Report on summer industrial training at

PIRAMAL GLASS LTD. JAMBUSAR

Prepared by

Utkarsh Sethia

Undergraduate student, SRM University, Kattankulathur

(Chennai)

Reg no – 1071310038

Under the guidance of

Mr. Dasgupta sir

Senior Manager – Glass

SELF DECLARATION

I UTKARSH SETHIA a student of SRM University Kattankulathur,Chennai (Reg no – 1071310038) states that I have completedmy industrial training in PIRAMAL GLASS LTD. JAMBUSAR from3/06/2015 to 18/06/2015.

I affirm that this industrial training report is the record ofauthentic work carried out by me and no part or whole of thisreport has been submitted to any where for any purpose.

Signature

ACKNOWLEDGEMENTI take this opportunity to thank PIRAMAL GLASS LTD.JAMBUSAR for giving me the opportunity to do industrialtraining here. It gives me immense pleasure to acknowledge allthose who have given me data, time and energy to supply allthe valuable facts and opinions that has helped me in gainingsome technical knowledge in glass industry during thisindustrial training.

I express my profound sense of gratitude to M.P. Rajesh sir(HOD , Chemical engineering , SRM University) ,Y N Jadeja sir(Sr. Manager – HR , Piramal glass ltd.) and Mr. Dasgupta sir (SrManager – Glass , Piramal glass ltd.) who have renderedconstant guidance, advice and help me when needed tocomplete this Industrial training successfully. I also express mygratitude to the company employees who have helped meduring this time.

Table of contents

Serial no. Title Page no.

1 Self Declaration

2 Acknowledgement

3 Introduction and company profile 5

4 Objectives during industrial training 6

5 Safety induction 7

6 Glass container/Glass bottles manufacturingprocess

8 - 11

7 Chemical Laboratory 12 - 16

8 Batch house 17 - 18

9 Glass melting Furnace 19 - 21

10 Physical laboratory 22 - 24

11 RO plant (reverse osmosis plant) 25 - 26

12 Bibliography 27

13 Conclusion 28

14 Learning and Observations 29

15 Suggestions 30

Introduction

Glass is an amorphous (non-crystalline) solid material which is oftentransparent and has widespread practical, technological, anddecorative usage in things like window panes, tableware etc. The mostfamiliar, and historically the oldest, types of glass are based on thechemical compound silica (silicon dioxide), the primary constituentof sand. Soda-lime glass, composed of approximately 75% silicondioxide (SiO2), sodium oxide (Na2O) from sodium carbonate(Na2CO3), calcium oxide, also called lime (CaO), and several minoradditives. A very clear and durable quartz glass can be made from puresilica; the other compounds above are used to improve thetemperature workability of the product.

Company profile

Piramal Glass Limited (formerly known as Gujarat Glass Pvt Ltd) is anIndian glass packaging company providing packaging for pharmaceuticaland perfume industry. Prior to acquisition in 1984 by Piramal Group,the company located its manufacturing plant in Kosamba, Gujarat. In1990 Gujarat Glass Pvt Ltd merged with its parent company NicholasPiramal India Ltd to become one of its many divisions.

Piramal glass manufactures glass containers and glass bottles. Atjambusar plant flint glass and amber glass bottles are manufactured.Jambusar plant has three furnaces 125 tpd, 160 tpd and 255 tpdfurnace. 255 tpd furnace produces amber type III Soda lime containerglass. 160 tpd and 125 tpd furnace produces Flint type III Soda limecontainer glass.

Objectives during Industrial training

1) To learn about how the raw materials used in glassmanufacturing processes are stored and handled.

2) To learn about various manufacturing processes involvedin making glass bottles from raw materials.

3) To observe and work in the industry as guided by thementor.

4) To learn about how the quality of a glass bottle ismaintained.

5) To gain practical knowledge in the field of glass industry.6) To know about the working of a glass industry through

interaction with company employees.

