“Towards a Sustainable Future” Environmental Improvements in Glass Batch Production “Towards a...

““Towards a Towards a Sustainable Sustainable

Future”Future”

Environmental ImprovementsEnvironmental Improvementsinin

Glass Batch ProductionGlass Batch Production


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PRILOX PRILOX ®®


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Overview

Introduction

What is Prilox

Why Prilox

Project Aims

Proposed Concept

Practical Experience

Benefits

Conclusion and Summary


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Health, Safety and Environmental pressures

continue to play an important role in the decision

making process within our industry. New European

Legislation currently being considered will reduce

the existing suspension level for lead in blood to

possibly 40 microgram/decilitre.

To continually meet the proposals, and satisfy

presumed future reductions, glass manufacturers

have to consider the best solutions for

manufacturing glass, both through the “ batch

house” and the delivery of that formulae to the

melting phase

Why Prilox?

Introduction


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Chemson has a history in Lead chemicals of circa.

150 years, with the past 50 years supplying

masterbatch ‘one-packs’ to the Plastics Industry.

The synergy between the two industries is

remarkable, and transferring some of the

techniques and protocols developed over the past

decade it making the plastics industry a highly

advanced and automated industry, competing on

a global stage, were used to develop this project

Prilox is a masterbatch of ingredients delivered in

a desired form.

What is Prilox?

Introduction


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Introduction

Project Aims

• Reduce Interface with Hazardous Materials

• Automated Handling

• Reduced number of individual components

• High Quality Product

• A long term cost acceptable solution


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Proposed Concept

Two Component Auto Handling System

Pellet

Batch

AZO TYPEMIXER

San

d

FEED

Cullet

for hearth


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Trail period

The Prilox test trial by:

Inn Crystal Glass / Braunau am Inn / Austria

started 16 .Aug. 2001 and completed 15. Sept. 2001.

At three times, the TÜV – (an external international

accredited body for certification of quality

management systems) measured the emission of

dust and lead in air at three different areas:

a) in the furnace (closed room)

b) production hall – over the production units

c) with the workers


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Date / Name

MAK

• Reduced power consumption of over 5 %

• Reduced vault temperature of over 20 %

• Reduced batch mixing time of over 40 %

• Reduced water consumption of over 80 %

• Reduced total dust emissions of over 90

%

incl. reduced lead emissions.


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Results of the Prilox test trial (16.Aug.01 to 15.Sept.01) measured on by TÜV

Dust and lead in air content in the exhaust air of the furnace

first measurement: after 2 weeks production with Prilox

• reduction the dust proportion by furnace 1 over 90 %

• reduction the lead in air by furnace 1 over 90 %Second

measurement: in the last week of the trial

• confirm the first test results


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Date / Name

Dust and lead in air content in the exhaust air of the furnace 1

0

200

400

600

800

1000

1200

1400

Dust Lead Dust Lead Dust Lead

TÜV 08.08.01 TÜV 29/30.08.01 TÜV 11/12.08.01

mg

/ m³

Furnace 1 Furnace1 - near feeder


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Date / Name

Fig 1. Furnace 1• cold top• closed surface• dust free

Fig. 2. Furnace 2• hot top• open surface• dust


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Date / Name

Results of the Prilox test trial measured by TÜV

Dust and lead in air content in the exhaust air of the production hall over the machines

First measurement: after 2 weeks production with Prilox

• no reduction of the dust load, by the last comparative

measurement because only furnace 1 are working (furnice 2

started on 11/99) but

• very low workplace concentration from lead, less than 0,14

mg / m³

Second measurement: in the last week of the trial confirm the

first test results


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Dust in air content in the exhaust air of the production hall over the producing units

0

1

2

3

4

5

DustTÜV 26.4.99

dustINUS 23./24.5.00

DustTÜV 08.08.01

DustTÜV 29/30.08.01

DustTÜV 11/12.08.01

mg

/ m

³

IBS-20/I RPH-16 RPH-6 RPH-12

1) Only furnace 1 works2) Furnace 2 starts his production to 11/19993) On the measurement 11/12.08.01 - production problems

according to Inn Crystall


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Date / Name

Lead in air content in the exhaust air of the production hall over the producing units

0

0,05

0,1

0,15

0,2

Lead Lead Lead

TÜV 08.08.02 TÜV 29/30.08.02 TÜV 11/12.08.02

mg

/ m

³IBS-20/I RPH-16 RPH-6 RPH-12

Information: in accordance with the Austrian Law / BGBL 498 /1994 –the limit of the emissions of the exhaust air in glass-producing production is 5,0 mg / m³


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Date / Name

Results of the Prilox test trial measured by TÜV

Measurement the dust and lead load at the furnace workers without protection

First measurement: after 2 weeks production with Prilox

• reduction of dust load over 50 %

• reduction of lead load over 70 %

Second measurement: in the last week of the trial

• reduction of dust load over 85 %

• reduction of lead load over 95 %


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Date / Name

Dust and lead load by furnace 1 workers with and without protection

0

0,5

1

1,5

2

2,5

3

Dust Lead Dust Lead Dust Lead

TÜV 10./11.7.00 TÜV 29/30.08.01 TÜV 11/12.08.01

mg

/ m³

Furnice worker with protection Furnice worker without protection


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Benefits

Date / Name

• Reduced number of raw materials

• Simplified Mixing Process

• Automatic Storage and Handling

• Encapsulation of hazardous refining chemical

• No moisture pick up

• Reduced energy consumption

• Reduced wastage

The easy-to-use oxide innovation enhances crystal strength and purity whilst improving the manufacturing process and gives users a more competitive edge.


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Summary & Conclusion

Date / Name

• The industry is seeking a permanent solution to the health, safety and environmental issues.

• The solution needs to be cost acceptable.

• Prilox provides a modern concept of material delivery, storage and handling to the melt furnaces.

• Technical and processing benefits became cost benefits.

• Modern handling concept provide a Sustainable Future.


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