1. INDUSTRIAL TRAINING REPORT
Completed at : AL TAJIR GLASS INDUSTRIES
JEBEL ALI – 28862, UNITED ARAB EMIRATES
Submitted by-
Ramalingam Kailasham, U09CH153
Final Year, Chemical Engineering
CHEMICAL ENGINEERING DEPARTMENT
SARDAR VALLABHBHAI NATIONAL INSTITUTE OF TECHNOLOGY, SURAT
2. Acknowledgement
I hereby register my heartfelt gratitude to the staff of Al Tajir Glass Industries who let me pursue my Summer
Industrial Training in their company. Special mentions to Mr.Lakshminarayanan, Mr.Michael Arasu and
Mr.Naresh Kumar who explained the various nuances of the industry in their precious time.
The company very graciously accepted my request to pursue my training here.
I would be failing in my duty if I do not extend the gratitude to my teachers at the Chemical Department of
Sardar Vallabhbhai National Institute of Technology,Surat.
3. Chapter Content
Chapter 1 Introduction
1.1 Al Tajir Glass
1.2 Glass
1.3 Raw Materials
1.4 Important terms used in
Glass Industry
Chapter 2 Demand And Supply Data
2.1 Products manufactured
Chapter 3 Process Flow Description
3.1 Glass Chemistry
3.2 Process flow diagram and
description
3.3 Product properties
Chapter 4 Pumps and Valves
4.1 Centrifugal pump
4.2 AODD Pump
4.3 Ball Valve
4.4 Gate valve
4.5 Butterfly valve
Chapter 5 Equipment & Instrumentation
5.1 Philips PW 2400 X-
Ray Fluorescence
Spectrometer
5.2 Perkin Elmer UV-VIS
Spectrometer Lambda
20
5.3 Perkin Elmer FT-NIR
4. Spectrometer 100N
5.4 Hays Gauge
5.5 Actuators
4.6 Solenoid Operated
Valve
Chapter 6 Environment, Health and
Safety
6.1 Fire Safety
6.2 Effluent Treatment
6. 1.2 Introduction : Glass
Glass, as defined by the American Society for Testing and Materials(ASTM), is an inorganic product of fusion
which has cooled to a rigid condition without crystallizing.Owing to its recyclability and biological
inactivity,glass is preferred by many manufacturers as the preferred containing material.Developed countries all
over the world are encouraging the use of glass over plastic products.
In Al Tajir Glass,the main commodity of production is container glass. There are types of container glass as
listed below.
Type I : Glass with borosilicate content in it. Excellent chemical resistance and strength at
smaller thickness.
Type II : Treated Soda Lime glass. The interior of the container is made to undergo sulphur
treatment which removes excess Na2O and makes the glass stronger.
Type III : Non-treated soda lime glass. Comparatively cheaper and less stronger than Type II
Glass.
Type IV : Non-Parenteral(NP) glass. It is used for topical or oral purpose.Also known as
commercial glass. Upto 20% alkali allowed.
Both flint type and green colored container glass is produced in Al Tajir Glass.
7. 1.3 Raw Materials
The use of raw materials from a particular source is determined by factors such as ease of availability and
transportation, purity and the cost. We shall see these factors at work in the following section.
Major Raw materials
Silica(SiO2)
Sand/silica is the major raw material in the production of glass.It is selected after meeting the required chemical
criterion (amount of moisture, percentage of impurities) and physical criterion like the size of particles. Pure
Silica has a melting point of about 1720o
C.This has to be reduced for economic processing.
Sand in the size range of 90-850 µm gives the best results.
Owing to its location, Al Tajir has a huge supply of local brown sand at its disposal. However, this has to
undergo several beneficiation processes before it can be used in the manufacturing process. Nearly 40% of the
silica requirement is met by brown sand.
The remaining 60% is met by sand imported from Egypt.
Limestone (Calcium Carbonate CaCO3)
CaO produced by heating of limestone is necessary to provide strength and stability to the molten batch.
