Presentation by Andreas Schleicher Tackling the School Absenteeism Crisis 30 ...
Float glass manufacturing process
1. Industrial Training
at Asahi India Glass Ltd.
Submitted By:
Ajeet Kumar Saini
Mechanical 4th year
Section- L
Submitted To:
Mr. Amit Dhiman
Assistant Professor
(Department of Mechanical
Engineering)
1
2. CONTENTS
Introduction to company
Utility Section
Boiler
Cooling tower
Float Glass manufacturing Process
2
6. RAW MATERIAL BATCH
Fine grained ingredients closely controlled for quality, are mixed to make a batch.
Silica Sand (sio2) – Primary RM(70-74%) Soda Ash (Na2O)
To lower Melting Point
(12-14%)
Limestone (CaO)
To reduce solubility
(6-12%)
Dolomite(MgO)
To reduce solubility
(0-4%)
Feldspar (Al2O3)
To increase hardness
(0-2%)
6
7. GLASS FURNACE
The batch then flows into the furnace,
Which is heated up to 15000C
If certain metal
oxides are mixed
to this batch they
impart colors to
the glass giving it a
body tint.
Broken glass aka
cullet, is added to
the mixture to the
tune of nearly 25-
30% which act
primarily as flux
(helps in reducing
the melting point
of the batch)
7
8. FLOAT BATH
Molten Glass from the furnace gently flows over the refractory spout on
to the mirror-like surface of molten tin, starting at 11000C and leaving
the float bath as solid ribbon at 6000C
8
9. ANNEALING LEHR
Despite the tranquillity with which the glass is formed, considerable
stresses are developed in the ribbon as the glass cools. The glass is made
to move through the annealing lehr where such internal stresses are
removed, as the glass is cooled gradually.
9
10. INSPECTION
To ensure the highest quality inspection takes place at every stage.
Diamond steel trim off selvedge – stressed edges- and cut ribbon to size dictated
by the computer. Glass is finally sold
Only in Square meters.
10
11. PACKAGING & DISPATCH
Glass is packed with suitable packaging in wooden crates to avoid any kind of
damage during the transit and is then load into the containers
to be shipped to the destination.
11
15. Efficiency of FO boiler that AIS has
Inlet condition:
The steam generated rate = 465.45kg/hour
Steam pressure = 8 bar
Quality of steam = 0.95 dry
Feed water temperature = 800c
Furnace oil consumption = 38.33kg/hour
CV of fuel (FO) = 42,258.4 kJ/kg
15
16. Calculation
PROCESS 4-1 REPRESENT THE BOLIER ON RANKINE CYCLE (Ts diagram)
The enthalpy of steam (h1) = hf + xhfg at 8 bar
=721+(0.95*2046)
=2664.7 kj/kg
The enthalpy of feed water (h4) = hf at 800c
=334.92kj/kg
Mass of steam = rate of steam generated/( FO consumption)
= 465.45/(38.33)
= 12.143 or 13
Therefore efficiency of boiler is given by :
= m*(h1-h4)/(cv)
=13*2329.78/(42258.4)*100
Ƞb = 71.6712%
16
17. 17
End-Use
Steam Load
Boiler
Distribution System
Loss 5-15% Heat Loss in Blowdown 1-
3%
Fuel
Steam
Energyinput100%
Radiation & Convection
Heat loss: 1-4%
Heat Loss in Flue Gases:
18-22%
Boiler Energy
Output: 71-80%
Overall System
Efficiency: 56-75%
Losses in Boiler
18. Ten step to improve the boiler
efficiency
Monitor feed water quality
Boiler sizing
Blowdown control & heat recovery from Blowdown
Furnace draft tuning
Excess air
Fuel quality
Tube cleaning
Online monitoring of boiler
Boiler automation
18
19. Waste heat recovery boiler
WHRB:
Waste heat recovery boiler utilizes the flue gas coming from
furnace for steam generation.
WHRB SPECIFICATION:
Feed water temperature =80.80c
Flue gas temperature=260.70c
Steam generated=1100kg/hour
At a temperature =1700c & pressure=8bar
19
20. Efficiency of Cooling Tower
Ti=380c
To=320c
Tw= 270c
Therefore efficiency = (38-32)/(38-27)*100
=54.545454 or 55%
20
21. Calculation Of Efficiency of Cooling
Tower that AIS has
Let Hot water temperature is denoted as Ti
Let Cold water temperature is denoted as To
& wet bulb temperature is denoted as Tw
21
22. Factors that affect the performance of
cooling tower
Blowdown Losses:
Evaporation Loss.
Drift loss:
22