orldwide The Pioneer in Material Pro cessing dvanced batch preparation for better melting properties

Transcription

1 Eirich i Group Wo orldwide The Pioneer in Material Pro cessing

2 dvanced batch preparation r better melting proper rties 1 Liter 12,000 Liters 400 Liters 5 Liters Presented By: Dan Britton North American Sales Manager Eirich Machines, Gurnee, IL

3 dvanced batch preparation r better melting proper rties Presentation ti Synopsis About EIRICH Glass Production From the raw material to the fin nal product Energy consumption factors Focus batch preparation Improvement of Batch Preparation Historical development of the pan mixer technology Independent studies R&D project EinFormGlas It pays off to improve the batch Summary preparation technology

4 ompanies in the Eirich Group artners for Process Technol ogy Worldwide Copyright 1300 Employees in 11 Countries on 4 Continents Hardheim Moscow Chicago Lyon Dnepr ropetrovsk Beijing Jiangyin Shanghai Seoul Tokyo Mumbai Sao Paulo Johannesburg Maschinenfabrik G Hardheim, Germany

5 echnology Supplied By Eirich Eirich preparation technology is used for batch or continuous processes with the following basic operatio ns: - Mixing - Dispersing - Pelletizing - Kneading - Drying - Reacting - Fine grinding

6 dvanced batch preparation r better melting proper rties There are different ways of mixing, but... it depends not only on how you mix

7 lass production rom the raw material to th he final product Consider the entire glass productio on chain Glass production does not start at the furnace The furnace is the most expensive mixer within the production line Numbers of different parameters influence each production step, so benchmarks to compare plants can not be generated Problems that start at the first production chains have not to be compensated symptomatically at a later production step Raw Mixing Melting Sheet aterials Forming Cooling Quality Packaging g Control Picture: Saint Gobain Oberland

8 lass production rom the raw material to th he final product Economic assessment From GMIC A technical and Economic Assessment, ISBN , August 2004 High costs for raw material and energy enable fast return of investment for high quality batching equipment

9 lass production nergy consumption factor rs Raw Melt Considerations During the first minutes of the first melting section, more than 75%-90% of the entire melting energy is used. The heat transfer rate and the distance of diffu usion transport determine the reactions Macro- and micro structure of the batch has d irect influence on the melting process Batch and melting segregation g has to be prevented

10 lass production nergy consumption factor rs Energy Degree of batch preparation Quality Specific melting rate Basic relationships of the melt

11 lass production nergy consumption factor rs Qualität Quality Wannenleistung Furnace pull Grad der Roh- stoffaufbereitung Energy Energie = con konstant

12 lass production nergy consumption factor rs Homogenisier Homogenising ren g Vorr Raw reagieren materials Strukturieren Structuring Energie Energy Furnace pull, quality = constant Wannenleistung, Qualität = konstant Grad der Rohstoffaufbereitung Degree of batch preparation

13 lass production ocus on batch preparation Improvements of batch preparation: Raw Materials and Storage Preconditioned Material Preventing Segregation during tra ansportation and storage Mixing Increase the amount of Homogenisation Sequenced mixing for better micro structure Batch Transportation Structured batches Mixing directly in front of the furn ace

14 mprovement of Batch Preparation istorical development of the pan mixer technology Mixer sold in the glass industry Ring trough mixer Up to 1906 Homogeneity of the mix: Planetary mixer Up to 1924 Homogeneity of the mix: Possible improvement Intensive mixer with rotating mixing pan, horizontal As from 1924 (with rotor as from 1960) Homogeneity of the mix: Intensive mixer with rotating mixing pan, tilted As from 1970 Homogeneity of the mix:

15 mprovement of Batch Preparation dependent studies

16 mprovement of Batch Preparation dependent studies Homogeneity dry glass batch for different mixer types orbit (1kW W/100kg) ring gp pan (2kW/100kg) ribbon (1kW/100 kg) Intensive (5kW/100kg) 150.0% 140.0% 130.0% 120.0% 110.0% 0% 100.0% var. coeff. / hom mogeneity 90.0% 80.0% 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% mixing time in minutes 4 5 6

