This report summarizes the author's summer training at Trakya Cam Sanayii A.Ş. Trakya Factory, which produces float glass. It describes the key steps in float glass production, including batch preparation using raw materials like sand, soda, and dolomite; melting the batch at high temperatures in the furnace; refining the glass through affination; shaping and annealing the glass; and cutting the finished glass to customer specifications. The report provides details on the manufacturing process and composition of float glass.

1.
T.R.
EGE UNIVERSITY
FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
SUMMER TRAINING REPORT
FLAT GLASS PRODUCTION
Summer Training In
Trakya Cam Sanayii A.Ş.
Training Date
20.06.2005‐15.07.2005
Prepared by
Ercüment SÖNMEZ
05‐01‐4340
Bornova, İzmir
2005

2.
Ö Z E T
Bu rapor, Trakya Cam Sanayii A.Ş. Trakya Fabrikası’ndaki stajım boyunca düz cam
üretim teknikleri, çeşitleri ve üretime yardımcı prosesler konuları hakkında edindiğim
bilgileri içermektedir.
Cam, çeşitli oksitlerin ergitilmesi ve kristalleşmesine izin verilmeden oda sıcaklığına
kadar soğutulmasıyla oluşan parlak yüzeyli, şeffaf bir inorganik üründür. Viskozitesi
oldukça yüksek bir madde olan cam, normal koşularda sıvı halde olmasına rağmen katı
madde özellikleri gösterir. Trakya Cam Sanayii A.Ş. Trakya Fabrikası’nda üretilen düzcamın
kompozisyonunda kum, dolomit, soda, kireçtaşı, sülfat ve feldspat bulunur.
Cam üretiminin aşamalarının ilki ve en önemlilerinden biri harmanın
hazırlanmasıdır. Harman, camı oluşturacak hammaddelerin belirlenmiş oranlarda
tartılması, karıştırılması ve fırına kadar kayıpsız olarak aktarılmasıdır. Oluşan herhangi bir
sorun nedeniyle istenen kriterlere sahip olmayan harman yani bozuk harman fırına
verilmez, bozuk harman bunkerine atılır.
Harmandan gelen karışım, iç sıcaklığı maksimum 1580°C olan fırında ergitilir. Bu
işlem sırasında açığa çıkan gazlar camın yüzeyine nüfuz ederler. Takip eden aşamada,
camın kalitesinin düşmemesi için bu gazlar afinasyon adı verilen işlemlerle camdan
uzaklaştırılırlar. Afine edilmiş cam, fırının boyun kısmında homojenize edilerek
dinlendirme havuzuna aktarılır.
Dinlendirme havuzunda şekillendirmeye uygun hale gelen cam, yaklaşık 1100°C
sıcaklıkta iken kalay banyosuna alınır. Burada cam, toproll makinesi ve daha sonra lift‐out
ruloları yardımıyla istenen kalınlığa ulaştırılır.
Kalay banyosu sonunda sıcaklığı 600°C’ye düşürülen ve şerit haline getirilen cam,
tavlama tüneline aktarılır. Bu bölümde, cam şeridinde gerekli sıcaklık farklılıkları
oluşturularak, cam kesime uygun hale getirilir ve tavlama tünelinden yaklaşık 50°C
sıcaklıkta çıkar.
Düzcam üretiminin son aşaması olan kesme kısmında cam, müşterilerin
taleplerinde belirtilen boyutlarda kesilir, kalite kontrol laboratuarında kalitesi belirlenir ve
kalitesine göre paketlenir.
Training Report – Şişecam/Trakya Cam Sanayii A.Ş.
I

