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WELCOMETO

OUR PRESENTATION ON

Manufacturing process of glass

DEPARTMENT OF MECHANICAL ENGINEERINGDHAKA UNIVERSITY OF ENGINEERING &

TECHNOLOGY, GAZIPUR-1700.

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TECHNICAL SEMINAR ON

Nasir Glass Industries LimitedJoinabazar, Sreepur,

Gazipur, Bangladesh.PRESENTED

BY

MD. Emamul Hossain ID NO: 093100

MD. Rashadul Alam ID NO: 093112

MD. Sultan Ahammed ID NO: 093120

SUPERVISED BYprof. Dr.Himangshu Bhowmik.

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OBJECTIVES

To take an idea about NGIL. To acquire knowledge on Glass manufacturing. To increase our knowledge about industrial application.

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INTRODUCTIONNasir Group, one of the largest renowned Group of Industries in Bangladesh .Specially it is famous for its glass manufacturing Industries in Bangladesh and abroad .The Group is proud of its lead for its many prestigious industries as a pioneer in Bangladesh. Nasir Group is no longer simply a Group of Industries now-a-days, it has established its own Brand Image in the country.

Fig : Nasir Glass Main Gate. Fig : Admin Building.

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MISSION & VISION

The group’s mission and vision is to satisfy all of their clients providing quality products with a competitive price through its companies innovation and constant developments. This image has also crossed the border long before ,because some products are continuously being exported to some Asian, Africa and Middle East countries like India, South Africa, Sri Lanka, Nepal, Bhutan, Kenya etc. Nasir Group, originally a regional biri manufacturer based in western Kushtia district, became a household name after setting up the country’s first float glass factory. The Group is also the country’s biggest melamine manufacturer, has a sports shoes plant and sells low-priced cigarettes. The Group started January 1977. Nasir Group is also involved in socio-cultural activities. Nasir Group has been operating some schools and Colleges education in district town Kushtia. The Group has also acquired a modern mother & children hospital.

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Products of NGIL Float Glass (Clear &Tinted) : 100,000 MT/Annum/Under expansion Shade: clear, coffee bronze, Dark Gray, Ocean Blue, Green. Tempered Sheets: Clear/Tinted/Coated Mirrors: Standard sizes; Thickness 3, 4 & 5 mm; excellent finish. Thickness range: 3mm to 12mm (2mm also possible). Sizes of glass Product cut on line: Large size 8 X 144̋4̋ 4̋� 4̋�

Medium size 8 X 74̋2̋ 4̋� 2̋�

Small Size 4 X42̋8̋ 2̋� 8̋�

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Flow chart of NGIL

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Raw materials for float glassMaterial Composition (%) Benefits

Sand (SiO2) 72.6 -

Soda Ash (Na2CO3) 13 Easier melting

Limestone (CaCO3) 8.4 Durability

Dolomite (MgCO3.CaCO3) 4 Working & weathering properties

Alumina (Al2O3) 1 -

Others 1 -

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Raw material for glass

Fig: Silica Fig : Soda ash Fig : Dolomite

Fig : cullet.

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QualityInternational ; Strictly conforms to Chines National Standards GB11614̋-1999 and GB/T 18̋701-2̋002̋ and Japanese National Standard J/S R32̋02̋.

ProcessFully automated with strict process control at every step from sand processing to finished ware, backed up by highly trained and experienced professionals. NGIL uses the best technologies and the manufacturing process is strictly controlled by the certified and skilled experts to ensure the international standard.

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Ore-dressing plant

Main purpose of this plant is mainly to remove Iron & alumina. To maintain the size of silica. 4 – 5% of water is maintained in the sand.

Fig : Slary pump. Fig : Sand crashing machine.

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BATCH PLANT

Batch plant is a very essential plant in NGIL. This plant is fully computerized. There are eight storage tank in this section. The amount of the elements are highly controlled. Specification of batch plant: Weight of a batch 1300 Ton

Cullet (broken glass) 20%

Raw materials 80%

Fig : Raw material storage tank.

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Regenerative furnace Specification of regenerative furnace Capacity 400 t/d

Temperature 1500 -1600ocFuel (natural gas) 80000 – 90000 m3/day

Length 62 mWidth 25 mFuel : Air 1 : 7-10

Fig:- Regenerative furnace.

