Museum, Eindhoven, the Netherlands

Bilderdijklaan 10, 5611 NH Eindhoven, the Netherlands

Wednesday 10. April

9.00 - 13.30 TC13 internal meeting

13.45 - 16.10 Welcome & Special Session on Innovation
16.10 - 18.30 Time slot for internal TC meetings
(TC14 10 people &TC21/TC15: 9 people)

Thursday

8.30 - 10.35
11.00 - 12.45
12.45 - 13.50
13.50 - 16.20
16.20 - 18.50

11. April

Session Energy & Environment (organized by TC13)

Session Refractory Materials (organized by TC11)
Lunch
Session Glass quality (organized by TC14 & TC18)
Time slot for internal TC meetings TC25 & TC18 &

TC11

Friday

12. April

8.30 - 12.15
12.15 - 13.20
13.20 - 14.50
15.00 - 16.00

Glass Furnace Design & Operation (TC21 & TC15)

Lunch & Separate lunch CTC core group
Forming Process (organized by TC25)
ICG Panel discussion: Cooperation TCs & formation
new TCs

This document includes:

General summary of seminar

Panel Discussion Minutes

Description of new Technical Committee: Energy Efficiency in Glass Production

Program of the Seminar: INNOVATION IN GLASS PRODUCTION

Collection of Abstracts of papers

General Summary Seminar

From 10-12 April 2013, the International Commission on Glass (ICG) and the injdustrial
consortium GlassTrend organized a seminar for the Technical Committees in the cluster Glass
Production and for GlassTrend members.
The TCs involved: TC11 (Refractory), TC13 (Environment), TC14 (Gases in Glass), TC15
(Sensors & Control), TC18 (Melting Processes), TC21 (Modeling Furnaces), TC25 (Forming
Processes).
The seminar welcomed 102 participants from 18 different countries and 29 different industrial
companies plus 11 institutes.
During the seminar 31 papers have been presented concerning innovation in glass production in
general, with some recent examples of innovative solutions for glass recycling and increasing
glass properties. In session W1 on Wednesday the 10th of April, ambitious roadmaps for
innovation in glass production have been presented as well.
Furthermore, the different Technical Committees highlighted their activities and research of their
members in different sessions chaired by the TCs.
Thursday, 11th April: One session (D2) was dedicated to energy efficiency and environmental
issues and was coordinated by TC13 and involved 5 papers on new emission control techniques
and energy saving methods plus chemistry and kinetics of evaporation processes. The session
D3 on refractory materials with 4 papers was chaired by TC11 with the focus on experimental
studies or tests for refractory materials applied in glass furnaces and new refractory materials.
A session (D4) on glass quality and glass defects was led by TC14 and included papers on
characterizing bubbles in glass, .measuring the contents of water in glass and promoting melting
performance in industrial furnaces.
On Friday, 12th of April, sessions were organized by TC15, TC21 and TC25. A session (V5) on
sensors and process control included 5 papers e.g. on electrochemical sensors, sensor
robustness, soft-sensoring (using CFD models to estimate time dependent process parameter
values in glass furnaces) and control of combustion processes using a recently developed
O2/CO sensor. This session was chaired by TC15.
TC21 chaired a session (V6) with 3 papers on the work of this TC on Modeling glass melting
processes in industrial glass furnaces, with results of the last Round Robin case of TC21: a TV
glass furnace. Future applications of glass furnace simulation (CFD based) models have been
discussed. Applications include: furnace design, optimum furnace operation, troubleshooting and
process control. The application of CFD modeling to develop furnace designs, furnace operation
and better combustion systems for glass melting with higher energy efficiency and lower
emissions has been shown.

TC25 presented in session V7, 3 papers on the forming process and characterization of the
mechanical performance of glass bottles. A short review of the activities of TC25 in the past 10
years was presented by the previous chair of TC25.

Panel Discussion & New Technical Committee

The seminar was finalized by a panel discussion. Here a new Technical Committee for the
International Commission on Glass was proposed:
ENERGY EFFICIENCY IN GLASS PRODUCTION
A call for members (experts in the field of energy performance of industrial processes & glass
furnaces) from industry and academia was launched. The objectives for such a Technical
Commission were shortly discussed.
The panel discussion with chairs of the Technical Committees: Wilfried Linz (TC15), Michael
Dunkl (TC11), Adnan Karadag (TC25), Erik Muijsenberg (TC21), Detlef Kpsel (TC14), Jaroslav
Klouzek (TC18) and delegates for the Coordinating Technical Committee of the ICG (Ren
Vacher, Hande Sesigur and Ruud Beerkens) addressed the following questions:

What are gaps in Glass Technology knowledge that we need to address?

What should we accomplish/achieve within the next 5-15 years?

How can we involve the younger generation of scientists and engineers?

Are there barriers for innovations (IP issues, financial means, certain tools, refractory
material requirements)? How can we eliminate barriers?

The detailed protocol/minutes of this panel discussion:

Date:
Attending:

Apologies absence:

12 April, 15.00-16.10 hours

Ruud Beerkens (chair), Ren Vacher (CTC), Hande Sisegur (CTC), Detlef
Kpsel (TC14), Michael Dunkl (TC11), Wilfried Linz (TC15), Erik
Muijsenberg (TC21), Adnan Karadag (TC25), Jaroslav Klouzek (TC18).
Jaap vd Woude and Guy van Marcke (TC13)

A short Introduction of the Proposal on a new TC on: Energy Efficiency in Glass Production was
launched and a call for future members for this TC was made.
It was recognized that within the TCs of the cluster Glass Production, Chemical Engineering and
Thermodynamic approaches need to be applied for some fundamental issues that may concern
the subjects in different technical committees.
Some important examples of a deficit in knowledge were mentioned such as: the heating and
melting-in process of batch blankets in industrial furnaces, the relationship of molecular scale
homogeneity and glass properties and the occurrence and decay of foaming on top of glass
melts. These areas need more fundamental approached and mechanisms of these phenomena
need to be understood using chemical engineering and thermodynamic or molecular dynamic
modeling approaches.
Few Task-Force groups may be formed for these subjects with representative from different
TCs.
5

Panel Discussion Minutes

Question 1:

What are the gaps in glass technology knowledge?

Detlef Kpsel:

Energy savings -> melting tank most important

A lot of chemical reactions and processes involved in glass melting that
need to be investigated
Batch melting models are not sophisticated ,these need improvement
Thermodynamics, chemical-kinetics modes , physical model needed
Relates to subject of Nemec- Space Utilization analysis of glass melting
tanks
Fundamentals of chemical and physics are necessary for important
phenomena (refractory corrosion, foaming, batch melting)
The ensemble of processes in a glass melting furnace is not understood

Ruud Beerkens:

Few other remarks:

Batch chemistry : the models for retention of Se and B are not
sophisticated
Batch blanket melting is a possible subject for ICG Taskforce & TC 21
(Erik Muijsenberg)
Hande Sisegur:

To improve batch & fining is not sufficient there should also be focus on
homogeneity of glass on all scales.
Weak point: glass properties are related to glass homogeneity on atomic
level
Modeling of glass structure on molecular level needed
Especially for high quality and specialized / optical glasses
Time & temperature distribution in furnace and conditioning zones and
mixing behavior are important elements in industrial glass melting.

Detlef:

Homogeneity related to glass melting: the glass melting tank is producing

visible defects that need to be minimized.

Ruud:

Molecular sized inhomogeneity is smaller than defects, inhomogeneity

now not seen as defect but can influence mechanical strength, optics and
inertness.

Ren Vacher:

Nano-metric scale defects relate to mechanical properties

Ruud:

2 types of defects: glass defects & defects on molecular level

(inhomogeneities)
Need for chemical engineering view on the process of homogenization in
glass melting process. Needs for molecular dynamic modeling plus finding
relations between glass properties and nano-scale homogeneity are
considered as being important.

Wilfried Linz:

3 levels of defects: glass defects (measured) & meso level inhomogeneity

(how to measure?) & on molecular level

Ruud:

Idea from Brig: Prof. Helmut Schaeffer: TC on Glass Quality

6

Subject is however seems to be too wide: different types of glasses,

defects
Maybe a Taskforce for these issues with focused subject could be
initiated.
Bruno Purnode:

There is a gap in understanding foam formation: bubble density, bubble

size, bubble structure in foams, etc
Characterization of foam is needed, and a method for the measurement
and prediction of foam formation in glass furnaces by some sort of a
sensor.

Ruud:

The investigations on glass melt foams demands thermodynamics and

chemical engineering approaches:
GlassTrend project on this subject has recently been proposed

Some other interim questions that were raised:

Do we miss sensors or measurements techniques?

Availability of raw material (also for refractory), now or in the future? Also in relation to
evaporation loss and in relation to recycling

Michael Dunkl:

Zircon raw materials become scarce. Recycling of Zr from end-of-life AZS

refractory seems to be difficult, this has to to be
investigated

Hande:

Look for alternative raw materials (other types or lower quality, other
granulometry)
Look at cost of total glass production chain: exploration/ production of raw
material, production chain of glass, recycling ability etc.

Ruud:

Dutch Roadmap: raw material selection for soda-lime-silica glasses and

glass compositions did hardly change in the last 50 years but for for Eglass big changes have been made in the glass fibre sector.
Changes in glass composition should be more often considered to get
better performing (e.g. stronger) glass
Reluctant behavior of glass industry to change glass composition and
properties of glass / glass melt.

Question 2:

What should we accomplish in the next 5-15 years

(Question by Klaus Bange)

E. g. Float technology and oxy-firing did not exist 50 years ago what are the next new
breakthroughs? What will be next technology in 2030?
Li Liangzuo:

Technology for more easy-melting, cheaper raw materials, stronger glass.

Extra treatments on material properties (toughness, coatings) to optimize
glass properties important in its applications

Ruud:

Weak spot in furnace is metal line: How to reduce corrosion, can we avoid
metal line corrosion of glass melting tanks in the future?
Different shapes of palisade (soldier) blocks or other tank designs should
be considered? Use of refractory metals to reinforce metal-line area.

Michael:

Ruud:

Way of refractory cooling may be improved using mathematical modeling.

Eric Muijsenberg:

Glass quality in some glass product areas are over-specified, this will
increase unnecessarily the costs and energy demands for these products.