17 mprovement of Batch Preparation dependent studies ethods to Increase Specific elting Rate furnace for tubes about 25% heat losses through the structure independent to the furnace pull!) Ring trough mixer: 60 kg/(m 2.h), 90% melting productivity 75 kg/(m 2.h), 75% melting productivity Intensive (Eirich)-mixer with rotating pan: 75 kg/(m 2.h), 90% melting productivity Results: 25% higher specific melting rate on same product quality level Average 6% energy saving

18 mprovement of Batch Preparation dependent studies Selective Batching (by W.M.Carty) wt% glass former raw material A wt% modifier raw material B wt% modifier raw material C wt% glass former raw material A wt% modifier raw material B wt% modifier raw material D Total weight mixed batch ABCD cullet C Selective Batching of Batch Components combination material AB for η control in melt pelletize AB combination material AC for solid state rxn melt pelletize AC ABCD added to glass melt residing in furnace melt tank Mix AB, AC and any remaining portion of A, B and/or C in a mix hopper Melting and Fining Add mixed batch to glass melt residing in furnace melter tank CONTROLLED REACTIONS DUE TO SELECTIVE COMBINATIONS Standard Preparation Structured Preparation

19 provement of Batch Preparation &D Project with EinFormGl as IRICH is an active research partner for universities and producers esearch Project with EinFormGlass Research cooperation sponsored by the German Government Production of lightweight containers in a single production step Final presentation at Glasstec 2010 EIRICH Test Center Hardheim, Germany

20 mprovement of Batch Preparation &D project with EinFormGlas tructuring the batch by sequential preparation Coating of single grains Granulating of different minerals or filter dust up to the entire batch -All Inside the same mixer -

21 mprovement of Batch Preparation P R&D project EinFormGlas EinFormGlas Structuring the batch by sequential preparation Sequenced mixing (basing on an old patent Nölle/TU Freiberg) 1st sequence: Mixing Mi i wett sand d with ith so oda d 2nd sequence: Addition of the remainin ng raw materials 2 5% 2.5% 5% 7% 8% 9% 10% 11% Test for 1st sequence : 2/3 sand, 1/3 soda a, different moisture addition => Mixing mill or intensive mixer necessa ary => Segregation stops at about 8-10% watter addition => Improved melting with reduced melt s segregation A

22 mprovement of Batch Preparation &D project EinFormGlas dvanced batch structuring Structured batch, 1,5 mm From batch to pellets with up to 15 mm diameter conventional new moisture 12-18% 8-10% additional binder yes no grainsize 70% < 100µm standard sand Significant reduction of batch and melt segr regation as well as carry over

23 mprovement of Batch Preparation &D project EinFormGlas omparison by primary melting tests (1) (2) (3) (4) h h h (1) standard batch 2,5% moisture (2) transport segregated standard batch 2,5% moisture (3) Sequenced mixed batch with light soda 4,25% moisture (4) Pelletized batch with fine raw materials 11,75% moisture green line = batch free time

24 mprovement of Batch Preparation &D project EinFormGlas omparison at a small melting furnace (TU Freiberg) a.) Standard batch (3,5% moisture) compared to b)st b.) Structured t dbatch h( (standard dsand etc., light soda, fine dolomite and lime, 8% moisture when fed into the furnace) (1.370 C, 140 min) a.) b.) Melt-segregated t silica

25 mprovement of Batch Preparation pays off to improve the batch prep paration technology

26 hank you for your atten ntion! In case of any further questions or comments: Eirich Machines, Inc. Division of Machinenfabrik Gustav Eirich Hardheim, Germany Dan Britton North American Sales Manager Tel.: (847) Mail to: Internet: