SEMINAR REPORT

ON

GLASS INDUSTRY

By
Harshit Aggarwal
Roll Number: 01016101416

University School of Chemical Technology

Guru Gobind Singh Indraprastha University, Delhi
(April, 2019)
 Contents
1. Introduction .................................................................................................................................. 1
1.1Different Types of glasses and their applications ................................................................... 2
1.3 General Properties of glass .................................................................................................... 4
1.4 Glass Uses .............................................................................................................................. 4
1.5Harmful Effects ....................................................................................................................... 5
2. Manufacturing Process................................................................................................................. 5
2.1.1Melting ................................................................................................................................. 6
2.1.2Melting: Chemical reactions ................................................................................................ 7
2.1.3 Finishing .............................................................................................................................. 7
2.1.4 Flow Sheet........................................................................................................................... 8
2.2Manufacturing Challenges ...................................................................................................... 9
2.3 Major Manufacturing Industries ............................................................................................ 9
2.3.1 In Abroad............................................................................................................................. 9
2.3.2 In India ................................................................................................................................ 9
3. Demand ...................................................................................................................................... 10
3.1Global .................................................................................................................................... 10
3.2India ...................................................................................................................................... 11
4. Conclusion ................................................................................................................................. 12
4.1Global .................................................................................................................................... 12
4.2 India ..................................................................................................................................... 12
6. References .............................................................................................................................. 13
 Tables

Table 1 Different types of glass and their applications .................................................................... 3

Table 2 Worldwide flat glass demand (million dollars) ................................................................ 11

Figures

Figure 1 Glass Transition ................................................................................................................. 1

Figure 2 Pot furnace ......................................................................................................................... 6
Figure 3 Glass bottle manufacturing flow sheet .............................................................................. 8
 1. Introduction
“Glass is an amorphous solid, brittle, transparent, obtained by fusing a mixture of a
number of metallic silicates, most commonly Na, K, Ca and Pb”.
Represented as xR2O . yMO . 6SiO2
R = monovalent alkali metals like Na, K
M = Divalent metals like Ca, Pb, Zn, etc.
x & y = whole numbers

Figure 1 Glass Transition

1
 1.1Different Types of glasses and their applications

Serial Type of Raw Properties Uses

No. glass Materials
1. Soda-lime Silica Low cost Window glasses,
(or) Soft CaCO3 Resistant to water electric bulbs,
glass Soda ash Attacked by acids bottles, jars, table
Melts easily wares etc.,
Molded easily to any shape
Poor thermal & chemical resistance
2. Potash-lime Silica High Melting point Combustion tubes,
(or) Hard CaCO3 Not attacked by acids, alkali and chemical apparatus
glass K2CO3 other solvents
Costlier than soda-lime glass
3. Lead glass Silica Bright, lustrous and possesses high High quality table
(or) Flint Lead Oxide specific gravity wares, neon sign
glass Potassium Expensive to manufacture , than tubing’s , optical
Oxide ordinary lime-soda glass lenses
Lower softening temperature than High dense glasses
soda-lime glass are used for
Higher refractive index and windows to protect
excellent electrical properties from X-rays and
gamma rays

4. Pyrex-glass Silica Substitution of alkali (Na2O) Industrial pipeline

(or) Jena Small amount and alkaline earth oxides(CaO) of for corrosive liquids,
glass of alumina the soda glasses by boron and gauge glasses,
Some oxides aluminum oxides results in low. superior laboratory
Thermal co-efficient. High softening apparatus etc.
point and excellent resistivity(shock
proof) High chemical resistance

2
5. Alumina 5 % more of Exceptionally high softening High pressure
Silicate alumina temperature mercury discharge
glass Addition of Chemically durable tubes, chemical
alumina Resistance to hydrolysis combustion tubes,
makes glass Affected by moisture due to high specific domestic
heat resistant surface area equipment
Fiber glass
6. Optical Phosphorous Low melting point Optical lenses
glass and lead Soft
silicate Chemical-resistance
together with Durability lesser than ordinary
small amount glasses
of cerium Absorbs UV light
oxide
7. Quartz Crystalline Outstanding resistance to thermal Special lab-ware
glass silica fused at shock and chemicals Crucibles
1900 C Reaction tubes
8. Opal glass Ca3 (PO4)2 Translucent white or milky glasses dinnerware, lamps,
(or) SnO2 Transparent when in liquid vases, and costume
Opaque when cooled jewelry
Table 1 Different types of glass and their applications

3
 1.3 General Properties of glass

 Amorphous Solid
 No definite melting point
 Very brittle
 Softens on heating
 Can absorb, reflect and transmit light
 Good electrical insulator
 Affected by alkalis
 Not affected by air, water, acid or chemical reagents. But soluble in HF which converts
into SiF4
 Possesses high compressive strength and since it doesn’t have any crystalline structure ,
no slippage between planes can occur
 Light in weight because it has homogeneous internal structure similar to liquids