Ruud:

Customer often influences the glass quality demands. However, glass

customer involvement in ICG is weak. How to improve involvement?

Bruno Purnode:

New glass melting concepts. Glass industry is strongly stressed by

production costs. Industry wants low investment, low energy, low cost, low
emission production. In the US and Japan methods for more cost-efficient
glass melting were established by several platforms: SCM (= Submerged
Combustion Melter), In-Flight Melting, Plasma-Melting.

Ruud:

A much better controlled forming process: If the thickness of the glass wall
in a bottle is uniform, the weight per bottle can be significantly reduced,
this will save material and energy.
Less weight, less material, less energy, per bottle
Stronger bottles if no surface defects

Question 3:

How to involve young engineers / scientist in glass industry?

Jaroslav:

Young people today, show interest in technical sciences: perception of

This area isd too difficult, no good jobs (low payment level, dirty)
main gap: funding of university research, this is the basis to attract people

Ruud:

Idea of Summer school for Students in the field of Glass Technology

(worldwide including students from EU, China, Japan, USA etc.) by ICG,
younger people will become part of ICG family
Intention to start GlassTrend ICG summer school (Glass Technology),
e.g. in cooperation with Sheffield , RWTH for the year 2014 etc
Situation USA: similar to Europe, lack of young people studying
engineering.
Situation China: young generation also reluctant (image glass industry is
bad, dirty etc).

Li Liangzuo:

Try to get support from China (e.g. by the ICG President Peng Shou)
In China local government may support students / universities / Summer
schools

David Lever:

Solving question 1 and 2 will solve question 3. This will attract scientists
Glass is not sexy now

Valli Murthy:

I am young mechanical engineer: education was boring because many

classes were hardly related to application. Teachers could not tell
students about the application of science for practical problems. Link to
application is important

John Parker:

The ICG Montpellier Summer schools attract students worldwide

In the UK there is a recent move for students to choose science and
technology
Move away from law and economics, because of the low perspective for
jobs
Industry can interact more with universities on projects for students, it is
low risk. Involve students in the industry: stages, practical training,
summer jobs.

Question 4

Barriers for innovation in glass industry? (IP, legislation, finances ..)

Bruno Purnode:

A lot of time is lost in IP-discussions before starting a new project or R&D

consortium

Ren Vacher:

How to improve the efficiency of the TCs:

Like Erik explained: subjects which are pre-competitive can grow into
competitive subjects (like modeling). How to retain efficiency of TC work?
What to do next? Ren Vacher will send questions to all TC chairs (week
of April 15) concerning their program of activities in the next years and
subjects of these TCs in the cluster Glass Production.
What topics to address in your TC on pre-competitive level?
Also important, do we need to merge TCs, do we need new TCs or do
we need joint projects (e.g. Task forces on specific themes).
Answers on the request from Ren Vacher are requested within 1 month
(mid May 2013). Rene Vacher will present the programs and intentions of
the TCs to the CTC before the ICG congress in Prague.
Decisions on merging of TCs or establishing new TCs will be made in
Prague at the ICG congress (1-5 July 2013).

10

Executive summary of the Panel Discussion

Question 1. What are the gaps in glass technology knowledge?
1. The batch melting models are not sophisticated, they need improvement and
chemical engineering approaches.
Thermodynamics, chemical models, physical models will be needed.
2. Homogeneity on molecular level important for glass properties,
This level of inhomogeneity is currently not detected as defect but important for glass
product performance. How can the glass melting process improve the nano-scale
glass homogeneity.
3. There is a gap in understanding foam formation: bubble density, bubble size,
structure, etc.
Characterization of glass melt foams, a sensor for foam is missing.

Question 2: What should we accomplish in the next 5-15 years?

1. Glass quality is some areas are over specified, this is an energy over-cost
(sometimes glasses are of a quality that needs high energy consumption, but this
quality is not needed for its application). More involvement of customers is
appreciated in defining specific glass quality demands.
2. New glass compositions with cheaper raw materials;
3. New glass melting concepts with lower melting costs;
4. Strongly reduced refractory wear in the most critical areas of glass melt tanks;
5. Recycling of refractory materials.

Question 3: How to involve young engineers / scientist in glass industry?

1. Different perceptions exist about attraction of young people to science & technology
Good idea to promote by means of Summer school for Glass Technology students
(MSc, PhD): contact between students (from around the globe) and industry. First
idea is to cooperate in the organization of a GlassTrend-ICG Glass Technology
Summer school in 2014.
Question 4: Barriers for innovation
1. Initiation of new R&D projects or consortia need a strong leader and patience, some
R&D consortia need 2-4 years before getting started and before setting IP
(Intellectual Property) arrangements, contract and financial issues.
2. Work in TCs can be frustrated by competitive nature of the work.
Important is to identify the major relevant topics of pre-competitive nature that can be
discussed and worked on in the TCs of the cluster Glass Production of the ICG.
Ren Vacher will make an inventory

11

Description of new Technical Committee: Energy Efficiency in Glass Production

Proposed name:
Energy Efficiency in Glass Production
Objectives & tasks of TC:
Identifying the major process steps, that are showing a potential for energy efficiency
improvement, including glass melting, glass conditioning, raw material supply &
recycling, post-processing of glass;
Select technologies with potential energy efficiency improvement in glass production;
Test or develop tools to support energy efficiency investigations (e.g. energy balance
models for glass furnaces, protocols for energy management, energy audit procedures
dedicated to glass production plants, LCA modeling).
Define research activities for developing energy saving glass production methods.
Organize symposia or sessions on energy efficiency in glass production at ICG annual
meetings and congresses;
Share energy consumption and CO2 emission data (anonymous) for benchmarking
purposes;
Share LCA data;
Share practical experiences and problems related to new energy saving technologies
(e.g. use of batch preheating, flue gas heat recovery systems, energy efficient furnace
designs, recycling etcetera).
Profile of TC:
The members (typically 10-16 persons) of the Technical Committee should be a balanced mix
between glass industry experts, technology suppliers and academia. Preferably, each major
glass sector, container glass, flat glass, glass fibres, specialty glass, domestic glass should be
represented.
A core team with at least a chair person, vice chair, secretary should be composed from the
members.
The TC should act as a link between industry and academia.
Activities of this TC:
The TC members should preferably meet twice per year and exchange information.
Once per two years the TC organizes symposia related to energy efficiency and/or CO 2
emissions in glass production. Also indirect CO2 emissions should be addressed (CO2 emission
due to raw material supply/production).
The TC should prepare a vision document of required future directions for R&D to develop
technologies improving the energy efficiency and CO2 footprint of industrial glass production.
The TC should try to summarize new developments and publish results of these inventories.
Additionally this TC may prepare a specific energy efficiency roadmap for 2015-2025.
The TC reports annually to the Cluster manager Glass Production of the Coordinating
Technical Committee of the ICG.
Organize excursions to sites that demonstrate energy efficient technologies in glass production.
Important is that this TC broadcasts its activities and results to the community.

12

Candidates for TC Energy Efficiency in Glass Production:

Demands on each member within the TC:
- Members should show active contribution to this TC:
o Participation by presentations
o Sharing information
o Co-Organizing seminars
o Participate in joint activities such as Round Robin tests
o Share experiences on applied energy saving technologies
- 2 x times per year participation in regular TC meeting

13

Program of the Seminar: INNOVATION IN GLASS PRODUCTION

Wednesday afternoon 10th April, 2013
13.45 - 16.15 hrs. Welcome & Special Session on Innovation AUDITORIUM
W1.0

Welcome & Introduction

Ruud Beerkens CelSian Glass & Solar, Eindhoven, The Netherlands
Hande Sesigur, iecam, Istanbul Turkey

W1.1

Hardglass An innovative technology for container glass production.

Guenter Lubitz, Vetroconsult/Vetropack, Blach, Switzerland

W1.2

From glass waste to glass foam, a path for sustainable reuse of natural resources
Dr. Arjen Steiner, Schaumglas Global Consulting GmbH, Zell am Main, Germany

W1.3

Gaps in Glass Melting Technology what are we searching for?

& Energy Efficiency in Glass Melting
Ruud Beerkens, CelSian Glass and Solar, Eindhoven, the Netherlands

W1.4&W1.5

Duo-Paper from glass manufacturers on needs for R and D in the glass industry for the
next 10 to 15 years
Roland Langfeld, Schott AG, Mainz, Germany
& Jaap van der Woude, PPG Fibre Glass, Hoogezand,

W1.4

Needs for R&D in the glass industry: perspective of a specialty glass manufacturer
R. Langfeld, H. Rmer, SCHOTT AG, Mainz, Germany
NL Roadmap 2030. Is 50% Energy Efficiency Improvement in Glass Product/ Production
Chain Feasible?
Jaap van der Woude, PPG Industries Fiber Glass bv, Hoogezand, The Netherlands

W1.5

14

Thursday 11th April,

2013

8.30 - 10.35

Session D2: Energy & Environment (TC13),

Chairs: Simon Slade

D1.1

An introduction to the work of ICG-TC13, with reference to practical studies and recent
environmental legislation, Simon Slade, Pilkington NSG, Lathom, UK

D1.2

Operating experience of the ceramic candle waste gas filter in the glass industry
Air Pollution Control in Glass Industry, a System for DeNOx, DeSOx & filtration
Denis Lalart, Arc international, Arques France & Andreas Kasper, Saint Gobain,
Herzogenrath, Germany

D1.3

Evaporation from glass melts boron and selenium species

Hans van Limpt, CelSian Glass and Solar, Eindhoven, the Netherlands

D1.4

Application of CO/O2 sensors for combustion control and minimizing CO and NOx
Emissions, AnneJans Faber, Stef Lessmann, Marco van Kersbergen, CelSian Glass and
Solar, Eindhoven, NL

D1.5

Problems, developments and energy performances of glass melting furnaces.