Safety inductionSafety, health and environment (SHE) cell guided me regarding the safetymeasures / equipments in the industry. Some of these are:-

Safety shoes – these are meant to provide protection to the feet underextreme conditions such as to avoid shocks, abrasion resistance, oilresistance, heat resistance and others.

Safety goggle – It is meant for protecting eye from chemicals, dust and fromthe radiations coming from high temperature sources.

Ear plug - An earplug is a device that is meant to be inserted in the earcanal to protect the user's ears from loud noises or the intrusion of water,foreign bodies, dust or excessive wind.

Dust mask - It is a flexible pad held over the nose and mouth by elastic orrubber straps to protect against dusts encountered during the handling ofraw material in batch house.

safety helmet – It is a type of helmet predominantly used in workplaceenvironments such as industrial or construction sites to protect the headfrom injury due to falling objects, impact with other objects, debris, rain,and electric shock.

Glass container/Glass bottles manufacturingprocess

The glass bottles manufacturing process is a three-part operation process:the batch house, the hot end, and the cold end. The batch house handles the rawmaterials; the hot end handles the manufacture process — the furnaces,annealing ovens, and forming machines; and the cold end handle the product-inspection and -packaging equipment.

a) Batch houseThe batch house simply houses the raw materials in large silos (fed bytrucks). The batch house measures, assembles, mixes, and delivers the glassraw material recipe (batch) via an array of chutes, conveyors, and scales to

the furnace. The batch enters the furnace at the 'dog house' or 'batchcharger'

b) Hot end Furnace - The batch is fed into the furnace at a slow, controlled rate

by the batch processing system (batch house). The furnacesare natural gas- or fuel oil-fired, and operate at temperatures up to1,575 °C.

Forming process - A stream of molten glass, at its plastic temperature(1,050–1,200 °C), is cut with a shearing blade to form a solid cylinderof glass called a gob. The gob is of predetermined weight justsufficient to make a bottle. The gob falls by gravity and is guidedthrough troughs and chutes, into the blank moulds. Now compressedair is blown through the glass, which gives the glass bottle a finalshape.

Internal treatment – It is a treatment to improve the chemicalresistance of the inside of the bottle. The process is also calleddealkalization. This is usually accomplished through the injection of asulfur- or fluorine-containing gas mixture into bottles at high

temperatures. Currently in Piramal glass Ltd. this process is understudy.

Annealing - As glass cools, it shrinks and solidifies. Uneven coolingcauses weak glass due to stress. Even cooling is achievedby annealing. An annealing oven (known in the industry as a Lehr)heats the container to about 580 °C (1,076 °F), then cools it,depending on the glass thickness, over a 20 – 6000 minute period.

c) Cold endThe role of the cold end is to spray on a polyethylene coating for abrasionresistance and increased lubricity, inspect the containers fordefects, package the containers for shipment, and label the containers.

Steps involved in manufacturing of bottles:-

a) Different types of raw materials are carried by trucks - (Dolomite, Calcitepowder, Silica sand – A , Silica sand – B , Silica sand – E, Limestone , Cokepowder, Soda ash (dense), Feldspar, Red oxide)

b) Different types of raw materials are stored in different bins.c) Different types of raw materials are moved to different silos through

conveyor belts.d) Different types of raw materials are individually weighed (as per required

quantity) with the help of weighing scales.e) The mixer mixes all these raw materials along with cullet in required

proportion to prepare batch.f) The batch thus prepared is moved to dog house, from where it is fed into

melter.g) In melter this mixture of raw materials react to give melted glassh) Now melted glass flows through:-

Throat (it connects melter to the distributor)

Distributor (it acts as a melted glass distributing system. It hasvarious zones at different temperatures)

Forehearth (here, glass conditioning takes place. In a particularforehearth , glass is maintained at a particular temperature as perglass bottles requirement)

i) At the plastic temperature of glass, a gob is formed.j) With the help of moulds, glass is given a particular shape to form glass

bottles.k) In LEHR , annealing process takes place . In this process stress is removed

from the bottles.l) Glass bottles are inspected for any defect by quality control department.m) Glass bottles are packed for marketing.