1.4 Glass Uses

 Windows and doors

 Facades
 Tableware (plate, cups, bowls)
 Insulation
 packaging for food
 Bottles for drinks
 Cosmetics and pharmaceuticals
 Renewable energy (solar energy glass, Wind turbines)
 Interior design and furniture element like mirrors, balustrades etc.
 Applications and electronics element like cook top, oven doors, TV, smart phones, etc.
 Automotive and transport like aircraft, ships, windscreens, backlights, etc.
 Medical technology, optical glass, biotechnology, etc.
 Fiber optic cables to carry information from phones, TV, computer.
 X ray& Gamma-ray – radiation protection

4
 1.5Harmful Effects

 The combustion of natural gas/fuel oil and the decomposition of raw materials during the
melting lead to the emission of CO2. This is the only greenhouse gas emitted during the
production of glass.
 Sulphur dioxide (SO2) from the fuel and/or from decomposition of sulphate in the batch
materials can contribute to acidification.
 Nitrogen oxides (NOx) due to the high melting temperatures and in some cases due to
decomposition of nitrogen compounds in the batch materials also contribute
to acidification and formation of SMOG.
 Evaporation from the molten glass and raw materials can cause release of particles into
the atmosphere.

2. Manufacturing Process

Manufacturing of glass

2.1.1Melting
2.1.2 Chemical reactions
2.1.3 Finishing (Forming, shaping, Annealing )
2.1.4 Flow Sheet

5
 2.1.1Melting

The combination of the individual raw materials at high temperature to form a molten
glass is the central phase in the production of glass. There are numerous ways to melt
glass depending on the desired product, its end use, the scale of operation, and the
prevailing commercial factors. The glass formulation, raw materials, melting technique,
fuel choice and furnace size will all depend on these factors. Majority of the glass melting
takes place in continuously operated melting furnaces, also called melting tanks, with
discontinuous melting being used for the production of glass products. In continuous
operations, the mixture of batch and cullet is continuously charged into the glass-melting
furnace to compensate for the glass withdrawn and keep the glass level in the furnace
constant. Combustion heating – using natural gas and fuel oil – and direct electrical
heating, as well as the combination of both, are commonly used heating methods for the
melting tanks. Electric boosting is commonly used in order to increase production rates
and/or to increase production flexibility. Currently, fiber glass production is the main user
of electric melting, as it allows producing a very homogenous and high quality product..
Normally, the higher the quality of glass produced, the longer the residence time, in order
to ensure a perfect homogenization and elimination of possible stones, bubbles, etc.
which would affect the properties of the final product. The difference in residence time of
the glass melt in the furnace is directly associated with the specific energy consumption;
therefore, for a given capacity of the melting furnace, the type of glass produced can be
associated with a significantly different energy consumption.

Figure 2 Pot furnace

6
 2.1.2Melting: Chemical reactions

• Cullet melts at relatively low temperature and assists in melting of rest of the charge
• During the melting process following reactions occur
• For colored gases desired pigment is added
• The molten mass is then cooled at about 800oC at later point of time
• CaCO3 + SiO2 → CaSiO3 + CO2
• Na2CO3 + SiO2 → Na2SiO3 + CO2

2.1.3 Finishing

Different finishing treatments – such as annealing, toughening, and coating – can be used
to influence product characteristics Annealing aims to reduce the strain in the glass by
slowly reheating the glass in an oven, called a lehr. The glass product is first heated to a
high temperature, varying between 400°C and 500°C, depending on the product, and then
is gradually reduced to a temperature at which no further strain can be induced. Next, the
product is cooled by fan air to room temperature. This process is usually completed in
less than an hour – actual times depending on the size of the product and its wall
thickness Thermal toughening includes re-heating the glass product uniformly to just
above deformation temperature and then rapidly cooling the surfaces by jets of air. Rapid
cooling of both surfaces leads to the build-up of a compressive stress layer upon further
cooling, since the hot core glass can still contract. Thermal strengthening can be applied
to flat glass or simple shapes like curved car windscreens or tumblers. For thermal
toughening to be applicable, the glass should have a minimum and uniform thickness and
the shape of the article must be such that all surfaces can be uniformly cooled at the same
time. Bottles cannot be toughened in this way, and require a chemical process for
toughening. The coating of glass surfaces (e.g. mirrors, strengthening of bottles, and
coloring) gives glass new physical, chemical, and optical properties. Lightweight glass
containers are coated with organic compounds to give the surfaces a degree of lubricity,
thus preventing abrasion in handling. This adds strength to the container and has enabled
glass manufacturers to make a lighter and better product.

7
 2.1.4 Flow Sheet

Figure 3 Glass bottle manufacturing flow sheet

8
 2.2Manufacturing Challenges

1. The refractoriness poses major melting difficulties –

The high temperature crystalline phase melts at about 1725 ºC. – The viscosity at that
temperature is about 107 poise. – This rules out conventional melting techniques.
2. Silica melts tend to react with their containers. For example –
3. SiO2+ C →SiO (gas) + CO (gas)
4. At high temperatures SiO2 is noticeably volatile. The boiling point is only 2,300 ºC.
5. The manufacturing processes often introduce chemical impurities, including dissolved
water and halogen gases, but high chemical purity (50-100 ppb impurities) is often
required by applications.