A. Unsal, L. Kaya, B. Orhan, iecam, Istanbul, Turkey

11.00 - 12.45

Session D3: Refractory / Glass Contact Materials (TC11),

D3.1

Recommended Test Methods of the TC11 for Refractories

Dipl.-Ing. B. Fleischmann,Httentechnische Vereinigung der Deutschen Glasindsutrie e.V.
(HVG), Offenbach am Main, Germany

D3.2

Refractory solutions for the new challenges in glass furnace construction

Stefan Postrach, Rongxing Bei, RHI GmbH, Wiesbaden, Germany

D3.3

Experimental regenerator refractory studies

1
1
2 1
Stef Lessmann , AnneJans Faber , Rongxing Bei , CelSian Glass and Solar, Eindhoven,
2
the Netherlands, RHI Refractories, Wiesbaden, Germany

D3.4

TC11/TC14 RRT Blistering behavior of fused cast Materials at glass contact.

1
2
3
4
5
Detlef Koepsel , Michael Dunkl , Stefano Ceola , Mustafa Oran , Noriyuki Yoshida
1
2
3
4
Schott AG (Germany), Dunkl Consulting (Germany), SSV (Italy), Sisecam (Turkey),
5
NEG (Japan)

13.50 - 16.20

Session: D4 Glass quality (TC14 & TC18),

D4.1

Formation of sulfur deposits in bubbles

1
2
3
4
Detlef Koepsel , John Buckett , Marie-Hlene Chopinet , Martin Gaber , Jaroslav
5
6
7
Klouek , Stefano Maurina , Mustafa Oran
1
2
3
4
Schott AG (Germany), NSG/Pilkington (UK), St.Gobain (France), BAM (Germany),
5
6
7
8
9
ICT (Czech Republic), SSV (Italy), Sisecam (Turkey), LUH (Germany), NEG (Japan)

D4.2

TC14 activities on water measurement in technical glass

Jan Hermans, Philips Lighting, Winschoten, The Netherlands

D4.3

Diagnostic determination of bubble defects in float glass furnaces

Mustafa Oran, A. Otken, iecam, Istanbul, Turkey

D4.4

Replacement of calcined lime in the place of limestone in a container glass batch

B. Arslan, H. Sesigur, M. Orhon, iecam, Istanbul, Turkey

D4.5

The processes controlling glass melting

L. Nmec, J. Klouek, M. Jebav, P. Cincibusov
Laboratory of Inorganic Materials, Joint Workplace of the Institute of Chemical Technology,
Prague, Czech Republic

Chair: Michael Dunkl

Chair: Detlef Kpsel & Jaroslav Klouzek

15

Friday 12th April, 2013

8.30 12.15

Session V5 & V6: Glass Furnace Design & Operation (TC15, TC21)
Chairs: Erik Muijsenberg, Wilfried Linz

SENSORS & OPERATION (TC15) Session V5

V5.1

Controls and Sensors for Glass Melting: A Look Backwards and Forward
Aaron M. Huber, Ph.D., Johns Manville Technical Center, Littleton, Colorado USA

V5.2

Electrochemical sensors for high temperature application in mass glass production:

available techniques, possibilities and limitations,
Hayo Mller-Simon, HVG-DGG, Offenbach, Germany

V5.3

In-line oxygen sensors for the glass melt and the tin bath
Paul Laimbck, Read-Ox & Consultancy B.V., Valkenswaard, the Netherlands

V5.4

Performance Optimization of Electrical Boosting in a U-Flame Container Glass Furnace

Andries Habraken, M. Rongen, CelSian Glass and Solar, Eindhoven, NL

V5.5

Real time visualization of temperatures and mass flows in the full 3D volume of a glass
melter tank by soft sensors
Piet van Santen, Anton Koenraads, Heike Gramberg, CelSian Glass & Solar BV,
Eindhoven, the Netherlands

GLASS MELTING MODELLING (TC21) Session V6

V6.1

ICG TC21 Modeling of Glass Melting Processes

How reliable and validated simulation tools can help to improve glass melting efficiency
and productivity
Erik Muijsenberg, Glass Service, Vsetin, Czech Republic

V6.2

Future Applications of CFD Modeling of Glass Furnaces

Adriaan Lankhorst, CelSian Glass and Solar, Eindhoven, the Netherlands

V6.3

Mathematical Modelling Analysis of Increasing Furnace Performance with Improvements

in Design & Operation
L. nsel, Z. Eltutar, S. zel Ucar, iecam, Istanbul, Turkey

13.15 - 14.55

Session V7 Glass forming (TC25)

Chair: Adnan Karadag

GLASS FORMING & GLASS PRODUCTS (TC25)

V7.0

Short introduction
Adnan Karadag, iecam, Istanbul, Turkey

V7.1

Short review of TC25 activities in period 2000 till 2010

Christopher Berndhuser, Schott AG, Mainz, Germany

V7.2

Glass Forming Simulation in 3-D for container glass industry

Alfons Moeller, Nogrid GmbH, Bodenheim, Germany

V7.3

Tin and iron concentration profiles at float glass surfaces CANCELLED

David Gelder of Math for Manufactures, UK

V7.4

Finite Element Analysis of container's geometry

Alberto D'Este, Mirko Silvestri, Roberto Dall'Igna
Stazione Sperimental del Vetro, Via Briati 10, Murano-Venice, Italy

16

Collection of Abstracts

ICG - GlassTrend
COLLECTION OF RECEIVED ABSTRACTS
INNOVATION IN GLASS PRODUCTION
10.-12. April 2013
Eindhoven

17

W1.1. Hardglass An innovative technology for container glass production

G. Lubitz
Vetroconsult/VetropackBlach, Switzerland
guenter.lubitz@vetroconsult.ch

For centuries container glass has continued to be a traditional and familiar packaging material.
The main favorable product properties are clarity, inertness, gas-tightness, taste preservation,
environmental integrity, and 100% unlimited recyclability. However, weight and fragility still offer
opportunities for improvement, but each are dependent on the other. Clearly, glass strength
increase is a prerequisite to achieving further weight reductions. This presentation describes an
innovative approach to reach these targets and to take a remarkable step forward in container
glass production.
The technology to significantly increase container glass strength is a tempering process which
has been successfully applied in the flat glass and tableware industry. Emhart Glass is
conducting a project called Hardglass to develop a reliable industrial application for the thermal
strengthening of bottles and jars and is currently operating an initial installation at its Research
Centre in Windsor, Connecticut. Several types of glass containers have been thermally
strengthened and test results have shown a significant increase of resistance to internal
pressure, impact, thermo shock, and vertical load, and excellent drop test results.
Now, Emhart Glass and Vetropack have decided to work together and to commercialize the
Hardglass process for industrial production conditions. A pilot line will go into operation at the
beginning of 2013 at Vetropacks Pchlarn plant in Austria. This presentation describes the
Hardglass process and shows results from the initial trials at Emhart.
In summary, Hardglass is an effective new technology for increasing strength and producing a
more robust glass container. It offers considerable benefits to fillers and consumers, including
reduced weight, a smaller carbon footprint and enhanced durability. We believe that this
technology is an industry milestone that over time promises to become the industry standard.
Keywords: tempered glass, glass strength, CO2 footprint, light-weight containers, internal
pressure, vertical load resistance, impact resistance, thermo shock.

18

W1.2. From glass waste to glass foam, a path for sustainable reuse of natural
resources
Dr. Arjen Steiner
Schaumglas Global Consulting GmbH
Josef-Bechold-Str. 31, D- 97299 Zell am Main, Germany
a.steiner@sgg-consulting.com

The recycling of waste glass is important for sustainable reuse of our natural resources.
Recycling of waste glass produces material streams that, until lately, had no significant field of
application. They are mostly dumped. Foam glass from waste glass is an ecology minded and
environmentally friendly product with sales to the construction industry of more than 700.000 m 3
in Germany, Switzerland and Austria
Waste glass with impurities, e.g. CSP > 5%, which cannot be reused in the container or fiber
glass industry can be used to produce foam glass gravel. The glass must be transferred to a
powder with 90% <100m and a d50=40m. The powder is then mixed with solid or liquid
foaming agents, depending on the process and the final application and heated treated in a
tunnel kiln having a defined heat profile. The endless produced foam ribbon breaks into pieces
by thermal shock after the kiln and the final product can be stored outside without any specific
protection.
The material is mainly use for heat and sound insulation as well as road construction.
Other fields of applications are landscaping and gardening.
In addition to the gravel material also foam glass blocks can be produced, however because of
the nature of the recycling glass, showing alterations in glass composition and impurities, the
quality of the blocks is not comparable to existing foam block qualities.
Keywords: foam glass, heat insulation, road construction, sound insulation, glass powder,
foaming agents, recycling glass waste

19

W1.3. Gaps in Glass Melting Technology what are we searching for?

& Energy Efficiency in Glass Melting
Ruud Beerkens,
CelSian Glass and Solar, Eindhoven, the Netherlands
ruud.beerkens@celsian.nl
Analysis of industrial glass production shows that commonly used technologies to melt glass, &
to shape glass articles or products from this melt, could be potentially improved with respect to:

Process control to be able to fabricate glass with high production yield, low reject and
within tight product specifications;

Emissions, to lower environmental impact of glass production especially in the glass

melting process. It includes primary measures and secondary measures. In several
countries, specific emissions of dust, NOx and SOx have been decreased by 65-75 %
over the last 20-25 years. Further, decreases in emissions, e.g. by better combustion
systems and process control are expected. Primary measures are preferred above
secondary measures.

Flexibility, the market asks for various different products and glass industries have to
address and respond swiftly and quick on changing market requests. Many glass
production systems are directed on large scale production and product, glass
composition and glass colour changes both needs longer transition times and
consequently produces waste glass during such transition without a market for it.

Energy efficiency; although glass melting (typically responsible for 40-85 % of total
energy demand for glass production) processes have become much more energy
efficient, especially in the container glass sector in the last 100 years, there is still a
potential for energy efficiency improvement. Parallel to that CO 2 emission reduction can
be achieved. For example, the recent energy efficiency benchmarks show that the
average container glass furnace typically consumes 20-22 % more energy than the best
practice. Even without revolutionary glass melter design and process changes, there is
on average this 20 % energy efficiency improvement potential. Most energy input in
glass melting is lost by flue gas heat contents. Energy Modelling studies show that for
container glass production, including partial recovery of energy from flue gases, energy
consumption of 2,9 3,6 GJ/ton molten glass, depending on cullet% is possible.

