1.
Glass
INDUSTRIAL PROCESS DESIGN
MARMARA UNIVERSITY
INDUSTRIAL ENGINEERING

2.
Introduction
►This presentation focuses on glass.
►It is designed to interpret the potential
impacts of the processes associated with
glass. It takes you through the cradle to
grave lifecycle of glass, paying particular
attention to the social, environmental and
public health impacts of these processes.

3.
1) We start by looking at the natural resources for making
glass.
2) We then go to the glass making processes and its
utilization.
3) This is followed by the disposal of glass waste.
4) I will analyze the social, environmental and health
impacts associated with each processes throughout my
presentation.
5) I will talk about the importance of environmental justice
in the life cycle of glass and discuss with you how can we
address the problems.
6) Lastly I will mention about glass usage in defense
industry.
Presentation organization

4.
What is Glass?
► Glass is a manufactured
material formed when a
mixture of sand, soda, and
lime is heated to a high
temperature and assumes a
molten, or liquid, state.

5.
Now, we start by looking at
the natural resources
for making glass.
►Distribution of natural resources
►Formation
►Purposes for utilization
►Extraction process
►Environmental and Social effects of extraction
process

6.
Natural Resources
► Silica sand 72%
► Soda Ash 17%
► Lime 5%
Percentage of Ingredients in Glass
silica sand
soda ash
lime
other ingredients
72%
17%
5%
6%

7.
Silica Sand

8.
Silica Sand
► Three of most common rock forming minerals on
earth
► Chemically named: quartz sand / rock crystal
► Properties:
 Extremely heat durable
 Chemical stack resistance

9.
World resources of Silica Sand
► Silica sand resources is
abundant on the world.
► Its extraction is limited by
 geographic distribution
 quality requirements for
some uses
 environmental
restrictions
► Extraction of theses
resources is dependent on
whether it is economic and
are controlled by the location
of population centers
Fig. 1

10.
Purposes for the Utilize of
Silica Sand
► History:
 Glass making & metallurgical activities few thousands
years BC ago
 Key raw material in ceramics, foundry & glass industrial
revolution
► Today:
 Glass making, foundry casting, ceramics, filtration,
specialist building applications, leisure ( e.g. golf
course), filters in numerous products, plastics, the
manufacture of chemicals, metal & refractory, as
addictives in horticultural & agricultural products &
simulating oil production

11.
Soda Ash

12.
Soda Ash
►Anhydrous sodium carbonate
►Texture: soft
►Color: grayish & white
►Appearance: lump / powder in nature

13.
Location & Integration of
Soda Ash
► Large soda ash deposits:
 U.S, Mexico, Canada, Kenya, Botswana, Uganda,
Peru, Germany, India, Egypt, S. Africa & Turkey
► World’s largest trona deposit:
 Green River Basin of Wyoming
 estimate to have 47 billion tons of soda ash

14.
Purposes for the Utilize of
Soda Ash
► History:
 Early Egypt: make glass
& soap
 Early Roman: make
glass, bread &
pharmaceuticals
(medicine) purpose to
cure choric & skin
rashes

15.
Purposes for the Utilize of
Soda Ash
► Glass manufacture (49%)
► Chemical production (27%)
► Mineral processing in mining
► Pulp & Paper manufacturing
► Sodium compounds
manufacturing
► Soap & detergents (11%)
► Water treatment (2%)
► Textile processing
► Glass fiber manufacture
► Cleaning preparations
► Petroleum refining
► Metallurgical refining
► Removal of sulfur from
smokestack emissions (3%)
► Distributors (5%)
► Metal refining

16.
Lime

17.
Lime
► Include hydrated
lime & quicklime
► Only quicklime can
use to make glass

18.
Development of Glass Making
► First automated bottle machine was created in
1905
► Nowadays, most of the glass containers are
manufactured by technological machines at large,
automated factories & control by computers
 cheaper and better
in quality
A Float glass
Plant

19.
Historical Glass Manufacturing
Process:
Historical method:
► heating and blowing
► shape the glass
products by hand
► requires high skills & is
time consuming
therefore using glass is
considered as luxury in
our old world

