Chemical Process Industries CH- 213

Assignment Evaluation Rubric

SAMRA MUSTAJAB CH-18028

Objectives Good [10-8] Average [7-5] Unsatisfactory [4-1]

Content well Covered all the content Covered all the Copied and didn't even
researched thoroughly and yet content Some key bother to make sure it
Weightage 30% concisely. No key concepts missed. covered the topic in a
concepts that missed way as asked for

Critical Analysis Clearly and creatively Clearly but not Not clearly understand
Weightage 30% understand each process creatively understand the processes
each process

Up to date and Ability to conceptualize Ability to Not able to

relevant the process and relate conceptualize the conceptualize the
Weightage 30% theory process but not relate process
theory

Timeliness All topics completed Almost 90% Less than 75 %

Weightage 10% and timely submitted completed and timely completed and not timely
submitted submitted
 DEPARTMENTS:GLASS AND FERTILIZER INDUSTRY
IMPORTANCE OF GLASS INDUSTRY:
With the increased use of glass by the massive population , the glass industry should have an
incredible hold over the quality produced.The importance of glass industry can be analyzed by
the use of glass on a wide scale like

 Packaging (jars for food, bottles for drinks, flacon for cosmetics and pharmaceuticals)
 Tableware (drinking glasses, plate, cups, bowls)
 Housing and buildings (windows, facades, conservatory, insulation, reinforcement
structures)
 Interior design and furnitures (mirrors, partitions, balustrades, tables, shelves, lighting)
 Appliances and Electronics (oven doors, cook top, TV, computer screens, smart-phones)
 Automotive and transport (windscreens, backlights, light weight but reinforced
structural components of cars, aircrafts, ships, etc.)
 Medical technology, biotechnology, life science engineering, optical glass
 Radiation protection from X-Rays (radiology) and gamma-rays (nuclear)
 Fibre optic cables (phones, TV, computer: to carry information)
 Renewable energy (solar-energy glass, windturbines)

IMPORTANCE OF FERTILIZER INDUSTRY:

Soils naturally contain many nutrients like nitrogen, phosphorous, calcium, and potassium. These
nutrients allow plants to grow. When soil nutrients are missing or in short supply, plants suffer
from nutrient deficiency and stop growing. When the nutrient level is too low, the plant cannot
function properly and produce the food necessary to feed the worlds’ population. Farmers turn
to fertilizers because these substances contain plant nutrients such as nitrogen, phosphorus, and
potassium. Fertilizers are simply plant nutrients applied to agricultural fields to supplement
required elements found naturally in the soil. Fertilizers have been used since the start of
agriculture. Native American people used crude fertilizers, such as burying a fish in their corn
plots, and organic farmers use fertilizer from natural source, such as compost. Most farmers
today use fertilizers that are either mined or manufactured.
Having acknowledged the widespread use of glass and fertlizers, the curiousity of an individual
rises as to how the glass industry and fertlizer industry functions and what is the criteria of
delivering it to the consumer society.

DIFFERENT DEPARTMENTS OF GLASS INDUSTRY:

PROCESS DEPARTMENT :

As the name suggests , this department utilizes the knowledge of different processes
to make glass.Following are the processes which are utilized in the making of glass.

1. Melting and Refining

In order to make clear glass, the right set of raw materials is required. This consists of
silica sand (SiO2), sodium oxide (Na2O) from soda ash, calcium oxide (CaO) from
limestone/dolomite, dolomite (MgO), and feldspar (Al2O3). These ingredients are
mixed in the right proportion, and the entire batch is flown into a furnace heated to
1500 degree Celsius.

In order to impart colour to the glass, certain metal oxides are also mixed in the
batch.

2. Float bath
The molten material from the furnace flows into the float bath which consists of a
mirror-like surface made from molten tin. This material enters the bath at 1500
degree Celsius and leaves the bath at around 650 degree Celsius. Its shape at the exit
is like a solid ribbon.

3. Coating for reflective glass

Thereafter, if one is producing reflective glass surfaces that help in keeping indoors
cooler, then coating procedures are followed in which either a hard coat or a soft
coat is applied on the surface of the cooled ribbon at high temperatures.
4. Annealing
Next, in order to remove the internal stresses built up in glass, a process called
annealing is done. This process allows the glass ribbon to pass through a layer which
eliminates any stresses on the glass surface and gradually cools it to give it its final
hardened form. This makes it easier to cut the glass and shape it accordingly.