Analysing conventional glass melting processes we can observe some weak points or
issues that should be more intensively addressed:
Poor control of the melting history in a melting tank, by badly controlled flow patterns
of the melt in the glass melting tank.
Variable input in the furnace by the batch, chemistry is not controlled or even not
known, due to variations in cullet quality and cullet composition.
Heat transfer to the batch is strongly dependent on glass melt flows, bringing refined
hot glass to the batch blanket for supplying the required energy for batch melting.
This recirculation flow leads to wide residence time distributions and long average
residence times in the melters.
20

Non-expected or non-predictable outbreaks of glass defects are occurring frequently

and disturb glass production. Often the sources or cause of these production
problems are poorly understood. Relationships between glass defect characteristics
and causes of such defects need to be further explored.
The control of temperature and position/orientation of a gob entering the blank mold
is poor. Temperature distributions of gobs arriving in the moulds is asymmetric and
gobs may not fall exactly vertically and centric in the parison mould. This leads to
glass distribution differences (glass thickness differences) and limits the possibilities
for reduction of glass mass in hollow glassware.
In the combustion processes, which are strongly turbulent and not steady, locally
and temporarily conditions exist with high temperatures, nitrogen and oxygen at the
same time and place. This leads to NO formation. Modelling studies and new
burners and combustion control systems have been developed and are still in
development to obtain conditions of high heat transfer intensity and lower level of
NOx formation.
Glass industries are rather competitive and are reluctant in sharing R&D results and innovative
technologies. However, technological tools can be developed to support glass companies in
further developing technologies for energy efficient, low emissions, high quality and flexible glass
production. Among these tools, we count for example:
Computational Fluid Dynamic models (glass furnace simulation models) to optimize
furnace design and to determine furnace settings that give best results.
Energy balance modelling for designing insulation, regenerators and to identify potential
energy savings.
Laboratory and pilot test facilities to test new raw materials and batches for improved
melting and fining, at conditions simulating industrial circumstances.
Sensors in combination with advanced process control, to stabilize throat, canal, gob
temperatures or sensors to measure oxidation state and (indirectly) glass colour in the
melter of feeder systems. Sensors for combustion control are currently in development,
e.g. for in-situ monitoring in exhaust gas or combustion space: CO, O2, NO contents.
Optical systems to monitor the gob size, gob position and gob orientation and even to
detect glass defects or glass distribution problems in the just formed glass containers (e.g.
using IR cameras).
Systems that can recover the energy contents in flue gases in a cost-effective ways,
examples are batch/cullet preheating, application of TCR (Thermo Chemical
Recuperation), gas and oxygen preheating, batch pelletizing and pellet preheating.
Development of new high-duty refractory materials or refractory metals or combinations
thereof.
This presentation will give some examples of innovative technologies that help glass
industries to further improve their performance and will identify gaps in our understanding of
the complexity of converting raw materials finally in homogeneous high quality glass
products at lowest costs and energy demand.
Keywords: innovation, glass melting, energy efficiency, technological tools, environment,
product quality, production flexibility, troubleshooting, process control, modelling, sensors.

21

Duo-Paper from glass manufacturers on needs for R and D in the glass industry
for the next 10 to 15 years
Roland Langfeld, Schott AG, Mainz, Germany
& Jaap van der Woude, PPG Fibre Glass, Hoogezand, Netherlands

W1.4. Needs for R&D in the glass industry: perspective of a specialty glass
manufacturer
R. Langfeld, H. Rmer
SCHOTT AG, Mainz, Germany
roland.langfeld@schott.com, hildegard.roemer@schott.com

The main drivers for innovation in glass industry are costs and quality. Glass making is capital
intensive, main cost drivers are energy and raw materials. These challenges together with a
further increasing demand for higher product quality in a globally competitive environment, and
the threat of substitution by other materials can only be met by innovation.
Specialty glass industry has additional boundary conditions which require specific attention in
R&D compared to soda lime glass production:
- higher melting and refining temperatures;
- broader variety of raw materials;
- broader range of tank-size, melting and hot-forming technologies;
- refractory material limitations and cooling limitations;
- slower reaction rates for melting and especially for (re)fining;
- significantly higher demands to glass quality in terms of homogeneity and freedom of
solid inclusions and gaseous inclusions
The direction for R&D is clear, improvements on the material side and on the process side have
to be made:
- Improved/new glass compositions to reduce costs, to improve glass quality, and to
enable new applications;
- Substitution of rare and/or costly raw materials;
- Reduction of energy costs in glass melting and post processing;
- Preparing for ever increasing environmental concerns;
- Improved/new melting technologies for optimized tank lifetime and flexibility;
- Improved sensors and controls;
- Better multi-scale simulation tools to support material and process development;
- Finding new applications for glass.
Specific examples for R&D requirements will be given. Any kind of innovation will only find its
way into industrial practice if stringent economic criteria are fulfilled. New glass compositions,
melting technologies, or production processes must not increase production costs !
Keywords: specialty glass, R&D requirements.

22

W1.5. NL Roadmap 2030.

Is 50% Energy Efficiency Improvement in Glass Product/Production Chain
Feasible?
J.H.A. van der Woude
PPG Industries Fiber Glass bv
vanderwoude@ppg.com

The Glass Industry in the Netherlands is diverse, including production of: container, tableware,
flat, insulation and continuous glass fiber as well as specialty glass. Over the last 20 years, the
industry as a total has improved its energy efficiency in joint programs under long term
agreements with the government between 20 and 25% and the Dutch glass manufacturers are
among the most efficient glass producing industries globally. This includes the fact that the
industry operates under a strict environmental regime and high glass quality standards. A new
national (Dutch) covenant (voluntary agreement), specific for companies under EU-ETS has set
new targets for energy efficiency for 2030. To achieve this, the NL glass industry has selected
focus areas that allow effective joint cooperation in order to meet energy efficiency improvement
objectives i.e. by optimization of production processes, strengthening the sustainability of the
product chain and improvement of innovation power. Each segment was thoroughly analyzed as
to its potential and technical viability for short, mid and longer term. Actionable initiatives were
formulated like workshops, technical programs, co-operations, need for better agreements on
recycling and recycling technologies as well as initiatives to maintain up to date know how to
allow integration of developments abroad. It was concluded that 50 % energy efficiency
improvement until 2030 may not be achievable, but that substantial improvements are still
possible based on both evolutionary and longer term revolutionary developments.
In this paper, the NL Roadmap 2030 for the glass industry and its targeted results will be
reviewed in more detail. It will be clarified how the industry will improve energy efficiency of
production and energy efficient use of our glass products. It will be demonstrated that
cooperation, both national and international, with suppliers, research institutes, other glass
producers and government is essential to guarantee that glass products are the effective
solution for a sustainable future of our society.
Keywords: energy efficiency, roadmap, Netherlands, glass industry, recycling, process
optimization, production chain, innovation, education

23

D2.1. An introduction to the work of ICG-TC13, with reference to practical studies

and recent environmental legislation.
Simon Slade, Pilkington NSG, UK
Simon.Slade@nsg.com

TC13 is the ICGs environmental technical committee. Its members are drawn from
industry, consultant bodies, research institutes and academia from around the world.
The presentation will explain the range of subjects covered by TC13 with particular reference to
some of its active areas of work driven by the diverse environmental legislation currently
affecting glass-makers. For example, legislation affecting the use of chemicals such as the
European REACH regulation has driven much of the practical studies conducted by TC13 in
recent years. Other work has focussed on emission control technology; both considering the
potential of new techniques and assessing the effectiveness of established abatement
technology and characterisation of emission by flue gases.
Keywords: glass production, emissions, environment, air pollution control, REACH, flue gas,
emission measurements

24

D2.2. Operating experience of the ceramic candle waste gas filter in the glass
industry
- Air Pollution Control in Glass Industry, a System for DeNOx, DeSOx & filtration Denis Lalart, Etienne Snchal, Arc international, Arques France;
denis.lalart@arc-intl.com
Hugues Abensour, Saint-Gobain Conceptions Verrires, Aubervilliers, France &
Andreas Kasper, Saint-Gobain Sekurit, Herzogenrath, Germany

A new type of air pollution control system (APC) has appeared on the market in the recent
period. Equipped with ceramic catalytic filtration candles, this technology is able to treat acid
gases, dust, heavy metals and NOx in one single unit. Since 2010, two catalytic ceramic filters
are in operation in the glass industry in Europe: one in float glass production, and the other in
the domestic glass sector for the production of soda-lime-silica glass. End of 2012, another
application of the same kind of technology has been done in the US, and some others are at
project phase.
The first results obtained are good, in terms of observed low emissions. But the practical side,
both in technical and economical point of view, has also to be considered. Our conclusion is that
the technology is promising, but has still to be considered as emerging, its technical and
economical assessment being possible only after a full campaign.
Keywords: ceramic candle filters, DeNOx, scrubbing, filtration, air pollution control, glass furnace

25

D2.3. Evaporation from glass melts boron and selenium species

Hans van Limpt, CelSian Glass and Solar, Eindhoven, the Netherlands
hans.vanlimpt@celsian.nl

Glass melts in industrial glass furnaces often contain intentionally added volatile components or
may contain impurities, originating from cullet or some type of raw materials. CelSian developed
dedicated laboratory equipment to simulate evaporation processes from model glass melt
compositions and industrial glass compositions. In this laboratory scale set-up, the effect of:
glass composition,
impurities in the used batch materials,
furnace atmosphere, temperature and
gas flow intensity,
on the evaporation of several components can be studied.
Information about the mechanisms of evaporation from batch and melt and the impact of
different operational parameters, such as temperature, gas atmosphere, glass composition will
help glass companies to select raw materials and to develop new batch recipes that show less
evaporation losses of expensive raw materials such as selenium and boron carriers.
Evaporation studies can be very supportive to find the relevant evaporation reactions and
mechanisms and ways to limit losses during glass melting processes. The studies provide data
for modeling the kinetics of evaporation processes in industrial glass furnaces.
Selenium and boron evaporation from the melting-in batch and from the molten glass can be
measured dependent on the type of selenium and boron raw materials used.
Studies showed that evaporation of boron species very much depend on the glass composition
and water vapor pressure above the molten glass. The boron evaporation loss behavior appears
to be far from proportional with boron oxide content of the glass. Increased boron losses start
above a certain threshold concentration level in the glass.
Selenium evaporation depends strongly on the type of selenium raw material and the kinetics of
batch melting.
Keywords: evaporation, simulation studies, furnace atmosphere, raw material selection,
selenium, boron species, evaporation mechanism.