The necessary limestone is imported from the Sultanate of Oman and Kingdom of Saudi Arabia.
Dolomite(MgCO3.CaCO3)
When a pure source of Calcium Carbonate is not available, dolomite may be used as an alternative. MgO also
offers strength to the final product.
Dolomite is mainly imported from Oman.
Soda Ash (Anhydrous Sodium Carbonate Na2CO3)
8. Na2O produced by heating soda ash is the main flux in glass production. It helps to reduce the melting point of
silica from 1720o
C to about 1500o
C.Soda ash is found naturally or can be produced from Solvay Process. The
Soda Ash requirement of Al Tajir Glass is met by import from Kenya.
Feldspar (KAlSi3O8, NaAlSi3O8, CaAl2Si2O8)
Feldspar is added as per requirement, mainly for the production of green/amber glass.
Cullet
This is basically rejected glassware from the production line that is crushed and ready to be remelted.
Minor Raw Materials
Salt Cake (Anhydrous Sodium Sulphate Na2SO4)
Once the raw materials are charged in the batch and melted,CO2 begins to evolve. Salt cake is added to speed up
the bubbling of CO2.This creates convection currents in the melt that helps in more efficient heat
transfer.Na2SO4 is obtained as a by-product from the textile industry.
Salt Cake imported from China is used.
Carbon
Sodium Sulphite is a better oxidizing agent than Sodium Sulphate for the evolution of CO2.Carbon helps to
reduce Na2SO4 to Na2SO3.Also,the presence of carbon in the reaction mix helps to control the redox
environment in the batch.
High quality carbon, imported from Germany, is used in the process.
Iron Chromite (Fe2O + Cr2O3)
This is used as per requirement in the production of green glass. The amount of chromite used depends on the
final shade of green required(Emerald/jade/rum/champagne/French/Dead leaf)
Masking Agents
9. In Flint glass production,the final colour of the container is as important as its chemical composition.It is not
possible to reduce the FeO content beneath a certain level.Sometimes,it is economical to mask the resultant light
green tinge instead of carrying out additional purification steps.
The addition of certain colours to the final product masks out(makes invisible) the greenish tinge. This is an
application of the Bezold-Brucke phenomenon.
Selenium(Se) and Cobalt Oxide(CoO) are prominent masking agents. Selenium is preferred due to its
comparatively lower cost. Se is obtained as a by-product of copper extraction.
Se granules imported from UK is used.
10. 1.4 Important terms used in Glass Industry
1. Viscosity
As glass is an amorphous substance, it does not have a fixed melting point.Its physical properties are,
therefore, specified on the basis of its viscosity. Viscosity is typically specified in “poise”. A viscosity
of, say, 100,000 poise is written as LOG 5 for convenience. The following table specifies the common
viscosity ranges for various operations.
Viscosity Operation
Log 2 Melting
Log 3 – Log 4 Feeder/gob temperature
Log 3.2 Hand gathering
Log 7 Ware removed from mold
Log 7.65 Softening point
Log 13 Annealing point
Log 14.5 Strain point
2. Cooling Time
The length of time (in seconds) required for a given mass of glass to cool from a temperature
corresponding to Log 3 to the temperature at Log 7.
3. Chromaticity Diagram
Any colour can be expressed in terms of its “trichromatic coefficient”.A chromaticity diagram is plotted
covering the normal range of human vision. Once we have the information regarding the colur present in
a particular glass sample,we can add suitable masking agents to make the glass clear.(See Bezolde-
Brucke Phenomenon)
11. 4. Bezolde-Brucke Phenomenon
The Bezold–Brücke shift is a change in hue perception as intensity changes. The resultant of mixing any
2 colours lies on the joining the 2 colour co-ordinates on the chromaticity diagram. This fact is used to
remove faint traces of colour from the glass.
5. Draw
Al Tajir glass uses continuous process for producing glass.For calculating consumption of glass we have
a formula called “draw”.