5. Inspecting
Through acute and advanced inspection technology, more than a 100 million
inspections can be made throughout the glass manufacturing procedure to identify
air bubbles, stresses or grains of sand that refuse to melt. This is essential in quality-
proofing the final form of glass.

6. Cutting to order

Finally, diamond steels are used to trim and cut the glass ribbons into square shapes.

7.Moulding into shapes:

According to consumer requirement , the glass is moulded into different shapes and
sizes with respect to its use.

PRODUCTION DEPARTMENT:

The department works to improve the efficiency of the production or assembly

line so that it can meet the output targets set by company’s management and
ensure finished products offer consumers the best value and quality. To meet
production targets, the department establishes the quantity of raw materials and
types of machinery and equipment required to achieve the desired output level,
such as some kinds of machinery used in the production of glass are

 Feeder machine which is used to place the lump of viscous liquid (gob) on
the IS machines and anyother production machinery.
 Press machines which are used for producing glass tumblers(flat bottom
beverage container), bowls, plates, tea cups, beer mugs, water jugs, juice
blenders etc.
  Fire/flame polishing machines are used for polishing of the surface of glass by
exposing it to the flame.

All of the machinery has some technical specifications which are the key aspects in
determining the quality of product produced.Now the working and maintainence of
the machines is the utmost priority of the production department team so that the
process can run smoothly.

RESEARCH AND DEVELOPMENT DEPARTMENT:

Research and development (R&D) includes activities that companies undertake to

innovate and introduce new products and services.Recently the research is done on
methods of efficient heat transfer required for melting of sand particles Partners
have developed a novel burner that increases luminosity and radiant heat transfer.
It will increase thermal efficiency and reduce energy use.

PROJECT DEPARTMENT:

A Project Management Office (also called PMO), is an office or department within

an organization that defines and maintains standards for project management. The
Project Management Office provides guidance and standards in the execution of
projects.This includes site management,time schedule,coordination of overseas and
local deliveries,supervision on machinery storage and installation, cost control and
time schedule follow-up and supervision on start-up and commissioning phase.

SAFETY DEPARTMENT:

The Glass manufacturing industry do follow up the safety check for its workers and
the environment.Some industries develop checklist to highlight safety issues for
workers engaged in manufacturing glass and glass products and provides
information on how to best manage those risks to minimise workplace injuries and
comply with occupational safety and health legislation. The safety department also
takes care of the product conditions after it has been manufactured like carry one
glass at a time , cover the glass with blankets so that it remains in the best
condition.
WAREHOUSE (STORE DEPARTMENT):

Warehousing is actually part of a material management process concerned with

storage of materials to deliver on time. It keeps track of items so they can be found
readily and correctly.It minimizes the total physical effort and thus the cost of
moving goods into and out of storage.It provides communication links with
customers.  Recently,the Italian facility (Fenzi group) leading alliance in flat glass is
expanding with a new integrated logistics center to optimize efficiency in
warehouse management and shipping.

UTILITY DEPARTMENT:

Utilities department builds and maintain the infrastructure needed to provide

electricity, gas, and water, or to manage wastewater and sewage; they also provide
the related service that utilizes that infrastructure.The glass industry relies on
electricity and natural gas to supply the bulk of its energy needs. Glass melting
consumes the most energy of all the production processes, and is accomplished
using natural gas, a combination of natural gas and electricity (electric boost), or all
electricity.

ADMINISTRATION & FINANCE DEPARTMENTS:

Every industry has an administration and finance department which governs its
corporate matters.The glass industries administration and finance departments
keeps track of the policies declared by the government regarding industries and any
environmental safety guidelines which they pass on to other departments.The
administration acts as a guiding source to all other departments of the glass industry

DIFFERENT DEPARTMENTS OF FERTILIZER INDUSTRY:

PROCESS DEPARTMENT:

Different industries have different processes to manufacture fertilizers.The process

department looks after the ongoing process of the fertilizers which are as follows:

Nitrogen Fertilizer: Nitrogen fertilizer (such as urea) is produced from natural gas. In
several transformation steps, natural gas, essentially methane, is upgraded by
 combination with nitrogen from the air to form nitrogen fertilizer. 80% of the gas is
used as feedstock for fertilizer while 20% is used for heating the process and
producing electricity.