26

D2.4. NOx control on the basis of in-line CO & O2 laser sensors

Marco van Kersbergen, AnneJans Faber, Dung Do Dang (NEO)
CelkSian Glass and Solar, Eindhoven, The Netherlands
anne-jans.faber@celsian.nl
In-situ measuring of oxygen and CO content of the exhaust gases of the glass furnace by
absorption of laser beams at specific wavelengths by a flue gas flow has been demonstrated.
The average CO and O2 concentration over the width of a flue gas channel or burner port can be
measured continuously by this optical method and shows very good agreement with other offline methods.
The presentation shows the applications for end-port fired and oxygen-natural gas fired
container glass furnaces. Applications for exhaust gas temperatures up to 1500 oC are possible.
Depending on the refractory material used in the flue system and regenerators, a certain CO setpoint can be applied for controlling the air-fuel ratio in the combustion process continuously with
acceptable CO levels, low residual oxygen content and minimizing NOx formation.
Tests with industrial glass furnaces show that combustion control based on in-situ monitoring the
CO and oxygen content of the exhaust gas in the burner port (regenerative furnaces) of flue
channel (oxygen fired furnace) allows NOx emissions of container glass furnaces below 0,75
kg/ton molten glass, depending on acceptable CO concentration level. This acceptable level
depends on the types and quality of refractory materials in the regenerators.
The advantage of CO-sensoring is that it offers a very sensitive method for accurately tuning the
air excess (more sensitive than oxygen sensoring) in a combustion process. In combination with
oxygen concentration measurement, the CO level is an indication for bad mixing in case of high
O2 and high CO levels at the same time.
Energy and oxygen savings are possible by the use of the CO and O2 sensor system in
combination with combustion air - fuel (natural gas or fuel oil) volume ratio control.
Keywords: CO sensor, O2 sensor, laser beams, NOx reduction, combustion control, regenerator
refractory, energy savings, oxygen savings

27

D2.5. Problems, Developments and Energy Performances of Glass Melting

Furnaces
Atilla Unsal1,a Levent Kaya1,b Bar Orhan1,c
1
SISECAM Melting Technologies and Engineering Directoriate, Is Kuleleri Kule No: 3, 4. Levent,
34330 stanbul, Turkey
a
aunsal@sisecam.com, blkaya@sisecam.com, cborhan@sisecam.com

This paper covers the experiences of the authors based on the studies and developments made
within the company over the years. Improvements on furnace design have always been a major
issue. Developments have been achieved by driving forces like requirements for higher glass
quality, different products, and increased number of product changes, energy efficiencies, lower
investments and environmental challenges.
Although in the glass world today, there are studies and projects to develop different radical
melting techniques, like plasma melting, submerged combustion, segmented melter and vacuum
refiners being the most promising among the many, the progress going from pilot to full scale is
slow and not all the glass manufacturers are giving many funds to support these projects. On
one hand the conventional furnace technology is quite mature and energy performances of the
most energy efficient furnaces [1] and pull rates are approaching near to the limits, there are still
differences between the energy consumptions, pull rates and life of furnaces in glass industry
today. Many small steps can be taken at different areas like optimizing furnace design criteria,
refractory selection, use of additional equipment, development of sensors to control the
operating parameters, better combustion equipment and, advanced control systems.
These all add to continuous incremental developments for each project and give us opportunity
to progress with feedback from onsite applications to target to be within the best performing
furnaces.
Keywords: Furnace design, Melting, Energy Efficiency, Environment, Refractory, Process
Optimization

28

D3.1. Recommended Test Methods of the TC11 for Refractories

Dipl.-Ing. B. Fleischmann,Httentechnische Vereinigung der Deutschen Glasindsutrie e.V.
(HVG), Offenbach am Main, Germany
fleischmann@hvg-dgg.de

In the last three decades the TC11 elaborated different testing methods for refractories and
carried out round robin tests to validate them amongst other activities. As a result of this work
the following test methods are recommended by TC11:
rotating cylinder face area to investigate the forced convection (throat)
static plate corrosion test to investigate the convection due to density variation
static plate corrosion test to investigate the metal line corrosion and the glass defect
potential of the refractories
dynamic blister test to investigate the seed potential on the boundary refractory/glass
melt
exudation to investigate the exudation behavior of fused cast AZS
The mode of operation of the different methods as well as sample preparation will be introduced
and the conclusions for the choice of refractories as well as the corrosion behavior during the
furnace campaign will be presented.
Keywords: TC11, tank refractory, glass melt, static test, dynamic test, blistering, metal line
corrosion, exudation test, forced convection, free convection, sample preparation, corrosion
behavior

29

D3.2. Refractory solutions for the new challenges in glass furnace construction
Stefan Postrach, Rongxing Bei, RHI GLAS GmbH, Wiesbaden, Germany
stefan.postrach@rhi-ag.com

As a result of the ongoing tendency to reduce the energy consumption in the glass production
process, the operation conditions, for the already highly stressed refractory materials, further
worsen. Especially, the superstructure is affected as strong insulation decreases the thermal
gradient within the refractories. Also new techniques, for example for batch pre-heating, are
changing the conditions of batch carry-over and therefore change to a more corrosive
environment.
In this presentation, the influence of energy saving measurements on refractory materials in
glass furnaces will be discussed. Important material characteristics will be presented.
Keywords: refractory corrosion, LowNOx, carry/over, insulation, furnace lifetime

30

D3.4. Experimental regenerator refractory studies

Stef Lessmann1, AnneJans Faber1, Rongxing Bei2
CelSian Glass and Solar, Eindhoven, the Netherlands
2
RHI Refractories, Wiesbaden, Germany
stef.lessmann@celsian.nl

Clogging of the regenerator checkers and corrosion of the regenerator refractories are common
problems in the glass industry. This paper is focused on simulating the refractory corrosion
process of regenerator checkers of container glass furnaces by sodium vapors combined with
sulfur dioxide at different conditions (temperature, oxygen excess, concentration levels, types of
refractory).
In this presentation the dedicated laboratory equipment for testing (candidate) regenerator
checker refractory materials will be described.
The set-up of the experiment is a combustion chamber connected (downstream) to a laboratory
scale tube furnace. The gases used for the flame inside the combustion space are adjustable
(natural gas with air or oxygen) and are generally set to normal oxidizing conditions. But also
near stoichiometric or slightly reduced conditions can be set.
Inside the tube furnace a temperature gradient is formed by the heat of the incoming combustion
gases. The refractory samples, to be investigated, are placed inside the tube furnace over a
temperature range with flue gas cooling from about 1000 - 650C (corresponding to the
condensation zone inside the regenerator). A sodium hydroxide solution is injected inside the
flame, resulting in sodium vapors inside the system. Sulfur dioxide is injected near the
connection point of the combustion space and the tube furnace. These two components create
an atmosphere inside the tube furnace rich in SO2 (high temperature) and sodium sulfate
(formed at low temperature from sodium vapors and SO2). These concentrations are much
higher than in an industrial regenerator. The test conditions are more severe to approach long
time duration behavior of the refractory exposed to these vapors and condensation products.
After exposure to the corrosive components the samples are tested on weight gain and are
analyzed with SEM/EDX to check the depth of the corrosion process. Mechanical strength and
porosity can be tested also.
Experimenting with different refractory materials will show the best resistant checkers to these
conditions. Other corrosive agents can be used to check the resistance of the refractory
materials under various conditions.
Keywords: regenerators, refractory attack, glass melt vapors, condensation, refractory selection,
simulated flue gases

31

D3.5. TC11/TC14 RRT Blistering behavior of fused cast materials at glass contact.
Detlef Koepsel1, Michael Dunkl2, Stefano Ceola3, Mustafa Oran4, Noriyuki Yoshida5
1

SchottAG (Germany), 2 Dunkl Consulting (Germany), 3 SSV (Italy), 4 Sisecam (Turkey), 5 NEG
(Japan)

The Technical Committee 14 of the International Commission on Glass has been working on
refractory blisters for the last 6 years.
Although the work on refractory blisters has not been finished yet, an overview on mechanisms of
blister formation at AZS materials including the resulting gas compositions of newly formed blisters,
the relationship with structure and typical impurities of AZS material is presented.
This work has been undertaken in close collaboration with TC 2 (chemical durability & analysis)
and TC 11 (refractory materials).
Keywords: refractory blisters, impurities, glass melt refractory interface, testing methods, fused
cast material, TC14, TC11

32

D4.1. Formation of sulphur deposits in bubbles

Detlef Koepsel1, John Buckett2, Marie-Hlene Chopinet3, Martin Gaber4, Jaroslav Klouek5,
Stefano Maurina6, Mustafa Oran7
1

Schott AG (Germany), 2 NSG/Pilkington (UK), 3 St.Gobain (France), 4 BAM (Germany),

ICT (Czech Republic), 6 SSV (Italy), 7 Sisecam (Turkey), 8 LUH (Germany), 9 NEG (Japan)

In the past the Technical Committee 14 has undertaken investigations to understand the origin of
so-called sulphur deposits observed in bubbles of many glasses, e.g. in soda-lime-silicate glasses
and borosilicate glasses. These deposits usually consist of either sulphur (S8) or alkali sulphates at
25C. In some rare cases not solid, but liquid deposits are found consisting of H2SO4.
In a few cases, the blisters contain only deposits and no other gases (vacuoles), in other cases
they contain deposits together with gases such as N2, Ar, CO2, SO2, H2S, COS.
These bubble deposits are observed in glasses melted under both, oxidizing and reducing
conditions, but their compositions may be different.
The formation mechanisms of these deposits are explained and a mathematical model is
presented which can predict the formation of such deposits in a bubble during cooling of the glass
from working temperature to annealing temperature.
Keywords: glass melt fining, sulphur species, sulphur deposit, sodium sulfate, bubble composition,
formation of bubbles, sulphur chemistry, vaccum bubbles, gases, bubble sources