Draw is defined as the multiplication of machine speed,bottle weight and time.
Draw = Machine Speed x Bottle weight x Time
For example
Speed of machine = 500 BPM (Bottles per minute)
12. Bottle Weight = 200 g = 0.200 kg = 0.0002 mt
Time = 24 hrs = 24 x 60 = 1440 minutes
Therefore, Draw = 500 x 0.002 x 1440
= 144 mt/day
6. Boosting
The process of assisting the melting of glass in the furnace by supplying electricity through electrodes is
known as boosting. Boosting improves the quality of glass through its localized application of heat and
also reduces the operating temperature of the furnace. This improves the furnace life and reduces dust
emission.
7. Narrow Neck Press and Blow Process (NNPB)
In this process, the metal plunger in the mold is much smaller in diameter. This process is used to
manufacture containers with narrow finish diameters(<=38mm).
The introduction of this process has enabled glass manufacturers to increases overall productivity and
reduce weight and variations in the thickness distribution of beer and beverage bottles.
8. Blow and Blow Process (B & B)
In the Blow and Blow process,compressed air blows a cavity into the molten gob in the blank mold of
the forming machine,thereby creating a perform shape known as a parison.
From there the parison is transferred to the blow mold where compressed air is used to blow the bottle
into its final shape.
13. Chapter 2 : Demand and Supply Data
2.1 Products Manufactured
Flint type container glass
This type of glass is predominantly used for storing soft-drinks and consumable items. For aesthetic purposes, it
shouldn’t have any tinge of coloring to it.
Coloring is removed by addition of masking agents, such as Selenium granules imported from the United
Kingdom.
While soft-drinks are normally stored in plastic bottles in western countries, the demand for glass containers is
particularly strong in North African countries.
Green colored container glass
Alcoholic beverages such as beer are generally stored in green colored containers.
Most of the green container glass manufactured in Al Tajir is exported to breweries in South Africa and
Australia.
Al Tajir glass produces nearly 470 tonnes of glass every day.
This puts their annual production at 6000 tonnes.
14. Chapter 3 : Process Description
3.1 Glass Chemistry
Solid state reactions below 1000o
C
Na2CO3 + MgCO3 ----------------> Na2Mg(CO3)2
Na2CO3 + CaCO3 ----------------> Na2Ca(CO3)2
Na2Ca(CO3)2 + 2SiO2 -----------------> Na2SiO3 + CaSiO3 + 2CO2 ( )
Na2CO3 + SiO2 -----------------> Na2SiO3 + CO2 ( )
2 CaCO3 + SiO2 ------------------> Ca2SiO4 + 2 CO2 ( )
At a temperature above 800o
C,the silica will react with the alkali rich carbonate melt into a sodium silicate melt.
Na2CO3 + SiO2 ------------------> Na2O.nSiO2 + CO2 ( )
Teut (Na2O.2SiO2 + SiO2 ) = 790o
C
In combination with calcium oxide, an even lower (ternary) eutectic temperature may occur.
Teut (Na2O.3CaO.6SiO2 + SiO2 + Na2O.2SiO2 ) = 725o
C
Actually a temperature 0f 1100o
C is enough but the reaction rate will be slow.
Hence, a furnace temperature of around 1450o
C is maintained for increasing the rate of reaction.
15. 3.2 Process Flow Diagram and description
The manufacturing of glass can be systematically divided into 3 sections : batch-house, hot end and cold end.
Preliminary :
The raw materials are regularly tested in the Quality Control department for conformity with the chemical
standards. This is done with the help of a PW 2400 Philips X-Ray Fluorescence (XRF) Spectrometer. A sample
of the XRF analysis is given.
Once the standards have been adhered to, a batch house formula is prepared by the authorized personnel.
Derived from the basic chemical equation stoichiometry, this formula dictates the amount of each raw material
(major and minor) that has to be drawn per batch.
A sample of the batch formula can be seen.
