INTRODUCTION

What is glass?

inorganic non metallic material no crystalline structure - amorphous

glasses range - soda-lime silicate glass for soda bottles --- high purity silica glass for optical fibers

Historically most products have been blown glass. In recent times most flat glass has been produced using the float process.

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Until 19th C customary crown process limited sizes of glass pane up to 0.75 x 0.5m - decline in the 1830s From the 19th C, the development of First Worlds Fair - Crystal framed building Palace 1850s structures liberated In the 1960's - Alastair window areas Pilkington - FLOAT GLASS eventually the all-glass PROCESS - revolutionized the wall At the turn of the 20th C industry. glass - various drawn flat Today 90% of all flat glass is 4/26/12 sheet processes: the

CURRENT SCENARIO

world market for flat glass in 2007 : 44 million tonnes, equivalent to 4.4 billion Sq.M. of glass with a thickness of 4 mm. primary manufacture of about 20 billion US$. volume of glass consumed - construction industry is the largest sector - 39 million tonnes. China - biggest market in the world.

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Total installed (or designed) capacity = 65 million tonnes annually: 185,000 tonnes of glass is pulled 4/26/12 every day.

Building products- 80% to85% of the float glass market. Refurbishment of existing buildings - 40% of glass consumption worldwide.

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2-6 mm glass has 79 % of the market share. Clear glass occupies 80% of the market share.
F A GL SD IONININD IN2010(MT L T AS IVIS IA )
0.037 2% 0.02 1%

1.73 97%

TOTALF ATGL SPROD L AS UCTION =1.7 MT. 87 FLOAT GLASS SHEET GLASS SAFETYGLASS

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F OA GL SP ANTSININD L T AS L IA
AIS( Asahi India Glass) Gujarat Guardian Ltd.(GGL) GoldplusIndia 2 2 Saint Gobain Hindustan National Glass(HNG)

TOTALNO. OF FLOAT GLASS PLANTS IN INDIA =7

F OA GLAS P OD TION ININD IN2010(MT) L T S R UC IA

0.21 0.21 0.72 0.16 0.43

ASAHI INDIA GLASS GUJARATGUARDIAN L TD. GOLDPLUS

SAINTGOBAIN HINDUSTAN NATIONALGLASS

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CHARACTERISTICS OF VIRGIN GLASS

Sources and Raw materials Fusion of several inorganic substances silica (SiO2) in the form of sand is the main one. For transparent glasses, the fused mass is cooled to ambient temperature "Glass at a rate fast enough to sand prevent crystallisation, i.e. the molecules cannot 4/26/12

Silica Sand Soda ash/ sodium oxide Limestone

Ingredient

MAJOR INGREDIENTS USED IN MAKING GLASS

Composition
SiO2 Na2CO3/ Na2O CaCO3

Percentage
70-74% 12-16% 5-11% 0-45%

Main ingredient lowers the glass transition temperature to make glass water nonsoluble Recycling glass

Purpose

Dolomite CaCO3.MgCO3 Cullet (recycled glass glass) Slag Cao.MgO.SiO2.Al2O 3 Salt Cake Na2SO4 Feldspar K2O.Al2O3.6SiO2

1-3 %

lowers the glass transition temperature better chemical durability

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MINOR INGREDIENTS IN MAKING GLASS Ingredient USED Composition

Magnetite Iron chromite Iron pyrites Carbon Selenium Cobalt(II) oxide lead boron Nickel Oxide, Cobalt Oxide, Blue dust Cobalt oxide, sodium, selenite, sodium nitrate, blue dust Blue dust Fe2O3 Fe2O3 (28%), Cr2O3 (45%) FeS carbon selenium CoO 30 % PbO 7-13% Boric acid

better chemical durability, colour(brown) better chemical durability, colour (brown or green)

Purpose

for colour (blue) to alter the refractive index to improve the thermal options Dark Grey colouration Bronze & Dark Bronze colouration

Green colouration

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PROPERTIES OF GLASS

Glass has two important properties. 1. Does not have a definite melting point but softens gradually over a range of temperatures. IS GLASS 2. It does not cleave in a plane face like diamond or LIQUID OR table salt. Many solids - crystalline SOLID? structure When heated the molecules vibrate about their position in the lattice until, at the molecular melting point, the crystal molecular arrangement arrangement crystal glass breaks down and the molecules start to flow. sharp distinction between the solid and 4/26/12 the liquid state.

supercooledliquids remain liquid below its melting point because there are no nucleation sites to initiate the crystallisation.

A sheet of glass left to stand for a long time - one hundred years - flow and change its dimensions
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Brittle material - does not deform plastically before failure. Low tensile/bending strength upto 80 Mpa. Mod. Of Elasticity 70 GPa Compressive strength upto 1000 MPa. Density: 2450-2500 HARDNESS kg/m3. Borosilicate glass - 2, Thermal Conductivity 3 times - hardness of 0.7-0.8 W/mC plate glass. Density of glass decreases harder than most with increase in silica grades of unhardened content steel. Min. density - quartz glass 2200 kg/m3 4/26/12 Most vulnerable at its CHEMICAL RESISTANCE

TYPES OF GLASS

Borosilicate Glass (Pyrex Glass) - silica (7080%) and boric oxide (713%) Commercial Glass (sodalime glass) Lead Glass (lead crystal) 30% lead oxide (PbO) Glass Fibre (aluminoborosilicate glass)
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SPECIAL TYPES OF GLASS

Optical Glass

Alkali-barium Silicate Glass

Glass Ceram

Vitreous Silica
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PROCESSING

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Float Glass Process

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EMBODIED AND TRANSPORT ENERGY