33

D4.2. TC14 activities on water measurement in technical glass

Jan Hermans, Philips Lighting, Winschoten, The Netherlands
j.hermans@philips.com

Water is one of the key components when studying dissolved gases in glass. Its influence on
glass properties, evaporation, infrared absorption and exchange with the atmosphere is well
known.
In the past 10 years, the TC14 committee has studied the properties and measurement methods
for dissolved water in glass. Measurement methods have included infrared spectrometry and
nuclear reaction analysis (NRA).
A standard set of samples (float glass from Pilkington, now NSG) was collected, and measured
by several laboratories. From this study, also a TC14 recommended method for measurement of
water in glass was derived and published. The results have been discussed in the meetings of
the TC14 committee and also in the forums on water in glass, organized by TC14.
Besides normal soda-lime glass, the TC14 study extends to CRT panel glass (a complex
barium/strontium glass), borosilicate glass and quartz glass.
The presentation for this workshop will give an overview of these TC14 studies on water in
glass.
Keywords: water in glass, infrared spectroscopy, nuclear reaction analysis (NRA), TC14, glass
properties

34

D4.3. Diagnostic Determination of Bubble Defects in Float Furnaces

Mustafa Oran and Ali Otken
SISECAM, Glass Research Center
moran@sisecam.com

Bubble defects are one of the major glass defect types for float glass as well as in all other glass
production processes. The quality of a float glass product is mostly degraded if the gas bubbles
remain in the molten glass as it is being pulled of the furnace. The new quality standards require
lower number and smaller sizes of bubbles in the float ribbon, especially for automotive, mirror
and other glass products requiring more transparency. Beside the bubbles remaining in the
glass melt due to poor melting/fining conditions, another major source for the bubble defect is
the de-vitrification phenomena in the float furnaces. Devitrification of a glass means that some of
molten glass has crystallized at a limiting temperature during some time. Tiny bubbles are
created in the colder zones of the furnace when crystalline material so-called devit is re/melted
unintentionally due to the furnace operations.
This paper reviews the investigations on the determination of major bubble sources in float
process, containing a statistical study for the classification of bubbles based on mass
spectrometric analysis. Diagnostic activities to support the removal of the bubble defects using
the data of furnace operations are also summarized in the paper.
Keywords: bubble analysis, bubble types, bubble composition, bubble origin, devitrification, float
glass quality

35

D4.4. Replacement of calcined lime in the place of limestone

in a container batch
Banu Arslan, Hande Sesigr, Melek Orhon
Glass Research Center, SISECAM
HSENGEL@sisecam.com

Calcination is a thermal treatment process in the presence of air applied to ores and other solid
materials to bring about a thermal decomposition, phase transition, or removal of a volatile
fraction. Calcined lime is produced from limestone by heating to 1100oC, forming calcium
oxide (quick lime) and carbon dioxide.
Calcined lime which can be a by-poduct of carbon dioxide production in order to be used in other
fields, is increasingly becoming known as a beneficial calcium oxide source in glass industry,
due to its ability to reduce energy consumption during melting via decreasing melting
temperatures and to reduce CO2 emissions.
Details of an industrial trial of calcined lime in a green container furnace at Sisecams Yeniehir
plant are presented. Calcined lime was introduced to a 400 tpd furnace with electrical boosting,
in 25% portions up to 100% of the limestone weight, replacing limestone as the calcium source
in the batch, resulting in reduction in energy costs.
The introduction of calcined lime drastically improved the melting behavior of the batch with no
extra energy requirement for the decomposition of limestone. During the trial furnace bottom
temperatures increased, allowing a 15% reduction in electrical energy consumption. In addition,
the natural gas consumption decreased by 3%, resulting in a 3.5% reduction in the total energy
consumption. A decrease in CO2 emission to 11% below the previous furnace emission was
obtained.
Besides these positive achievements, some disadvantages were also observed. Dust formation
at the doghouse and the adhesion of batch due to the exothermic hydrolysis reaction of the CaO
were the two main problems. Other than them, batch costs became higher and it had minimal
effect on glass color parameters during the trial.
Keywords: calcination, quick lime, energy efficiency, melting behavior, batch costs, batch
behavior

36

D4.5. The processes controlling glass melting

Lubomr Nmec, Jaroslav Klouek, Marcela Jebav, Petra Cincibusov
Laboratory of Inorganic Materials, Joint Workplace of the Institute of Chemical Technology
Prague, Technick 5, 166 28 Prague 6 & Institute of Rock Structure and Mechanics ASCR, v.v.i.,
Holeovikch 41, 182 09 Prague 8, Czech Republic
Lubomir.Nemec@vscht.cz

Glass melting is a complex phenomenon including several homogenization processes. In the

continuous melting operation, the batch conversion runs in series with mostly parallel processes
occurring in the melt, dissolution of solid with liquid inhomogeneities and bubble removal. Two
aspects play a significant role in the energy consumption and melting performance of glass
melting, the process kinetics and utilization of the space.
The separated batch conversion area is characterized by the optimal area utilization for the
process and the set up beneficial thermodynamic conditions open a way for the rapid conversion
kinetics if the batch conversion is the controlling process. In addition, the capacity increase of
the conversion area by its rational enlargement can prevent from melting control by batch
conversion.
The impact of process kinetics and space utilization on the energy consumption and melting
performance in the melt can be separately defined for each process and the critical aspect of the
melting can be thus defined in detail. The utilization of the space, resulting from the character of
melt flow, becomes frequently the controlling process of glass melting. The uniform melt flow or
controlled melt circulations (helical flow) lead to the high space utilization in horizontal melting
spaces, but the beneficial circulations cannot be practically set up in the spaces with the main
vertical flow. The beneficial melt flows show similar features for both dissolution and bubble
removal process. The uniform flow is sensible to small changes of temperature, whereas the
helical flow character is more stable. But, the optimal value of the space utilization in the space
with circulations depends on the mutual and absolute intensities of transversal and longitudinal
melt circulations, the process kinetics and the length of the space. If bubble nucleation occurs,
the dissolution and removal of nucleated bubbles are in series and share in the process control
at the above-mentioned efficient melt flow conditions.
The optimal natural circulation flows enhance dissolution kinetics owing to temperature
equalization in the space and melt convection with high velocity gradients. The application of
forced convection would enhance the dissolution kinetics but the space utilization may become
the critical aspect of melting. The kinetics of the bubble removal process can be expressed by
the bubble growth due to chemical reaction releasing a gas in the melt. The long and intensive
bubble growth in the period from accomplishing dissolution till the end of the bubble removal is
desirable to optimize and control bubble removal.
The definition of controlling processes helps to intensify the melting process in its weak point.
Keywords: flow patterns, space utilization, melting kinetics, fining, bubbles, forced convection,
free convection, helical flow, residence time

37

V5.1. Controls and Sensors for Glass Melting: A Look Backwards and Forward
Aaron M. Huber, Ph.D., Johns Manville Technical Center, Littleton, Colorado USA
Aaron.Huber@jm.com

Glass has existed as a manufactured product for over 5,000 years and it has been a continuous
effort to improve the glass making process. Control schemes and sensors to provide feedback
for control are crucial to effective and efficient glass manufacturing. A general overview of
control schemes will be discussed from the authors experience over the past 24 years in the
glass industry along with future possibilities.
One of the limits of control systems is sensors. A general overview of sensors and some of the
issues and needs will therefore be covered. Application examples of control and sensor
performance and related issues will be presented.
Keywords: glass melting control, sensor for glass furnaces, thermocouples, process control

38

V5.2. Electrochemical sensors for high temperature application in mass glass

production: available techniques, possibilities and limitations
Hayo Mller-Simon, HVG-DGG, Offenbach, Germany
mueller-simon@hvg-dgg.de

The prevailing glass melting process is highly effective with respect to economy as well as
ecology. As such it requires real-time information about important process parameters like partial
pressures or concentrations of critical components in melts, for instance sulfur which is
commonly used as a refining agent during melting. But, sulfur species are simultaneously
unwanted components of the emitted waste gases of the melting process or in the protective gas
of float chambers. Some of this information (concentrations in melts or gases) can be achieved
even at high process temperature by means of electrochemical sensors. In recent years
electrochemical sensors became increasingly available for that purpose.
Applications in gases and melts will be demonstrated for the float glass and container glass
production.
The different working modes - potentiometric or amperometric -, signal reliabilities, control
properties, corrosion behavior and lifetime will be discussed.
Keywords: polyvalent ions, electrochemical sensors, oxygen activity, sensor robustness, glass
melt, tin melt, flue gases, sulfur

39

V5.3. In-line oxygen sensors for the glass melt and the tin bath
Paul Laimbck, Read-Ox & Consultancy B.V., Valkenswaard, the Netherlands
p.laimbock@readox.com

Measurements using in-line oxygen sensors for the glass melt and tin bath (in float glass
production lines) are presented, showing the benefits of these sensors for the industrial glass
melting and glass forming process.
A small and economical disposable oxygen sensor has been developed for the continuous
measurement of the redox state of the glass melt in the feeder (container glass), forehearth
(fibre glass) or canal (float glass) using a water-cooled lance. Redox monitoring and control is
especially useful
in furnaces melting a high share of recycling cullet,
during a colour conversion or
for evaluating the redox effect/effectiveness of new batch components
The allowed redox ranges of green glasses with an amber color component, like olive green or
antique green are very narrow. The smallest variation in air/fuel ratio, COD of the recycling cullet
or even residence time in the furnace (pull) may already shift the color to green or amber.
Moreover, these colors are sensitive to over-reduction, at which the amber color component
disappears again. A daily spectrometer measurement of the glass product appears often
insufficient for necessary fast redox corrections.
Emerald green glass can be melted in a relatively large redox window, ranging from Fe2+/Fetot of
0.15 to even as high as 0.55, close to the onset of amber color formation. This is due to the
stability of the Cr3+ ion over a large redox range, responsible for the typical emerald green color.
However, the best heat transfer of the melt and the lowest seed count are obtained in the more
reduced range. An in-line sensor will help to keep the melt as reduced as possible, without
risking the formation of amber cords, even if a large share of recycling cullet is used.
Oxygen sensors are presented for the continuous monitoring of the oxygen activity of the molten
tin and atmosphere in the tin bath chamber of float glass production lines. By monitoring the
oxygen activity of the tin, oxygen related surface defects such as bloom, tin pick-up and tin
dripping can be reduced. Moreover, the effectiveness of side wall sealing activities are
optimized, as the sensors are able to detect even the smallest air leaks. By a combined
measurement of the oxygen activity of the atmosphere and the oxygen activity of the molten tin,
the driving force for de-oxidation of the tin melt can be monitored, enabling optimization of the
required hydrogen level in the gas mixture. Hydrogen consumption can be reduced without
compromising on glass quality.
Keywords: glass color, oxidation state, oxygen activity, oxygen equilibrium pressure, sensor,
color change, amber chromophore, emerald green, tin bath, tin defects, heat transfer, hydrogen
control