Phosphorus fertilizer: To produce a phosphorus fertilizer, the phosphorus rock is

treated with acid; sulfuric, phosphoric or nitric. Each method has its advantages and
constraints. The sulfuric acid route produces a low phosphorus fertilizer –
single superphosphate - which is half gypsum. The use of phosphoric acid produces
a higher concentration phosphorus fertilizer.

Potassium fertilizer: Most potassium used in fertilizer production is taken from

natural deposits of potassium chloride. The mined material is crushed and purified
by the removal of rock particles and salt. Deposits of potassium sulfate
and potassium nitrate are more rare, but when used, are treated in a similar manner.

PRODUCTION DEPARTMENT:

The production department is tasked with finding effective ways to lower production
costs. They keep the production machinery and equipment well-maintained so the firm
does not regularly incur repair costs.The department can also assess the production line
to identify opportunities for cost reduction. A production department must ensure
finished goods meet quality standards.Some kinds of machinery used in the fertilizer
industry are as follows:

 Granulators: There are many kinds of granulators such as roller press granulator ,
rotatory drum granulator, pan granulator. These machines are used to produce
granules.

 Mixers: There are many kinds of mixer machines such as Disc Mixer,Double shaft
Mixer,Horizontal Mixer .These machines are used for mixing composites.

 Grinders:There are many kinds of grinders such as Chain Mill , Horizontal type
semi wet material crusher , Cage Mill.These machines are used for grinding the
substances.
Now all these machines have different technical specifications and requirements in
terms of functionality and energy usage.The production team works to select the best
output machinery for the production and keeps check and balance on the equipment for
better product quality.

RESEARCH AND DEVELOPMENT DEPARTMENT:

As the name suggests,this department plays an integral role in the subjects of

innovations in fertilizers.New techniques are introduced for working on a vast scale and
fulfilling the needs of massive population.Recent developments are focused on
increasing nutrient efficiency and minimize environmental effects.Recently a new
technique of nanofertilizers has been developed.Nanofertilizer is a novel technique
toward attaining sustainable agriculture. It helps in enhancing nutrient supervision
because of its properties like increased infiltration capacity, slow release, large surface
area, nutrient use efficiency, stress tolerance ability, temporal and spatial release, and
eco-friendly.Industries are also developing methods that provide opportunities to
implement state-of-the-art technologies that capture GHG (greenhouse gas)
emissions, achieve zero water discharge, capture waste heat for energy
production.

PROJECT DEPARTMENT:

Fertilizer industry is a huge industry hence it requires excellence in planning and

managing all other departments.In fertilizer industry, the project department team
manages all the departments and ensures their smooth running.Their duties normally
involves planning and defining scope,activity planning and sequencing,resource
planning,developing schedules,time estimating,cost estimating,developing a
budget,documentation.

WAREHOUSE (STORE DEPARTMENT):

The fertilizer industry follows a checklist to manage fertilizer storage and handling.The
storage location follows a set of rules such as (there should be large drums to carry
fertilizers and small containers and shelves).There are numerous guidelines for
containment, inventory and record keeping,monitoring , lightening , security and
temperature.

UTILITY DEPARTMENT:
The production of commercial fertilizers requires a significant amount of natural
resources, such as natural gas, water, and land. Water is a significant resource in the
production of phosphate and potash fertilizers, and to a lesser extent for nitrogen.
The amount of water used to produce one ton of phosphate fertilizer in 2017 has
increased four percent since 2016.

SAFETY DEPARTMENT:

Like all other industries,fertilizer industry also provides guidelines over the
occupational safety and handling.The necessary guidelines like building
construction,fire protection,bulk storage to prevent contamination,storage to prevent
fires from impacting piles of ammonium nitrate,storage building,separation and
siting,emergency response are given to the workers.

ADMINISTRATION AND FINANCE:

Like all other industries , fertilizer industries also has an administrative department
which sets the revenue generation of the industry and pass on guidelines to all the
departments.Its is the main head of the industry and plays pivotal role in every walks of
industry matters.They look up on the matters of boosting economy and profits.

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