20.
Today’s Glass Manufacturing
Process:
1. Silica sand, limestone,
soda ash and cullet
(recycled glass or broken
glass) are keep dry and
cool in a batcher house
in silos or compartments
2. Mixing and weighting
into proper proportion
3. Send to furnaces in
hoppers
 operated by natural gas
 heat the mixture at 1300-
1600 degrees Celsius into
soften or molten state
Fig.12

21.
4. Molding --- molten glass flows to forming machine to
mold into desire shapes
5. Annealing --- reheating the glass in an oven
 to ensure even cooling of glass for strengthening of
the products
6. Cooling process --- Cool for 30 min to an hour for
safe to handle.
7. Glass products are then decorated,
inspected again and finally packaged
and shipped to our customers.
glass furnace
cooling systems

22.
Effects From Glass Manufacturing
Process
Workers:
 Dangerous & harmful to workers if breakage occurs
while glass holds heated or corrosive, can result in
serious injuries
►Glass making process occurs at high temperature
►Glass can broke easily under pressure, impact or
thermal shock
 Prevention: wear protective
clothing and gloves to prevent
those injuries

23.
Environmental Impact
Environmental degradation:
► Air pollution:
 raw materials used for glass making
decompose at furnaces produce large
volume of gas such as carbon dioxide
 combustion of gas for energy production
release large amount of pollutant gases, such as
sulphur dioxide and oxides of nitrogen
► Green house effect:
 green house gases release from the plants increase
global temperature and can form acid rain

24.
Utilization of Glass
►History of glass
►How is the utilization of glass importance for
communities?
►Global marketing and consumption status of glass
►The impacts of glass products

25.
History of Human Using Glass:
► People have used glass dating back to 5000 B.C
► Ancient Egypt: earliest use of glass, for royalty
and priest as luxuries
► Usually use as containers or for decoration
purposes in human history

26.
History of Glass
► In Byzantium Empire, glass was used extensively in
buildings and many examples can be found today
reminiscent of that era. Many glass centers in Syria and
Egypt were well-known from the beginning of 7th century.
► The art of glass making in Turkey started with the Seljuks
and improved after the conquer of Istanbul. In and around
Istanbul, many glass workshops have been established. At
the beginning of 14th century, a crystal glass factory has
started in Çubuklu, Istanbul with a special design named
Çeşm-i Bülbül ( The nightingale's fountain). The first
modern glass factory in Turkey was established in
Paşabahçe - Istanbul in 1934 and this factory renews itself
with its new investments and developments.

27.
Different type of glass:
► practical glass
► industrial glass
► inspiration glass
► glass of science and
medicine

28.
Examples of Today’s Glass
Products:
 Containers (jars and
bottles)
 Flat glass (windows,
vehicle glazing, mirrors,
etc.)
 Lighting glass (fluorescent
tubes, light bulbs, etc.)
 Tableware (drinking
glasses, bowls, lead
crystal, etc.)
 Laboratory equipments
(test tubes, cylinders,
measuring flasks, etc.)
 TV tubes and screens
 Decorative glass
 Fiberglass
 Optical glass
 Vacuum flasks

29.
Export & Import of Glass
►Largest Importer of past decades: Europe
and Australia
►Today largest Importer : U.S.
►China and Indonesia has increased their
import of glass dramatically

30.
Glass Industries
The World Glass Industry has a gross production value
totaling $82.3 billion
Fig. 14

31.
First Ten Companies
Company Name Year founded
Total Sales ( Million
$)
Saint-Gobain 1665 11,480.00
Durand 1815 1,100.00
Pilkington 1826 4,700.00
Corning 1850 2,940.00
PPG 1883 6,021.00
Schott 1884 2,400.00
Asahi 1907 7,600.00

32.
Glass Consumption in Europe
Europe is one of the large importer of glass. Through observing
the consumption pattern of glass in different countries of
Europe, we can get an image of how large is the human
consumption of glass is:
Average glass consumption in kilo/annum 1990-1995/capita in different countries
When considering the whole EU, projections suggest that glass consumption
will increase between 24 and 53% up to the year 2010, using the year 1995 as
a base year (European Topic Centre on Waste, 1998).
Fig. 15