Batch-House
The Programmable Logic Control (PLC) system in the Batch-house is fed with the formula at the beginning of
each day. Accordingly, the raw materials are withdrawn from their silos and mixed together. A small amount of
moisture is added in this step to avoid excessive dust formation.
(Moisture has to be removed from the stored raw materials as it hinders flow).
The mixed raw materials is fed into a 6-port side entry furnace. The furnace area is 132 m2
.It furnace has 6 side
ports(on right and left side) that are fired with the help of Fuel Oil. The ports are fired alternately between the
right and left side at an interval of 20 minutes. Fuel Oil is heated to about 110o
C( @ 5.2 bar) in a fuel oil
preheater and fed in to the furnace. This heating reduces viscosity and permits easy flow. The atomized fuel-oil
mixes with the compressed air to provide the necessary heating.The furnace is maintained at a positive pressure
with respect to the environment to avoid the rushing in of cold air that can reduce the flame temperature.
Regenerators are provided on the left and right sides of the furnace. The hot exhaust gases pass through the
regenerators which are lined with refractory bricks known as “checkers”.The checkers retain the heat and this is
used to heat the cold,compressed air when the next cycle begins.The use of preheated air increases flame
temperature and improves fuel economy.
16. 3 - 5/8% Voltage Regulators, known as boosters, are provided to provide extra heat in the furnace. Electrical
boosting is a must if NNPB quality is required.
The temperature in the furnace is maintained at around 1500 o
C. The amount of material drawn depends on the
pre-fed formula. Molten glass is contained in the melting end refining chambers to a depth extending from the
furnace bottom to the elevation identified as the Metal Line. The metal line in the furnace is usually maintained
at 57 inches. Any variation in this height is detected with the help of a probe that loops back to the batch-house
PLC.
Typical daily production is around 470 Tonnes.
Hot-End
From the refining chamber,the glass flows to the forming machines through the forehearths.These latter devices
are relatively shallow,narrow channels connected to the refining chamber at the glass surface.They have
refractory roofs and individual firing systems so as to control the glass temperature.Sufficient cooling time is
provided for the melt to reduce to Log 3 from Log 2.
At a viscosity of Log 2,gobs are cut and passed into the assembly line with the help of compressed air.
Depending on the demand and properties of the finished product, NNPB or Blow and Blow process is employed
for shaping of the glass.
After the glass is shaped, we reach a viscosity level of Log 7.The time required in seconds for the melt to go
from log3 to log 7 is known as the cooling period.
The glass containers are then led in to a lehr.
A Lehr is a long tunnel shaped oven for annealing glass by continuous passage. Annealing is necessary to
prevent/remove objectionable stresses by controlled cooling. The Lehr used here has 9 zones (with alternate hot
and cold zones)
Cold-End
Once the bottles come out of the annealing Lehr,they are top and bottom sprayed with Duracoat to prevent
abrasion while they collide against one another.
17. After this,the bottles pass through various stations where they are subjected to several visual and optical tests.
For example, in the ICK machine, the bottles that can withstand a pressure of 30-35 psi are allowed to move
forward in the assembly line.
The approved bottles are then moved to the ACL (Applied Color Labelling) or the palletizing section depending
on whether the bottle needs decoration or not.
18.
19.
20. 3.3 Product Properties(Container glass – flint type)
Cooling time : 95 to 102 seconds
Thermal expansion co-efficient : 85 x 10-7
/ o
C
Density : 2.48 – 2.52 g/cc
Dominant wavelength : 565 – 568 nm
Purity : <11 %
Brightness : >50 %
(Dominant wavelength, purity and brightness defined for a flint sample of thickness 40 mm)
21. Chapter 4 : Pumps & Valves
In a Glass Industry, the transportation of raw materials and the finished product is either in the solid or molten
state.Hence pumps and valves are used as auxiliary equipment only. They are involved in the transport of
cooling water to the Lehr and Gob-cutters. As such the flow rates are not monitored. Only the suction line and
discharge pressures are controlled by the PLC systems.