2.3 Major Manufacturing Industries

2.3.1 In Abroad

America – Corning Inc., Guardian Glass Industry

Germany – Schott AG
France – Saint-Gobain
England – Morgan Advanced Materials
Japan -The NSG Group, Asahi Glass Co. Ltd.
China –Xinyi Glass, Fuyao

2.3.2 In India

Hindustan National Glass & Industries Ltd.

Binani Industries Limited
Borosil Glass Works Ltd

9
 3. Demand

3.1Global

The demand for glass has grown phenomenally in the last two decades, outstripping the
GDP growth in most countries. Largely fuelled by China, the demand for glass is
expected to grow at nearly 4 percent per annum.
The demand for glass is fuelled by legislation and regulations that look at safety, noise
control and energy conservation. Design trends that favor glazed buildings that allow for
maximum natural light will ensure the growth of the glass industry.

Fabricated flat glass demand will benefit from rapid growth in sales of energy efficient
products such as solar control, insulation, and low-E glass. The solar energy market,
which was hurt by recent global economic weaknesses, will take off briskly once again. It
should be noted, however, that demand for flat glass used in solar energy applications
totaled just around 120 million square meters in 2011, so this is a niche market.

Production of flat glass is projected to reach 75.4 million metric tons in 2016, of which
close to 70 million metric tons will be high-quality float glass. The remainder will consist
of low-quality float glass produced primarily in China, as well as sheet glass and rolled
glass.

This study analyzes the 6.6 billion square meter world flat glass industry. It presents
historical demand data for the years 2001, 2006 and 2011, and forecasts for 2016 and
2021 by product (float glass, flat glass), market (e.g., nonresidential building
construction, residential building construction, OEM motor vehicles, automotive
replacement), world region and for 21 countries.

10
3.2 India
India is at an early stage in terms of market maturity at present, but glass demand is
growing steadily. Aggressive and organized efforts on the part of manufacturers and
processors are expected to achieve higher levels of awareness among glass specifies and
users. In the next five years, the Indian architectural glass market will move to higher
maturity levels. However, policy and regulations including the lack of standards and glass
codes for India are a source of anxiety for manufacturers and processors alike. The
industry also needs increased exposure. Followed the opening up of FDI for the real
estate sector, here appears to be more chance of foreign investors coming in and a greater
demand for international standards in construction. This, and the ever-growing popularity
of glass as a material, will ensure growth.

Table 2 Worldwide flat glass demand (million dollars)

11
 4. Conclusion

4.1Global

At a global level, demand is growing steadily. To satisfy this growth, companies will add
about 100 new float lines worldwide by 2010. According to a new market report, the
future of the global flat glass industry looks good with opportunities in the building
construction glass, automotive glass, and specialty glass. The global flat glass industry is
forecast to grow at a CAGR of 5.5% from 2016 to 2021. The major drivers of growth for
this market are growth in the construction market, rising automotive production and sales,
rising per capita income, and technological advancement.

4.2 India

Indian Glass Market is assessed to increase at a CAGR of 15% throughout the next three
years. Fuelled by development in parts like real -estate, infrastructure, retail,
car and food and refreshments, the nation’s glass industry will procure a
market measure worth Rs640 billion by 2030 from Rs340 billion at present,
as indicated by an ASSOCHAM body.
The glass utilization development is normal in construction (10 -12%),
automotive (20%), consumer good (15-20%) and pharmaceuticals (15-18%)
sectors.
The growth in the glass industry is characterized by the increase use of
processed and reflective glass as the Indian customer has become more aware
about the importance of glass in effectively addressing the concerns of safety
and energy efficiency.

12
 6. References
For content
1. Journal of non-crystalline solids
2. The Associated Chambers of Commerce and Industry of India (ASSOCHAM)
3. Werner Vogel: "Glass Chemistry"; Springer-Verlag Berlin and Heidelberg GmbH
& Co. K; 2nd revised edition (November 1994), ISBN 3-540-57572-3
4. Benvenuto, Mark Anthony (2015-02-24). Industrial Chemistry: For Advanced
Students. Walter de Gruyter GmbH & Co KG. ISBN 9783110351705.
5. https://economictimes.indiatimes.com/industry/indl-goods/svs/paper-/-wood-/-
glass/-plastic/-marbles/indias-growth-picture-is-as-clear-as-glass-for-saint-
gobain/articleshow/62926640.cms
6. http://www.chemistryexplained.com/Ge-Hy/Glass.html

For figures
7. [Fig 1] https://www.sciencedirect.com/journal/journal-of-non-crystalline-
solids/vol/471/suppl/C
8. [Fig 2] B. H. W. S. de Jong, "Glass"; in "Ullmann's Encyclopedia of Industrial
Chemistry"; 5th edition, vol. A12, VCH Publishers, Weinheim, Germany,
1989, ISBN 3-527-20112-2, pp. 365–432.
9. [Fig 3]http://nearsoft.eu/industries/glass-industry/

For tables
10. [Table 1] Kolb, Kenneth E., and Kolb, Doris K. (1988). Glass: Its Many
Facets. Hillside, NJ: Enslow
11. [Table2] Report by The Freedonia Group (Market research company).

13