REFractories FOR GLASS-TRL PDF

REFRACTORIES
FOR
GLASS INDUSTRY
Overview of Glass Industry
• Refractories for Glass- Market
• Present operational practice in Glass making

Process.
• Fundamentals of refractories selection for

Glass Industry
• Recent Trends in Refractories for Glass
• Conclusion
Refractories for Glass - Market
Specific Refractories Consumption in Glass
25
22
20
16 16 India
15
12
Kg/t
12
10 8 9
World 5 7
5 4
0
1975 1990 1995 2000 2006
Year
World Market Trend of
Refractories for Glass Industry
• Declining specific refractory consumption
• Conventional products losing ground
• Customer driven product design
• Increasing demand for Total Refractories

Solutions
Indian Glass Market
• Indiarepresents one of the largest markets and

manufacturing capacity in Asian region for glass
products after China.
• About 100 large scale companies which operate with

modern and large scale melting technologies.
• They are mostly located in Gujarat, Mumbai, Kolkata

and Hyderabad.
Indian Glass Market
•The Indian Glass industry is also represented

by more than 300 medium and small-scale
cottage industry units.
•The historical Glass-making town of Firozabad

in UP state, which meets 30% of the demand for
glass products in the country.
Present Operational
Practice in Glass Making
Process
Present Operational Process for Glass Industry
• Higher Operating temperatures

• Use of higher capacity Furnaces
• Longer Campaigns
• Oxy Fuel firing & higher melting rate
• High Value Products like Float Glass(Infrastructure
developments) and Fiber glass
• High resource and Energy Consumption(Float Glass)
• Fuel oil-50.2%,
• Raw Mix/ Coal-35.7%,
• Power-6.4% and
• Others-7.7%
Fundamentals of Refractories
Selection
Chemical Sress
Mechanical
Stress
Selection of
Proper
Refractory
Thermal Sress Material
Recent Trends in
Refractories for Glass
Schematic Diagram of Glass Tank Furnace
Insulation Crown
Bottom-Sidewall
Super-structure
Bottom
Dog-House Side-Wall
Refractories for Different Parts of
Glass Tank Furnace
Application Application Application Recommended
Conditions Requirements Refractories
Alkali Vapors, High Volume stability, Super duty silica

Crown temperature Low permeability, bricks
high refractoriness
Wear by carried High thermal

Zirconia-Mullite
Super structure over batch shock resistance,
Bricks ,
constituents, High Corrosion and
Mullite Bricks
temperature. erosion resistance
Lower Side walls High Temperature, Corrosion Zirconia-Mullite

Glass Corrosion resistance Bricks
Refractories for Different Parts of
Glass Tank Furnace
Application Application Conditions Application Recommended
Part Requirements Refractories
Bottom Paving High Temperature, High Refractoriness Fusion Cast AZS-
Glass Corrosion, High under Load, Refractories
load Corrosion resistance
High Load High Refractoriness High Alumina Bricks
Safety Layer under Load
Insulation Higher Thermal Load Low Thermal Silica Insulating

Conductivity, good bricks
mechanical strength.
Repair Alkali Vapor Corrosion. Good Thermal Shock Fused Silica bricks,
& Corrosion Zircon based
resistance Ramming &Patching
masses
Super-Structure, side wall and Port Area
Special properties:
• Zircon Mulite, Chrome

Alumina, Mullite Corundum,
AZS pressed & sintered, AZS
fused-cast block etc. are used
for low porosity, high thermo-
mechanical strength, chemical
resistance leads to enhance
furnace life, lower Sp.Ref.
consumption and for energy
savings which reduces cost of
production.
Bottom Paving by AZS Fusedcast block
Special Properties:
• Zero Tollerance, paving

block
• High temperature Chemical
and erosion resistance
• High Temperature Volume
stability.
• Low porosity
• S-3 DCL quality
Refractories for Re-generator
Application Application Application Recommended

Part Conditions Requirements Refractories
Wear due to flue Fusion cast AZS

Port Lining gases and batch Erosion Resistance refractories.
carry over
Alaklies, High Volume stability, Super duty silica

Chamber Crown temperature Low permeability, bricks, Fused
high refractoriness Mullite bricks
Chamber Wall Alkali Vapors Alkali Resistance 96-98% Magnesite

Bricks
Solidification and Alkali Resistance Andalusite Bricks

Ride arch. Liquification of
Lower wall alkalis
High Alumina and Basic Chimney Checkers
Block for Regenerator
Alumina Chrome,
Magnesia, Mag-Zir
Chimney checkers
block with new design
for Regenerators
application for
Energy savings solution
due to large heating
surface, high heat
transfer and low
tendency of blocking
and clogging.
New Generation Refractories for
Glass Industry
• Fusedcast AZS (ZrO2 Content: 33, 36%, 41%)
• Chromic Oxide block (Cr2O3%: 30 to 90%)
• Zircon Mullite
• Fused Mullite (High creep resistance)
• Silimanite/ Andalusite Block
• Fused Silica Bricks
• 98% MgO, MgO-ZrO2 bricks and Checkers
• Silica Insulation bricks
• Mullite light wt insulation bricks
• Bubble Alumina Insulation
Conclusion
• Glass industry is going through a key challenges for:
• Enhance furnace life
• High productivity
• Energy efficiency
• Protection of environment
• Refractory industries needs to accelerate the development of

technology & product quality.
• Refractory industry needs to have close association with

Technology providers to render a complete refractory solutions to
meet above demands from Glass Industry .

THANK YOU

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REFRACTORIES

• Refractories for Glass- Market

• Present operational practice in Glass making

• Fundamentals of refractories selection for

• Recent Trends in Refractories for Glass

• Declining specific refractory consumption

• Conventional products losing ground

• Customer driven product design

• Increasing demand for Total Refractories

• Indiarepresents one of the largest markets and

• About 100 large scale companies which operate with

• They are mostly located in Gujarat, Mumbai, Kolkata

•The Indian Glass industry is also represented

•The historical Glass-making town of Firozabad

• Higher Operating temperatures

Alkali Vapors, High Volume stability, Super duty silica

Wear by carried High thermal

Lower Side walls High Temperature, Corrosion Zirconia-Mullite

Insulation Higher Thermal Load Low Thermal Silica Insulating

• Zircon Mulite, Chrome

• Zero Tollerance, paving

Application Application Application Recommended

Wear due to flue Fusion cast AZS

Alaklies, High Volume stability, Super duty silica

Chamber Wall Alkali Vapors Alkali Resistance 96-98% Magnesite

Solidification and Alkali Resistance Andalusite Bricks

• Refractory industries needs to accelerate the development of

• Refractory industry needs to have close association with

meet above demands from Glass Industry .

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