Chemical Laboratory (Quality analysis lab)

Following are the equipments in chemical lab for testing the quality ofglass and the raw material from which it is made:-

a) X-ray fluorescence (XRF) spectrometer - An x-ray instrument used forroutine, relatively non-destructive chemical analyses of rocks, minerals,sediments and fluids. In glass industry it is used for elemental and chemicalanalysis in the investigation of glass.

b) Fume hood - It is a type of local ventilation device that is designed to limitexposure to hazardous or toxic fumes, vapors or dusts.

c) Density comparator - For determining the density of glass.

d) Fractionating column - for obtaining very pure distilled water by theprocess of fractional distillation.

e) Hydride generation atomic absorption spectrometer (HGAAS) - Metalloidslike antimony, arsenic, selenium, and tellurium are analyzed by HGAAS.

f) Flame photometer – This instrument is used for analyzing and measuringthe content and concentration of elements (K , Na , Li , Ca , Ba) in glass andraw materials.

g) Muffle furnace - A box-type oven for high temperature applications such asfusing glass.

h) Hydraulic press - A device using a hydraulic cylinder to generate acompressive force. In glass industry it is used to make small disc shapedsample of sand, limestone, soda ash etc. The sample thus formed is furtheranalyzed for its chemical composition.

i) Autoclave - It is a pressure chamber used to sterilize equipment andsupplies by subjecting them to high pressure saturated steam at 121 °C foraround 15–20 minutes depending on the size of the load and the contents.

j) Electromagnetic sieve shaker – An equipment used in sieve analysis (fordetermining the particle size distribution of a granular material).

k) Moisture analyzer - for measuring moisture content in both high level andtrace amounts in solids (sand, limestone, feldspar etc).It displaystemperature, time, moisture%

l) Weight balance – For weighing purposem) Electric oven – It is used to heat the sample and thus remove moisture from

it so that it can be analyzed further.n) Glass cutting machine – It is used for cutting glass to form small disc shaped

sample of glass. The sample we get after cutting process has rough surface.

o) Twin variable speed grinder polisher – It is used to polish the sample ofglass. Polishing paper discs, cerium oxide powder and water are used in theprocess of polishing.

p) Mini ball mill – It is used to reduce the particle size of sample by usingimpact energy. The energy from the impact of the moving balls beaks downthe sample until the final required fineness is achieved.

q) Silica gel – It is used to control moisture in the sample.

r) Binding agent – PVA solution (it is used while preparing test sample of sand, feldspar etc)

s) Acetone - It is used along with binding agent to make test samples. It acts as adrying agent.

t) UV/Vis Spectrometer – It uses the principle of Beer-Lambert law to findtransmittance and absorbance of a glass sample.

Sample reading for UV/Vis spectrometer - Lambda 35 (taken withpermission)

Data for JBR AMBER_04 06 15-01 . Sample (A). (For a particular knownthickness of glass)

S.no. Wavelength of radiation (slit width – 1 nm) Absorbance

1 290 nm 3.4972 310 nm 3.3833 330 nm 2.4214 350 nm 2.4235 370 nm 2.3556 390 nm 2.1917 410 nm 2.1378 430 nm 2.0779 450 nm 1.80310 550 nm 0.68111 650 nm 0.46912 1050 nm 0.680

Similar data is recorded for different thickness of glass and following result isobtained.