PUMPS
4.1 Centrifugal Pumps
A centrifugal pump is a rotodynamic pump that uses a rotating impeller to increase the pressure of a fluid.
Centrifugal pumps are commonly used to move liquids through a piping system. The fluid enters the pump
impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward into a
diffuser or volute chamber (Casing), from where it exits into the downstream piping system. Centrifugal pumps
are used for large discharge through smaller heads.
A centrifugal pump works by the conversion of the rotational kinetic energy, typically from an electric motor or
turbine, to an increased static fluid pressure.
At Al Tajir Glass,the centrifugal pumps are normally operated at either 1450 rpm or 300 rpm.
4.2 Air Operated Double Diaphragm Pumps
22. The AODD pump design features few moving parts. Those that do move have simple, specific tasks:
1. Air Chamber. Houses the air that powers the diaphragms.
2. Air Distribution System. The heart of the pump, it is the mechanism that shifts the pump to create suction and
discharge strokes.
3. Outer Diaphragm Piston. Connects the diaphragms to the reciprocating common shaft and seals the liquid
side from the air side of the diaphragm.
4. Inner Diaphragm Piston. Located on the air side of the pump, it does not come in contact with the process
fluid.
5. Valve Ball. Seal and release on the check-valve seats, allowing for discharge and suction of process fluids to
occur.
6. Valve Seat. Provide the ball valves a place to check
23. 7. Discharge Manifold. Allows fluid to exit the pump through the discharge port that is typically located at the
top of the pump
8. Liquid Chamber. Separated from the compressed air by the diaphragms, it fills with process fluid during the
suction stroke and is emptied during the discharge stroke
9. Diaphragm. Acts as a separation membrane between the process fluid and the compressed air that is the
driving force of the pump. To perform adequately, diaphragms should be of sufficient thickness and appropriate
material to prevent degradation or permeation in specific process-fluid applications.
10.Inlet Manifold. Allows fluid to enter the pump through the intake port located at the bottom of the pump.
In Al Tajir Glass,AODD pumps are used for transporting lubricating oil. Gear pumps or centrifugal
pumps,because of the shear they exert on the fluid,negatively affect the lubricant properties. Hence
AODD’s,despite their higher cost,are used for pumping lubricants.
VALVES
4.3 Ball Valve
A ball valve is a valve with a spherical disc, the part of the valve which controls the flow through it. The sphere
has a hole, or port, through the middle so that when the port is in line with both ends of the valve, flow will
occur. When the valve is closed, the hole is perpendicular to the ends of the valve, and flow is blocked. The
handle or lever will be inline with the port position letting you "see" the valve's position.
24. 4.4 Globe Valve
A globe valve is a type of valve used for regulating flow in a pipeline, consisting of a movable disk-type
element and a stationary ring seat in a generally spherical body.
Globe valves are named for their spherical body shape with the two halves of the body being separated by an
internal baffle. This has an opening that forms a seat onto which a movable plug can be screwed in to close (or
shut) the valve. The plug is also called a disc or disk.In globe valves, the plug is connected to a stem which is
operated by screw action using a handwheel in manual valves. Typically, automated globe valves use smooth
stems rather than threaded and are opened and closed by an actuator assembly.
4.5 Butterfly valve
A butterfly valve is a valve which can be used for isolating or regulating flow. The closing mechanism takes the
form of a disk. Operation is similar to that of a ball valve, which allows for quick shut off. Butterfly valves are
generally favored because they are lower in cost to other valve designs as well as being lighter in weight,
25. meaning less support is required. The disc is positioned in the center of the pipe, passing through the disc is a
rod connected to an actuator on the outside of the valve. Rotating the actuator turns the disc either parallel or
perpendicular to the flow. Unlike a ball valve, the disc is always present within the flow, therefore a pressure
drop is always induced in the flow, regardless of valve position.