40

V5.4. Performance Optimization of Electrical Boosting in a U-Flame Container

Glass Furnace
Andries Habraken, Mathi Rongen, CelSian Glass and Solar, Eindhoven, NL
Andries.habraken@celsian.nl

Electrical boosting in fossil fuel-fired glass melting furnaces becomes more and more
attractive in some countries, due to the current trend in energy prices. Furthermore, by
applying boosting properly, a positive effect on glass quality and/or an increase in pull rate
can be achieved. Numerous options for electrical boosting systems exist though, such as
positioning and number of electrodes, choice of electrical circuit, grouping of electrodes and
their power. To come to an optimal electrical boosting configuration for a specific furnace and
glass type, Computational Fluid Dynamics (CFD) modeling of the entire furnace (glass melt
and combustion space), employing a sophisticated model for boosting is the key approach.
Furnace efficiency, NOx emission and furnace lifetime is monitored in the computer model to
ensure practical and optimum applicability of model results.
In this presentation we demonstrate for a U-Flame Container Glass Furnace to what extend
specific electrical boosting configurations influence important aspects of the glass melting
process, such as:

Glass product quality (melting and fining/refining behavior);

Emissions: CO2, CO, NOx, SO2(dust);

Furnace energy efficiency;

Furnace lifetime.
In a typical optimization project, a combination of laboratory experiments, furnace audits, and
computer modeling is applied to find the best solution for each unique customer. A multidisciplinary team closely works together with the customer to ensure a long lasting and easy-toimplement solution. Outcome of the project is an optimal configured electrical boosting system
using judgment criteria based on energy consumption and glass quality. A significant advantage
here is the availability of GTM-X, CelSians state-of-the-art multi-physics CFD (Computational
Fluid Dynamics) software for optimization of glass melting, combustion and forehearth
processes. Multiple systems are modeled with variations in electrode locations, electrode
orientation, boosting power, and electrode switching (transformer connections). This study is an
example from daily practice in which GTM-X is applied by CelSian and in glass industry for
trouble-shooting.
Keywords: Optimum electrode configuration, electric boosting, glass quality, energy efficiency,
CFD modeling, glass melt flows, residence time distribution.

41

V5.5. Real time visualization of temperatures and mass flows in the full 3D volume
of a glass melter tank by soft sensors
Piet van Santen1, Anton Koenraads1, Heike Gramberg1,
CelSian Glass & Solar BV, Eindhoven - The Netherlands
piet.vansanten@celsian.nl

Nowadays, Computational Fluid Dynamics (CFD) models are broadly accepted to calculate the
temperatures, mass flows and glass properties in a glass melt for the purpose of furnace design,
optimization and trouble shooting.
The CFD package GTM-X by CelSian Glass & Solar is capable of detailed, fast and accurate
simulation of the time dependent behavior of the glass melting process as well as able to cope
with complex geometrical structures. In a single effort, these models can have multiple
applications: the design and optimization of the melter or forehearth, the configuration of model
based supervisory process control systems and the design of so called soft-sensors* that are
capable to provide real-time information on local temperatures and mass flows in the melter or
forehearth.
*Soft-sensors have been given that name, because a soft-sensor does not show process values
from direct physical measurements, but through feeding a detailed 3D model with the actual
process inputs and measurements and estimating accurately the time dependent process values
(e.g. temperatures or flow or redox state) at arbitrary spots in the simulated 3D space. CFD
models for complex structures as a glass melt tank or a forehearth are too complex to run much
faster than real-time. Dedicated model reduction techniques are developed and applied to
convert the complex CFD models to much faster models without losing accuracy.
The paper gives results of the application of a soft-sensor for the real time visualization of
temperatures and mass flows in a container glass furnace. Results are shown of methods to
keep the model on track by using a limited number of physical temperatures.
Keywords: CFD modeling, model reduction, soft sensors, model-tracking, glass furnaces,
stability, furnace performance, temperature, glass melt flows.

42

V5.6. Furnace Erosion and Health Monitoring Sensor (FEHMS)

CANCELLED
Yakup Bayram1, Eric K. Walton1, Alexander C. Ruege1, Jonathan Young2, Robert Burkholder2,
Gokhan Mumcu3, Elmer Sperry4, Dan Cetnar4, Thomas Dankert5
1
PaneraTech, Inc., Columbus, OH, 2The Ohio State University, Columbus, OH
3
University of South Florida, Tampa, FL, 4Libbey Glass, Toledo, OH , 5Owens-Illinois,
Perrysburg OH
yakup.bayram@paneratech.com

PaneraTech, in collaboration with the Ohio State University, Libbey Glass, the
University of South Florida, and OwensIllinois, has recently demonstrated the feasibility of a
nondestructive sensor technology to deterministically identify furnace wall erosion, while the
furnace is operational. A key component of the sensor technology is efficient &
effective coupling and sensing of radio waves within the wall structure.
We also demonstrated that the same sensor system is capable of detecting voids and defects in
cold refractories before the installation.
Erosion of the refractory lining in glass melting furnaces is a major problem for the glass
manufacturing industry.
When erosion on the walls is not detected early enough, it may lead to molten glass, leaking
through the refractory lining & resulting in suspension of production for several weeks and
in some cases, resulting in catastrophic accidents.
Accordingly, glass manufacturers have to shut down their furnaces, based on a conservative
schedule to avoid any catastrophic molten glass leakage.
Currently, there is no technology that can deterministically measure erosion of furnace walls.
The underlying fundamentals of the Furnace Erosion & Health Monitoring Sensor, the
measurement results pertaining to the feasibility of the sensor and in-situ tests and the path
forward to an integrated sensor system for structural health monitoring of furnace walls will be
discussed.
Keywords: residual refractory thickness, sensor, refractory health monitoring, furnace lifetime,
glass furnace

43

V6.1. ICG TC21 Modeling of Glass Melting Processes

How reliable and validated simulation tools can help to improve glass melting
efficiency and productivity
Erik Muijsenberg (chair TC21), Glass Service, Vsetin, Czech Republic
erik.muijsenberg@gsl.cz
Mathematical modeling of glass furnaces started around 1965. The question is what can these
models do and how reliably are the prediction of such models? In 1990, the ICG (International
Commission on Glass) started the TC number 21 focusing on Modeling of Glass Melting
Processes. The aim of TC21 is to share and exchange current practice and to develop the theory
and application of mathematical modeling of glass furnaces. The activities of TC21 are carried
often our as round robin tests where model results of members are compared to each other and
in some case with actual measured data. A step wise validation of different components of the
models related to the whole glass furnace is undertaken. The idea is to come up with
improvements to improve the mathematical modeling of each member. The paper will show some
validation experiments carried out by several authors over the years within, but also without
TC21. These validations show a fairly good agreement between measurements and models.
Certain errors are more likely to come from unknown glass properties and boundary conditions,
than from the mathematical model itself. As example we show the error that can be caused when
we do not know the glass properties very well.
Key words: ICG, TC21, Modeling, reliability, validation, furnace optimization, glass quality,
bubbles

44

V6.2. Future applications of CFD Modeling of Glass Furnaces

A.M. Lankhorst, L. Thielen, A.F.J.A. Habraken
CelSian Glass & Solar B.V., Eindhoven, The Netherlands
adriaan.lankhorst@celsian.nl

Nowadays, in the glass industry, Computational Fluid Dynamics (CFD) simulation modeling of
the glass melting process is completely accepted as integral part of the design process,
optimization efforts and trouble-shooting of industrial glass melting furnaces. Most glass furnace
simulations today still focus on prediction of glass temperature distributions and glass flow
patterns only, although these are strongly influenced by the combustion process, supplying most
of the energy required for batch fusion and glass melt heating. Also, currently, the Rosseland
radiation transfer model often is used for clear glass melts, although for these transparent
glasses the validity and accuracy of the model is questionable. Therefore, the production of
special transparent glass types, such as low iron ultra-clear glasses for solar applications,
requires more accurate models for the radiative heat transfer in the glass melt itself.
Secondly, there is an increasing drive to increase the energy efficiency and to reduce the
emissions of glass furnaces. Most of the energy and emissions reductions are to be achieved by
improving the design of the combustion process. This typically necessitates the use of accurate
combustion, NOx formation and radiation models.
Thirdly, the efficiency of regenerators and recuperators has a large influence on the overall
energy consumption of the complete glass furnace, but it generally is too time-consuming to
completely model the glass tank, combustion space and the regenerator(s)/recuperator(s) by
detailed CFD.
For these future applications of modeling of glass melting processes, CelSian Glass & Solar
B.V., adopted a dual-track policy strategy, in which smart combinations are made between
accurate and detailed CFD models on one hand and more global macroscopic energy balance
models on the other hand.
The presentation will address this successful strategy for a variety of glass furnaces. Results will
demonstrate that by using a smart mix of models and modeling tools CFD modeling of (entire)
glass furnaces is possible and yields accurate results, also when focusing on more than glass
temperature distributions and glass flow patterns, enabling the user to improve and optimize the
production process.
Keywords: Glass Furnace, CFD Simulations, Radiation Modeling, Ultra-clear Glass, Energy
Efficiency, Energy Balances, Low NOx emissions, Combustion Chamber Design, Quality,
Minimum residence time