Result (Transmission report) Transmission at 550 nm 32.91% FeO 0.244 Redness factor 1.5374 450 nm 3.86

Types of samples tested in Quality analysis laboratory:-

Dolomite Calcite powder Silica sand – A Silica sand – B Silica sand – E Limestone Coke powder

Soda ash (dense) Feldspar Red oxide

Safety in quality analysis lab:-

Emergency shower (safety body shower and safety eye shower)

Fire extinguishers (Carbon dioxide based and Dry powder based) Emergency exit

Some reasons for rejection of raw material (ex – sand, feldspar, sodaash etc):-

High fines ( ex – 100 BSS < 15% for dolomite ) Low SiO2 % Low CaO % High MgO % High Fe2O3 % High amount of coarse size particles

Batch houseBatch house is one of the most essential parts of a glass manufacturingsite. A batch house normally needs to supply several different recipes ofraw material batches to multiple furnaces.

The batch process of the glass facility is divided into four sections.

a) Silo feedingIt consists of feeding the raw material into one of the multiple silos or

hoppers. When unloaded from the trucks raw material is conveyed through

a series of bucket elevators and conveyor belts to the silica, soda ash,

limestone, feldspar or sodium sulphate silo. Each of these silos are fitted

with level transmitters, pressure switches and over pressure flaps that are

all controlled by the batch control room . The silos have a series of de

dusting units that help in trapping the excess dust, which tends to rise as

the silos get filled up. These de dusting units comprise of dust collectors

and blower fans. At every stage magnetic separators will prevent iron

impurities finding their way into silos.

b) Batch weighing and transportThis section deals with the weighing, dosing and transport issues of the

batch plant. Dosing into the weigh scales is either through screw feeders,

pneumatic feeders or vibrating feeders. The time and sequenced dosing of

the raw material is completely controlled by batch control room. The

conveyors are again controlled by batch control room.

c) MixersNormally a plant is equipped with several mixers each driven by a motor.

Raw material is fed to the mixer that has to be filled through a swivel pipe.

Batch control room ensures that the mix reaches the desired consistency

before it is fed on to the main conveyor belt.

Cullet is added to the mix on the conveyor belt to get the final mixture that

is ready to be loaded in the furnace .Single or multiple batch chargers takes

the final mix from the furnace silos from where it is fed into the melting

furnace.

d) Cullet and cullet returnGlass production companies use cullet from external suppliers as well as

the cullet that is returned from their own production line. Conveyor belts

are used to transport the cullet into the batching process. Incoming cullet

from external sources is loaded into a hopper that feeds the cullet to a

series of crushers. On its way to the cullet silo the cullet passes magnetic

detectors and magnetic separators that keep iron parts away from the silo

and finally from the raw glass melt.

Glass melting FurnaceWith the viewpoint of Piramal glass ltd., glass melting furnace is explained asfollows:-

Type of furnaces in piramal glass ltd. – Regenerative end port (a type of tankfurnace)

Tank furnace:-

Tank Furnaces are used where continuous flow of glass is needed to feed automaticglass forming machines. They are more economical (as compared to pot furnaces) intheir use of fuel and are used for the large scale production of containers (glass bottles).

A tank furnace consists of a bath, built of a very special high refractory material, whichcan resist chemical attack of molten glass at temperatures in excess of 1500°C and asuperstructure where combustion takes place.

In order to achieve high melting temperatures and fuel economy, a regenerative systemis used. This system utilizes the waste heat of combustion for pre-heating the incomingcombustion air.

Regenerative furnace (a type of tank furnace):-

In a regenerative furnace, air for combustion is preheated by being passed over hotregenerator bricks, typically called checkers. This heated air then enters an inlet port tothe furnace. By using one or more burners, fuel is injected at the port opening, mixeswith the air, and burns over the surface of the glass. Products of combustion exhaustout of the furnace through a non firing port and pass through a second set of checkers,thereby heating them. After a period of 15 to 30 min (20 minutes for 105 TPD and 160TPD furnace and 30 minutes for 255 TPD furnace in piramal glass ltd.) , a reversingvalve changes the flow and the combustion air is passed over the hot checkers thatwere previously on the exhaust side of the process. The fuel injection system alsoreverses. After reversing, the exhaust gases pass through and heat the checkers thathad previously heated the combustion air.