33.
Disposal of Glass

34.
Glass Waste
► Most of glass waste is generated from glass packaging
► Glass waste generated from packing is among the top forth
in the world.
Waste (mPEMwdk2000 per kg of packaging
Fig. 17

35.
How is glass waste treated?
►Landfill
►Recycle
►Vitrification

36.
Example: Landfill at Seoul
►The Sudokwon landfill site at Seoul (S.
Korea) covers 20,749,000 square meters
Construction of the Sudokwon
Landfill at Seoul
Large area of sea
is filled by land
Fig. 18

37.
Recycling of Glass
► Recycle of glass is mostly used for packaging
► Recycle process

38.
Myths of Recycling Glass
► Refillable bottles require more energy to make as they are
about 50% heavier than non-refillable bottles to prevent
breakage, and to transport them over long distances to
sparsely located processing facilities. Since the raw materials
of glass are abundant and cheap, recycling glass only
consumes and wastes the more valuable non-renewable fossil
fuels (Warmer Bulletin November, 1993)
► It takes more energy to collect and recycle glass into another
bottle than to make one from raw materials. However, the
energy requirement to produce a refillable bottle will decrease
with the number of returnable trips, and an eight-trip bottle
can reduce the energy requirement by about two-thirds
compared to a non-returnable bottle (Porteous, 1977)

39.
Vitrification
► Definition: a new technology has
been discovered to use recycle
glass for radioactive waste
management
► Process:
 melt glass together with
radioactive waste in barrels or
some other container
 glass will then bind up with
radioactive contamination into
a huge glass block
 radioactive waste is bond by
the glass and become
immobilized
 keep radioactive waste from
interacting with water, stop
spreading the waste Fig. 20

40.
GLASS USAGE IN
DEFENCE

41.
Glass in DEFENCE
► These are primarily silicates containing oxides such as
Alumina (AL2O3), TiO2, LiO2, and others.
► In amorphous form, the glasses are transparent. Most
glasses can be made to transform into a
polycrystalline state by a suitable heat-treatment
process, called devitrification.
► An initiator, such as TiO2, is added to begin the
nucleation of ceramic crystals. The product is called a
glass ceramic.
► Desirable properties include: high strength and
thermal conductivity, low thermal expansion, resistant
to thermal shock, ease of fabrication. using
conventional methods.

42.
Composite Armor
Projectile
Outer hard
skin
Ceramic-
Discontinuous
Inner
ductile
skin
Personnel
and
Equipment
Ceramic Armor System

43.
Glass in DEFENSE
Here you see a sample of usage fiber-glass in defense industry.
Wings and the Cover of missile is produced from fiber-glass.

44.
Glass in DEFENSE
A fiber-glass shipyard in assembly

45.
References
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Commodity Summaries. Retrieved 05/19/2003, from
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pubs.usgs.gov/gip/ deserts/minerals/
5. Petruccl, R. H. (2002). The Solvay process for the manufacture of NaHCO3. A
Pearson Company. Retrieved 05/19/2003, from
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minerals/gnsmaps
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Inc. Retrieved 05/19/2003, from www.miningimpacts.net/ micpic3.html
9. Cable Sands & RZM. www.cablesands.com.au/cswa/ company-profile.asp
10. RockWare Glass. How is Glass Made? www.glassforever.co.uk/howisglassmade/
11. http://www.bisnis.doc.gov/bisnis/country/000727glass_samara.htm
12. Bled, S. (2001, June 20-22). International Federation of Chemical, Energy, Mine
and General Workers’ Union. www.icem.org/events/ bled/matdocen.htm
13. http://www.mst.dk/project/NyViden/2000/08030000.htm
14. The citizens’ committee for green Seoul. Construction of the Sudokwon Landfill.
smg.metro.seoul.kr:9000/ waste/part4.html
15. Vitrification International Technologies, Inc. (2002, March, 3).Schematic of waste
vitrification transformations. www.vitrification.com/ vitrification.htm

46.
ANY Q ?
► enjoy your life……..
Kerim GOZTEPE
kerimgoztepe@yahoo.com