45

V6.3. Mathematical Modeling Analysis on Increasing Furnace Performance

with Improvements in Design and Operation
L. nsel, Z. Eltutar, S. zel Uar
lonsel@sisecam.com, zeltutar@sisecam.com, sozel@sisecam.com
Research and Technological Development Presidency
Melting Technologies and Engineering Directorate
iecam, stanbul, Turkey
With requirements for higher glass pull rates, lower energy consumption and higher glass quality
along with environmental concerns, research and development studies have been undertaken to
improve the design and operation parameters of different types of glass furnaces in iecam
with iecam Mathematical Model.
In glass furnaces, many parameters related to design and operation interact and it is not
possible to distinguish the role of each parameter on the results. Modeling enables to see the
effect of each parameter separately. Then, according to the extent of the advantage provided by
each of the specific parameters, collective effects can be evaluated.
In the analyses related to glass bath and combustion space, it is seen that glass depth, crown
height, burner positions and port geometry are critical design parameters besides main furnace
dimensions. Bubbling and electric boosting are used as auxiliary systems to improve the process
and add flexibility in operation. These investigations are, then, used to optimize different types of
glass furnaces for higher thermal efficiencies and lower emissions. Results related to furnace
performances have been followed during operation for the progress achieved. Moreover,
providing these criteria at higher capacities has been a challenge each time.
Research on new concepts in glass melting and glass furnaces is supported from the outcomes
of productive furnace design and furnace operation in iecam.
Keywords: Glass furnace, mathematical modeling, furnace design

46

V7.1. Short review of TC25 (Modeling of Forming Processes) activities, period

2000 till 2009
Christoph Berndhuser
Schott AG, Mainz, Germany
christoph.berndhaeuser@schott.com
Objectives of TC25
Identification and/or development of appropriate software for glass forming processes to
correctly describe the relevant process physics (e.g. treatment of free surfaces in
drawing processes, large grid deformations in pressing processes, radiative heat
transfer).
Development of models to describe product quality as result of relevant process
parameters. This requires specific techniques to handle totally different length scales
relevant for the glass product specifications.
Determination of specific, critical material properties relevant to glass forming processes,
such as stress- and structural relaxation data.
Model validation.
Work-plan
Definition and accomplishment of bench marking (Round Robin tests) for specified
forming processes
Identification of necessary model enhancements/improvements and initiation of
developments
Sensitivity studies to identify material properties critical to simulation results
Definition and accomplishment of experiments for model validation
Bench Marks / Round Robin Tests
TC25 has defined and ran three Round Robin Tests for different glass forming applications
RRT-I TV panel pressing
RRT-II Single and triple gob forming
RRT-III Single and multi-fibre forming
Round Robin Test - I 3D TV-Panel-Pressing
A RRT-I-definition document including all required geometry information, boundary conditions,
initial conditions, material parameters, output data requirements was prepared.
Several reviews and updates of the RRT-I-definition document became necessary to finally
describe a model process that could be simulated by different software codes and that
provides valuable and comparable results.
Calculations finally have been completed by three different codes (TNO-GPP, AnsysPolyflow, NoGrid-FPM)
Comparison of available results have been presented in November 2008 (GlassTrend
Meeting, Eindhoven) and May 2009 (EFONGA Workshop, Montpellier).
Round Robin Test - II Gob Forming
A RRT-II-definition document for a single gob forming application including all required
geometry information, boundary conditions, initial conditions, material parameters, output
data requirements was prepared.
Calculations finally have been completed only by two different codes (Ansys-Polyflow,
47

NoGrid-FPM).
A brief comparison of available results had been presented in November 2008 (GlassTrend
Meeting, Eindhoven)
Beyond that, possibilities for model validation have been evaluated: at Emhart Glass an
experimental program for a triple gob feeder aimed at developing an experimental database
of gob forming and delivery data had been initiated and Emhart kindly agreed to provide data,
to be used for TC25 activities.
To meet Emhart experiments an extended RRT-II.2-definition document for a triple gob
forming application was prepared.
A draft version of the definition document was discussed during the November 2008
meeting in Eindhoven. To achieve the best possible conformity with the current set up some
fine tuning of the definitions had been done and the final definition document was distributed
in summer 2009.
Round Robin Test - III Continuous Fibre Drawing
A RRT-III-definition document for a single fibre forming application including all required
geometry information, boundary conditions, initial conditions, material parameters, output
data requirements was prepared.
Calculations were performed by two different codes (Polyflow, Fidap) and a brief comparison
of the results had been presented and discussed
But, this first single fibre forming RRT was not of real interest for industrial TC25 participants,
because several physical phenomena of the real process were not taken into account.
Beyond that, possibilities for model validation have been evaluated: at Cleveland State\
University (CSU), an experimental program for a multi tip fibre forming process aimed at
developing an experimental database of fibre forming was initiated.
Prof Simon Rekhson of CSU joint TC25 meetings twice to present the SU experimental set
up and related results and to advise preparations of an extended multi-fibre modelling case.
A draft version of an advanced RRT-III.2 definition for a multi tip set up was discussed
and reviewed in Trencin, June2008 - the final version was then presented at the Glass Trend
meeting in November 2008.
Due to the attained complexity of the current definitions the identification of suitable software
Packages for this case was difficult and could not be finalized.
Conference Sessions & Workshops
TC25 has initiated and co-organized sessions and workshops on international conferences /
meetings:
Session Modelling of Glass Forming at ESG conference in Sunderland, UK 2006
(13 papers)
Joint modelling session TC21/25
Heat transport phenomena in furnace and
forming modelling at the ICG Congress in Strasbourg, France 2007
(20 papers)
Co-organisation of Glass Trend Workshop Conditioning of Glass Melts & Forming of
Glass Products in Eindhoven, NL 2008 (12 papers)
Papers & Publications/Presentations of TC25:
TC25 a platform to benchmark software capabilities for glass forming
GlassTrend Seminar, Eindhoven, NL, November 2008
C. Berndhuser, D.Hegen
Keywords: Modeling, Heat radiation, free surface, Round Robins, Fibre drawing, TV panel
pressing, gob forming, tripler gob, multiple fibers
48

V7.2. Glass Forming Simulation in 3-D for container glass industry

Dr. Alfons Moeller, Nogrid GmbH, Bodenheim, Germany
alfons.moeller@nogrid.de

The real world is 3-D and nearly all containers produced do have unsymmetrical thickness
distribution, even though the mold shape is axis-symmetric. In order to reduce the container
weight or to achieve the increasing product quality by simultaneously reducing the costs it is
fundamental to understand all mechanisms in glass forming processes. Some mechanisms are
hidden and coupled with each other and therefore it is very difficult to distinguish between them
by experiments. For instance, when one experiences a certain unexpected bottle wall thickness
distribution (e.g. too much glass in the neck area), it is sometimes not clear, what are the
reasons:
- neck mold area too cold
- glass contact time too long
- gob temperature not high enough
- gob shape not correct
- or other causes.
In production you cannot simply increase the gob temperature, because also the gob shape will
change. So one cannot distinguish what is the effect of temperature and what is the effect of
gob shape. In simulation we can change the gob temperature and the gob shape remains the
same. That means, with modeling one can investigate each cause of defect independently from
others.
Fortunately in computer simulations we are able to separate the conditions and as a result we
are able to investigate the dependencies step by step.
The most sensible material property for the glass forming process is the viscosity, which
depends on temperature. Unfortunately glass temperatures are often entirely unknown and can
be measured only with considerable effort. For that reason one important question very often is:
What is the influence of the gob temperature on the container wall thickness distribution and
what happens if the temperature distribution within the gob is not homogeneous? Beside
inhomogeneous temperatures a non-symmetric gob load is also a major reason for an irregular
wall thickness distribution.
In this paper we will give some answers to these questions. As in reality, the simulation starts
with gob loading and ends at take out. All process steps are integrated into one computer model
and all walls are switched on and off at the corresponding time step given by the IS machine
time data: The walls for the plunger, blank mold, blank mold bottom and final mold are combined
to one single geometrical model. The software switches the corresponding faces on and off
according to the IS time data.
The shape of the container can be each possible 3-D shape. Thus, there are no limits regarding
container design and we can test and evaluate a design without any restrictions. The
asymmetric conditions are applied to typical glass containers and the process type used in this
paper is the blow and blow process.
Keywords: container glass simulation, glass forming, CFD, container wall thickness, container
weight reducing

49

V7.3. Finite Element Analysis of container's geometry

Alberto D'Este, Mirko Silvestri, Roberto Dall'Igna
Stazione Sperimental del Vetro, Via Briati 10, Murano-Venice, Italy
adeste@spevetro.it

FE Analyses of glass containers are usually carried out for 3 main purposes: verification, design
or optimization of glass containers.
Verification aims to determine the level of the stress field induced by external loads on a given
containers and to verify whether it is allowable. Together with fracture analysis, verification
analysis may also assess the load or stress at which a failure occurred.
We talk about design analysis when a new container's geometry (i.e. thickness or shape) is
sought in order to achieve stress lowering or glass weight reduction. As the verification
approach, also design is usually based on limiting the local stresses peaks.
A more advanced procedure to define both the geometry and weight of a glass container can be
referred to as optimization analysis, in which the bottle's shape ranking is not simply based on
the reduction of the tensile stress peaks. Indeed, the main target is to achieve minimum failure
probability in service, which depends on the extension and the location of the zones under
tensile stress. This evaluation is carried out by means of the Weibull statistics, using the
parameters derived from breakage tests and fracture analyses on containers that have
undergone the degradation resulting from normal manipulation.
This work elucidates the fracture probability assessment under a multi-axial stress state. The
way to estimate the Weibull parameters through burst testing and FEA of the tested bottles is
also discussed. Previous topics are combined in order to evaluate the geometry of a glass
container which is deemed capable of withstanding internal pressure. Some practical case
studies will be reported.
Keywords: FEM analysis, strength, tensile stress, shape optimization, Weibull statistics, burst
testing, fracture analysis, failure identification

50

V7.4. Tin and iron concentration profiles at float glass surfaces

CANCELLED
David Gelder, Math for Manufactures, UK
david.gelder@btinternet.com

The importance of minimising surface and near surface transmission losses in float glass panels
intended for solar energy applications is accepted.
However the reaction diffusion equations controlling the tin and iron effects are not easy to use
to optimise the processing.
This is partly just a general lack of important materials properties, but a careful investigation is
also needed of the dominant mobile species in the regime considered to avoid misinterpreting
what data there is.
Modelling techniques for the development of the iron and tin oxide profiles are developed and
used both within and beyond the bath (where advantageous regimes both during cooling and in
any subsequent thermal processing are of interest) will be investigated.
Keywords: surface properties, iron concentration profile, tin concentration profile, solar glass

51