Type of fuel used:-

Heavy fuel oil or natural gas is normally used for firing tank furnaces. Glass, being anelectrical conductor at high temperature, can also be melted by electricity. However,electricity is far too expensive and is normally used to boost the output from a gas or oilfired furnace.

End-Port regenerative furnace:-

In an end-port furnace, the ports are located on the furnace back wall. Batch is chargedinto the furnace near the back wall on one or both of the side walls. The following figureshows the layout of a typical end port furnace.

The above figure shows the inside view of a melter

Physical laboratory (Quality control laboratory)Quality control (QC) is a procedure or set of procedures intended to ensure that amanufactured glass product adheres to a defined set of quality criteria or meetsthe requirements of the client or customer.

Following are the equipments/tests that are used in quality controllaboratory:-

a) Polariscope – It is used to help detect the presence of glass strain. Bylooking through two polarized filters held in varying orientation one canvisualize the stress patterns in a piece of glass.

b) Inspection of cold end coating - Glass containers receive surface coating atthe cold end just after annealing. At the cold end a layerof polyethylene wax is applied on the surface of glass bottles. This makesthe glass slippery, protecting it from scratching and stopping containersfrom sticking together when they are moved on a conveyor.

c) Thickness tester – This device measures the thickness of glass bottles

d) Shaker testing - A shaker is a device used in vibration testing/shaker testingto excite the structure for endurance testing. This test is mainly used fortesting nail polish bottles

e) Drop test – This test is performed to ensure that containers have sufficientresistance to withstand impact during Transportation and Packaging.

f) Vertical load testing machine – This test is used to determine product’sresistance to vertical load forces.

g) Profile projector - The projector magnifies the profile of the glass bottle,and shows this on the projection screen. It is utilized for measuringdimensions and for designing purpose.

h) Weight and capacity measurement devicei) Digital vernier caliperj) Leakage test or vacuum test - Leak Test Machines have the ability of testing

minutest leakages with utmost accuracy with pressure drop & vacuummethod.

k) Thermal shock testing machine – It is used to test containers strength towithstand stresses due to high temperature gradient. This test is performed

on glass containers that may be subjected to high differences intemperature during their normal use.

l) Bursting test – This test is performed to Ensure that bottles are able towithstand internal pressure due to evaporation at high temperatures

m) Inspection of hot end coating - Glass containers receive surface coating atthe hot end, just before annealing. In lab this coating is analyzed.

n) Impact tester – This test is performed to ensure that the glass bottles canwithstand impact force in day to day use.

RO plant (reverse osmosis plant)Following are the steps involved in an RO plant process at piramal glass ltd.

a) Feed tank – Water after being treated in effluent treatment plant (sewagetreatment plant) comes here and is stored in the tank.

b) Feed pumpc) Acid dosing system – Hydrochloric acid (HCl-33%) is added into the feed

water just before filtration to maintain a pH level of about 6.5 to allow anyun-precipitated materials to be filtered.

d) Filter pumpe) Sand filter – It removes the particles of size greater than 15 microns from

feed water. It also removes turbidity from water.f) Anti scaling dosing system – The purpose of this system is to reduce the

potential of calcium carbonate scaling in the RO system. Certain acidicchemicals (HCl, H2SO4) are added to feed water to prevent the formation ofscales.

g) Cartridge filter –It removes the particles of size greater than 10 micronsfrom feed water.

h) High pressure (H.P.) pump -1,2,3 and 4 All of them are used to pumpwater in membrane module 1

i) Pulsation dampers - pumps produce pulsating flows which lead to pressurespikes. These pressure spikes may not be desirable in a given piping system, therefore there is a need for a pulsation dampener.

j) Membrane modules (stage 1) It has 37 modules (1 module has 183membranes and 185 hydraulic discs)

k) Booster pump 1l) Membrane modules (stage 2) It has 28 modulesm) Booster pump 2n) Membrane modules (stage 3) It has 28 moduleso) Booster pump 3p) Membrane modules (stage 4) It has 27 modules

q) Now two types of streams are formed:- Reject (this water is send to MEE (multiple effect evaporator) plant

for further processing. Permeate – This is the stream of water that has passed the

membranes.r) Intermediate permeate tanks) Intermediate permeate transfer pumpt) Degasser blower motor – Impurities are removed further in this processu) Final permeate tank and pumpv) Final storage tank – used everywhere in the plant except for drinking and

food making purpose.

Note:-Particles of size greater than 1 angstrom cannot pass membrane modules.

Bibliography

Information from various departmentheads and employees in the company

Information from the specification boardsin the company

Wikipedia -https://en.wikipedia.org/wiki/Glass_production

Information obtained from variouswebsites –http://www.eurotherm.com/industries/glass/glass-applications/batch-house-control/

Various research papers available oninternet

Information obtained from learningcentre in the company.

ConclusionI conclude that while going through the entire industrial training, the cooperationis found to be very well organized and developed in every walk of its production,administration & management aspects.

During this industrial training I have gained a lot of practical knowledge in thefield of glass bottle manufacturing, RO plant working, effluent treatment plantworking etc.

I extend my heartiest thanks to PIRAMAL GLASS LTD. JAMBUSAR for making myindustrial training a memorable period in my life. Interaction with companyemployees has also helped me in learning about various processes and machinesused in the industry. I feel myself lucky to get an opportunity to do industrialtraining in such an esteemed company.

At last I want to say THANK YOU

Learning and Observations

I have learned a lot about how a glass industry works. Through interaction with company employees, I came to

know about new things and what is the future in/of glassindustry.

I have learned new ways to treat the fellow members which isa very important thing in any industry.

Everyone here in the company is very cooperative and thishelped me a lot during this industrial training.

Safety is promoted, followed and maintained in everydepartment of the company, this helps in preventing anyindustrial accident/disaster.

There is a team spirit in every department of the industry. There is cooperation among the departments which is a key

factor in the growth of any industry. Food quality is good. The company has a friendly environment for students doing

industrial training here. Besides glass making process I have also learned about how

waste water is treated in an industry and how a reverseosmosis plant works.

The quality of raw material used for making glass ismaintained and also the quality of glass bottles formed ischecked.

The buses from vadodara to piramal glass limited are alwayson time and are comfortable.

SuggestionsMy suggestions regarding the improvement of this industry are as follows:-

The ambient air temperature in 160 TPD plant is much less than 255 TPDand 105 TPD plant. Something must be done (ex – use and maintenance ofappropriate insulating materials) to reduce the heat loss from the furnaces(especially 255 TPD and 105 TPD plant). Also 255 TPD plant and 105 TPDplant are too much compact as compare to 160 TPD plant and this may bethe reason for their higher ambient air temperature.

A research and development (R and D) lab must be set up in PIRAMALGLASS LTD. JAMBUSAR which will work for the development andimprovement of processes in all the departments.

Company must derive a part of its energy and electricity needs fromrenewable sources ( ex solar , wind etc)

The use of proper safety equipments must be encouraged in culletprocessing plant. There is one place in cullet processing plant where finedust of glass flows / is suspended in air (if a person is there for around 15minutes then itching starts). So, my suggestion is to cover the whole culletprocessing plant inside closed walls.

My suggestions regarding the improvement of industrial training process inPIRAMAL GLASS LTD. JAMBUSAR are as follows:-

Online forms for doing industrial training in piramal glass ltd. must beavailable on internet (on websites like internshala).

In spiral type RO plant usually there is no one to guide the trainees whilein disc type RO plant and MEE plant the employees are very cooperative,so company must look into this aspect.

In batch control room also usually the employees are very busy, so theremust be someone for guidance.