26. Chapter 5: Equipment & Instrumentation
The equipment used in a glass industry are slightly different from the ones used in a typical process plant.
The following are the key equipment and instrumentation involved in Al Tajir Glass Industry.
1. Philips PW 2400 X-Ray Fluorescence Spectrometer
2. Perkin Elmer UV-VIS Spectrometer Lambda 20
3. Perkin Elmer FT-NIR Spectrometer 100N
4. Hays Gauge
5. Actuators
6. Solenoid Operating Valve
5.1 Philips PW 2400 X-Ray Fluorescence Spectrometer
27. What is X-Ray Spectroscopy ?
X-ray spectroscopy is a gathering name for several spectroscopic techniques for characterization of
materials by using x-ray excitation. When an electron from the inner shell of an atom is lost due to some
sort of excitation, it is replaced with an electron from the outer shell; difference in energy is emitted as
an X-ray photon of characteristic for the element wavelength (there could be several of characteristic
wavelengths per element). Equipment Specifications
Type: automatic sequential wavelength dispersive X-ray fluorescence spectrometer
PW 2400 (Philips)
Year of construction: 1996
HT generator: high frequency (ultra sonic), microprocessor controlled, 60 kV, 125
mA, 3000 W max., 0.0005 % stability
Tube: super sharp end window X-ray tube, 60 kV, 125 mA, 3000 W max.,
Rhodium anode
Spectrometer: sample changer (2 positions), spinner 30 rpm, 8 analysing crystals
(LiF 200, LiF 220, PE 002, Ge 111, PX1 multilayer, PX2 multilayer, PX4
multilayer, TlAP 100 coated), Argon flow counter 2 µm (13° to 148° 2theta, 2000
KCPS max.), scintillation counter (0° to 104° 2theta, 1000 KCPS max.), masks 10,
25, 30 and 35 mm
Goniometer: theta/2theta decoupled, direct optical position sensors, slewing speed
40° 2theta/s, scanning speed 0.0001° to 2° 2theta/s,angular accuracy 0.0025°
theta,2theta, angular reproducibility 0.0001° theta,2theta
Multi channel analyser: non-linearity > 1 %
Filters: Al (200,750 µm), Brass (100,300 µm), Pb (1000 µm)
Primary collimators: 150, 300, 700 µm
Beam path: Vacuum or He (liquids)
MS Windows based Super-Q / Semi-Q software
Peripherals: automatic fusion machine Perl’X 3 (Philips)
28. 5.2 Perkin Elmer UV-VIS Spectrometer Lambda 20
The UV-VIS spectrometer is used for the optical properties analysis of glass samples.After the sample
has been fed in,we get information regarding the dominant wavelength,purity and brightness via the
attached computer.Windows-95 based PRISMA 100 is used in Al Tajir Glass.
5.3 Perkin Elmer FT-NIR Spectrometer 100N
Near Infrared Spectrometry is used especially to check for entrapped water molecules in the final glass product.
The instrument is designed for safe use in indoor conditions, within ambient temperatures of 5o
C to 40o
C and a
voltage fluctuation of not more than ± 10 %.
29. 5.4 Hays Gauge
Hays Cleveland Model D-06200-00 MULTIPOINTER GAUGES, available in semi-flush or
surface-mounted enclosures, are designed for applications requiring two or more indicating
scales in a limited area and on a limited budget. A three-way selector valve is a standard feature
that permits the operator to reset to zero and clean the sample lines without disturbing the
unit's factory-set calibration. Another standard feature is a special beryllium calibrating spring
that provides permanent, unvarying tension.
5.5 Actuators
The commonly used actuator types are shown in the following figures.
31. 5.6 SOLENOID OPERATING VALVE:
A solenoid valve is an electromechanical valve for use with liquid or gas. The valve is controlled by an electric
current through a solenoid coil. Solenoid valves may have two or more ports: in the case of a two-port valve the
flow is switched on or off; in the case of a three-port valve, the outflow is switched between the two outlet
ports. Multiple solenoid valves can be placed together on a manifold.
Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut off, release,
dose, distribute or mix fluids. They are found in many application areas. Solenoids offer fast and safe switching,
high reliability, long service life, good medium compatibility of the materials used, low control power and
compact design.
Besides the plunger-type actuator which is used most frequently, pivoted-armature actuators and rocker
actuators are also used.
32. Chapter 6 : Environment, Health and Safety (EHS)
6.1 Fire Safety
With the growing stringent environmental regulations and human rights awareness, the EHS department of any
company these days occupies a crucial position. It is no different at Al Tajir Industries.
Owing to the techniques used in the packing and palletizing section, fire is a very prominent hazard. Here’s a
brief discussion on the topic.
Fire is a chemical reaction in which heat & gas are generated. Technically it is called Combustion. For fire to
take place, three things viz. FUEL, OXYGEN & SUFFICIENT HEAT SOURCE are necessary.
There are 3 common ways in which a fire-break out can be controlled
Starving : By removing the fuel/combustible substance from the site of fire.
Smothering : By cutting off the supply of oxygen to the fire.
Cooling : By reducing the temperature of the ambient air.
Types of Fire
Fires are classified on the basis of the fuel involved. This helps in identifying the right type of extinguisher to be
used in a particular situation.
Class A : Fire caused due to solid fuels like paper, rubber, clothes, etc.
Class B : Source of fire is liquids like petrol,kerosene,paint oil,etc.
Class C : Fire caused due to gases like methane,butane,etc.
Class D : Fire caused due to metals like magnesium,aluminium,etc.
Class E : Fires caused due to overloaded electrical circuits,short circuits and bad practices.
33. Types of fire extinguishers and cases where they can be used
Class of Fire Extinguishing Agent (Effective Range) Colour of the cylinder
Water (30-40 ft)
RED
Foam(10-12 ft)
CREAM
CO2 (3-8 ft)
BLACK
DCP(5-20 ft)
BLUE
A YES YES NO YES
B NO YES YES YES
C NO YES YES YES
D NO NO NO YES
E NO NO YES YES
Fire Fighting facilities and preventive measures at Al Tajir Glass
Portable Fire Control Equipment
1. Extinguishers
2. Fire blankets
3. Fire buckets
Fixed Fire control Equipment
1. Fire station with Control Room, Booster pumps, Store for fire fighting accessories.
2. Mobile phones and naked flames not allowed near the LPG and Fuel Oil yard.
3. Smoke detectors placed at regular intervals; connected to sprinklers
4. Hose reels
6.2 Effluent Treatment
Water usage in the plant is limited to furnace cooling and glass-mold cooling.As such,water disposal is not a
problem and there is no hazard to the underground water-table.
The plant,however,has to adhere to strict standards as whereas gaseous emissions are concerned.
34. The commonly monitored gaseous components are
NOx,SO2,CO,Volatile Organic Compounds (VOC),CO2,water % and O2 %.
The Furnace Exhaust Abatement Device suggested for Al Tajir Glass is a combination of Electrostatic
Precipitator(ESP) and dry scrubber.
ESP
It is a series flow,multiple zone system.The electrodes are connected to high voltage rectifiers/transformers.As
the gaseous stream is passed through the ESP,the particles get negatively charged and get attracted to the
collection plate(which is maintained at ground potential).
These particles are removed by vibration with a rapping hammer/sonic horn.
A stack fan is used to force the exhaust out of the system.
Dry Scrubber
A dry re-agent such as soda ash/sodium bicarbonate is usually milled to a fine powder and injected to the
exhaust stream.
The reagent reacts with the exhaust to form a sulphate precipitate,thereby removing the SOx gas.
The solid precipitate is then collected by the ESP or Bag House.
With a relatively small pressure difference of 125 Pa and reasonable maintenance charges,the ESP-Dry scrubber
combination is an economical option.