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Regenerative furnace

Features• high furnace capacity up to 400 t/d• high quality glass for architecture or automotive purpose• low energy consumption• low emission values

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Regenerative furnace

Working principle• The furnace have two chamber.• Refractory materials.• Flow is reversed in every 20 min.• Air is preheated heated by checker.• preheat temperature 1200 – 1350 ˚C

Fig:- Regenerative furnace.

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Tin bath Molten glass from furnace is fed into in bath. Tin bath contain molten tin. Density of glass is lower than tin. Glass is float on the tin. Viscous effect. N2 & H2 gas are supplied.

Specification Length 50 m

Width 3-4 m

Depth 6 cm

Entering temperature 1100oc

Exit temperature 600oc

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Fig : Inside view of the tin bath.

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Nitrogen plant N2 is used to prevent corrosion of tin. The capacity of nitrogen plant is 2100 m3/h. Natural air is used as raw materials.

Fig: Nitrogen plant.

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Working principle of nitrogen plant

Cleaning the air :

In a typical plant, air is drawn in through a filter to remove the dust, compressed to about 6 atm and cooled to below ambient temperature where much of the water vapour condenses.

Al2O3 : It is used to absorb CO2.

Zeolite molecule sieve : It is used to absorb H2O, CO, oil e.t.c.

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Working principle of nitrogen plant

Liquefying the air The manufacture of nitrogen, oxygen and argon from atmospheric air

involves liquefying the air and then separating it into its component parts by fractional distillation. Since nitrogen and oxygen have very low boiling points they liquefy at cryogenic temperatures.

Constituent helium neon nitrogen argon oxygen krypton xenon carbon dioxide

Boiling Point/K, at atmospheric pressure

4 27 77 87 90 120 165 195 (sublimes)

Fig: The boiling points of the gases that make up dry air.

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Working principle of nitrogen plant

Distillation of the liquid air The liquid air is separated into its constituent components

by fractional distillation. At each distillation the vapour is richer in nitrogen, while the liquid remaining contains more oxygen.

To produce pure oxygen the distillation system has two distillation columns, a 'high' and a 'low' column. Nitrogen plants often use a single column but some use two.

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Hydrogen plant Hydrogen used in tin bath to prevent oxidation of glass. Chemical reaction : 2NH3 3H2 + N2

Fig : Ammonia cylinder.

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Electric furnace Specification of electric furnace Raw material NH3

Temperature 800 – 850 ᵒc

Power consumption 80 KW

Max. pressure 5.5 bar

Min. pressure 4 bar

Fig : Electric furnace.

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Annealing process

Molten glass from furnace feed into annealing unit. Remove the inherent stress in glass and improve glass yield.

Fig : Annealing unit.

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Annealing process

Specification of annealing unit : Production capacity 400t/d

Glass thickness 2 ~ 16 mm

Glass temperature when the glass enters annealing equipment 600±10 ℃

Glass temperature when the glass exits annealing equipment 80 ± 10 ℃

Crosswise temperature difference when the glass enters annealing equipment

≤10 ℃

Annealing lehr length ≈ 120m

Annealing lehr inner width 4200mm

Annealing lehr outer width 4900mm

Annealing equipment roller speed 80 ~ 800m/h

Residual stress (6mm) < 9kg/cm2

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Annealing process Different zone of annealing unit : Zone A, B & C No contact of air with glass.

Zone D, E Natural cooling.

Zone R1, R2, R3 Recirculation i.e direct contact of air supplied by blower.

Zone F1, F2 Direct contact of air supplied by nozzle.

Fig :Different zone of annealing unit.

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Cutting & Finishing

The cutting line is fully automatic. Carbide cutting tool is used. All roller are operated by main driving unit.

Fig : Main driving unit. Fig : Rollers connected with main driving unit.

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Cutting & Finishing

Fig : carbide cutting tool. Fig : Automatic cutting line.

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Final Product of NGIL

Fig : Final product of NGIL.

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CONCLUSION

Today, more than ever, engineering are often interdisciplinary, involving the interrelationship of several of the basic engineering science. Therefore the modern engineer must have a fundamental knowledge in each of these areas theoretical and practical. To make a bridge between theoretical knowledge and practical knowledge by arrange this type of industrial visiting resulted an engineer build up own criteria very much widely in practical life.