Embodied energy of different types of glass Glass MJ/kg MJ/m3 float 15.9 40 060 toughened 26.2 66 020 laminated 16.3 41 080 tinted Source: Manufacturer, Lawson 14.9 375 450

MJ/m2 240/6mm 396/6mm 246/6mm

Melting area (m2) Gas usage (m3 year-1) Electroboost usage (kWh year-1) Maximum throughput (T day1)

Summary of a glass producing plant Capacity (Tonnes) 200

65 6 491 000 114 400 200

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EMBODIED ENERGY COMPONENTS

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ENVIRONMENTAL POLLUTION AND ECOLOGICAL DAMAGE

Emissions of GHGs - result of fuel combustion and the volatilization of raw materials. Carbon dioxide (CO2) Methane (CH4) nitrous oxide (N2O) The U.S. Inventory (EPA 2008b) reports 0.7 Teragrams CO2 Eq. of process emissions from glass manufacturing in 2006.

Stationary combustion emissions : fossil fuels are combusted to

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Net Emissions for Glass under Each Materials Management Option (MTCO2E/Ton) Net Source
Material/ Product Reduction (Reuse) Net Net Net Net GHG Recycling Compostin Combustio Landfilling Emissions GHG g GHG n GHG GHG For Emissions Emissions Emissions Emissions Current Mix of Inputs 0.53 0.28 NA 0.05 0.04

Glass

Transportation Energy Use Material/Prod Average Miles Retail Transportation Retail Transportation and GHG Emissions
uct per Shipment Energy (Million Btu Emissions (MTCO2E per Short Ton of per Short Ton of Product) Product) 0.411

Glass

383

0.031

Source : Waste and Resources Action Programme (WRAP)

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RECYCLING

Why recycle glass?

Glass can be recycled indefinitely : its structure does not deteriorate when reprocessed. In the case of bottles and jars, up to 80% of the total mixture can be made from reclaimed scrap glass, called "cullet".
Glass recycling in 03 saved enough energy to launch 10 space shuttle missions !

4/26/12 345 kwh of energy is saved for every tonne used

Main sources of glass waste: demolition projects replacement of windows in refurbishment projects fluorescent lighting PC monitors and TV screens structural glass - e.g. in modern office blocks
Source : Waste and Resources Action Programme (WRAP)

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RECYCLING PROCESS

Viridor Glass Recycling company UK based company dealing with recycling of many materials including glass. Two main sources of flat glass: 1. manufacturers of glass and glass products for architectural, automotive and other purposes who, of necessity generate a certain amount of waste in their processes. 2. The other includes vehicle recyclers and those involved in demolition and the removal of waste architectural glass. Viridor offers advanced recycling technologies to facilitate the recovery of important flat glass products including . Float glass 4/26/12 . Automotive glass

The process of recycling includes the following steps: 1. Collection and separation of mixed waste 2. Crushing of glass to small fragments 1. Separatioto producers to convert into new products 3. Transport n Process

10

11

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2.

Crushing Process

1 2

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1. Centrifuge for crushing glass

2. Trommel for separating in sizes

2. Fine particles sieved out

3. Medium and coarse particles sent back to the centrifuge

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4. Lab testing

Ready for dispatch to manufacturers

1 recycling unit processes 1, 00,000 Tonnes of waste glass per year. Almost 95 % of the glass is reclaimed 4/26/12 and reused.

Source : Waste and Resources Action Programme (WRAP)

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OTHER APPLICATIONS
1.

Added to concrete as aggregate. Crushed glass - lighter than the sand and gravel, so the concrete weighs less per square foot - just as strong. Substitute for sand in blasting car parts, stainless steel, wood, fiberglass and plastics.
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2.

COMPARISON OF VIRGIN AND RECYCLED GLASS

Process and Transportation Energy for Manufacture of Glass Using Virgin Material Virgin Manufacture and Recycled Inputs Manufacture Recycled
Process Energy Transportation Total Process Transportation Total / Energy per Energy per Energy per Produc per Short Ton Made from Virgin Short Ton Made Short Ton Short Ton t Inputs (Million from Virgin Made from Made from Btu) Inputs (Million Recycled Recycled Inputs Btu) Inputs (Million Btu) (Million Btu) Glass 6.49 0.58 7.08 4.32 0.34 4.66

Process and Transportation CO2 emission for Mfg.of Glass Using Virgin &Recycled Inputs Product Difference Between
/ Product Manufacture Using Product Manufacture Using Materi 100% Virgin Inputs 100% Recycled Inputs al (MTCO2E/Short Ton) (MTCO2E/Short Ton) Recycled and Virgin Manufacture (MTCO2E/Short Ton)

Transpor Process Transpor- Process Process Transpor- Process Process -tation Non- Process tation Non- Energ tation NonEnergy Energy Energy Energy Energy Energy y Energy Energy Source : Waste and Resources Action Programme (WRAP) Glass 0.37 0.07 0.16 0.23 0.06 4/26/12 -0.14 -0.02 -0.16

FINANCIAL BARRIERS

Disposal to landfill favoured by a factor of 10:1 over recovery and recycling Transport and labour costs high. Cullet collectors will either charge a collection fee for the collection of scrap glass or will accept the glass free of charge at their collection centres Lack of an established collection and distribution infrastructure - delivery of recovered glass to the reprocessing facilities difficult.
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CONCLUSION

System devised to facilitate the collection of waste glass and transportation to recycling plant on a large scale Incentives to scrap glass collectors Glass is infinitely recyclable and has many applications other than reproducing glass itself

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