3.
A B S T R A C T
This report contains all my experimentation about float glass production
techniques, varies and utilities to the production processes during my summer training in
Trakya Cam Sanayii A.Ş. Trakya Factory.
Glass is a transparent inorganic product with bright surface, which is produced by
smelting of various oxides and the solidifying by cooling to room temperature without
crystallization occurrence. Glass, which viscosity is very high, despite of being a liquid
phase material, shows the properties of a solid. There is sand, dolomite, soda, limestone,
sulfate and feldspar in the composition of the float glass produced in Trakya Cam Sanayii
A.Ş. Trakya Factory.
Batch preparation is the first and one of the most important steps of glass
production. In this process, the raw materials are weighed in the predetermined ratios,
mixed and transferred to the furnace without any loses. Corrupt batch that does not have
the desired criteria as a result of any problem is not allowed into the furnace but taken to
the corrupt batch bunker.
Mixture coming from the batch section is smelted in the furnace of which inside
temperature is maximum 1580°C. The gases revealed during this process enter the
structure of the glass. These are removed by affination process in the next step so as no
to reduce the quality of the product. The affinated glass is homogenized along the neck of
the furnace and transferred to the resting pool.
The glass, made suitable for shaping in the resting pool, is taken into the tin bath
at the temperature about 1100°C where it is brought to the desired thickness with the
help of top rolls and lift‐out rolls.
The temperature of the glass is decreased to 600°C; it is made into ribbon shape at
the end of the tin bath and transmitted to the annealing lehr. In this section, required
temperature differences on the glass are maintained and the glass is prepared for cutting.
The temperature of the glass at the exit is about 50°C.
In the cutting section, which is the final step in float glass production, the glass is
cut in the dimensions demanded by the customers, classified according to its quality in
the quality control laboratory and packed with respect to its quality.
Training Report – Şişecam/Trakya Cam Sanayii A.Ş.
II

4.
TABLE OF CONTENTS
ÖZET I
ABSTRACT II
TRAINING PROGRAM in the FACTORY III
1.0‐ INTRODUCTION 1
1.1‐ Introduction to ŞİŞECAM 1
1.2‐ Introduction to Trakya Cam Sanayii 2
2.0‐ HISTORY of FLOAT GLASS 6
3.0‐ INTRODUCTION to FLOAT GLASS 8
4.0‐ MANUFACTURING PROCESS of FLOAT GLASS 10
4.1‐ Raw Materials 10
4.1.1‐ Sand 10
4.1.2‐ Soda 10
4.1.3‐ Dolomite 11
4.1.4‐ Limestone 12
4.1.5‐ Feldspar 12
4.1.6‐ Sodium Sulphate 13
4.1.7‐ Coloring Agents 13
4.2‐ Batch Preparation 14
4.3‐ Mixing 16
4.4‐ Melting and Refining 18
4.5‐ Floating (Sn Bathing) 23
4.6‐ Annealing 27
4.7‐ Finishing Operations 28
4.7.1‐ Cold End 28
4.7.2‐ Cutting 28
4.7.3‐ Conveying 29
4.7.4‐ Flexibity with Robots 29
4.7.5‐ Stacking 30
4.7.6‐ Packaging 30
4.7.7‐ Control 30
Training Report – Şişecam/Trakya Cam Sanayii A.Ş.

5.
5.0‐ QUALITY CONTROL 32
6.0‐ TRAKYA RESEARCH LABORATORY (Trakya XRF) 34
7.0‐ PLANT AUXILARIES 35
7.1‐ Description of the Utility Foundation Chieftaincy Department 35
7.1.1‐ Natural Gas 35
7.1.2‐ Hydrogen 36
7.1.3‐ Nitrogen and Instrument Air (Pressurizes Air) 36
7.1.4‐ Technologic Water 37
7.1.5‐ Crude Water 37
7.1.6‐ Drinking Water 38
7.1.7‐ Boiler 38
7.1.8‐ Fire System 38
7.1.9‐ Purifying Systems 38
7.1.10‐ Fuel‐Oil Systems 38
7.1.11‐ Duty Homes 38
8.0‐ HEALTHY‐SAFETY‐ENVIRONMENT 39
9.0‐ RESEARCH and DEVELOPMENT 40
9.1‐ Is glass solid or liquid? 40
9.2‐ H2 and N2 Production 45
9.2.1‐ H2 Production 45
9.2.2‐ N2 Production 54
10.0‐ ENGINEERING APPROACH to the PROCESS 56
10.1‐ Heat Transfer in Glass Melting 56
10.2‐ Problem about LHV of Natural Gas 58
10.3‐ Basically Energy Balance around the Furnace 61
10.4‐ Problem about Steam Generator (Boiler) 63
CONCLUSION 67
REFERENCES 68
APPENDICES 69
Training Report – Şişecam/Trakya Cam Sanayii A.Ş.