ACKNOWLEDGEMENT

On successful completion of our training in plant training

program, we wish to convey our heartful thanks to Mr. SUBBA
RAO, Head of the department, G.I.C.T., Gudur for giving this
opportunity.
We wish to thank Mr. RAMMOHAN RAO, Principal of G.I.C.T.,
Gudur for giving this opportunity.
We wish to thank Mr. R.K. RAO, General Manager Plant
operations for assisting us to complete our training successfully.
We wish to thank Mr. B.MAHENDER, Leader of Hot End for
assisting us to complete our training successfully.
We wish to thank Mr. MACHI REDDY, Leader of Size & Batch
House for his kind Co-operation and excellent guidance during our
training at BATCH HOUSE and GRM LAB.
We wish to thank Mr. PAVAN KUMAR, Head of Furnace for his
kind Co-operation and excellent guidance during our training at
FURNACE.
We wish to thank Mr. G. CHANDRU for his kind Co-operation and
guidance during our training at GRM Lab.
We sincerely thank Mr. PICHANDI for his Kind co-operation,
Support and excellent guidance during our training in the plant.
We express our deep gratitude to each one in this plant who
extended their co-operation in making this program a memorable
experience.
 BATCH HOUSE
Definition:-
A group of raw materials according to the composition
is called BATCH.
BATCH HOUSE is a section where the raw materials are
stored, weighed and mixing all of the entered process for supplying
to furnace.
Raw Materials are divided in to two types:
1. Major Raw Materials,
2. Minor Raw Materials

MAJOR RAW MATERIALS:

1. Quartz.
2. Lime stone.
3. Clay. (Bhuj & Mine clay)
4. Dolomite.
MINOR RAW MATERIALS:
1. Sodium Sulphate.
2. Soda Ash.
RAW MATERIALS OCCURRENCE :-

Quartz : We receive in powder form. The suppliers are

from HYDERABAD.

Limestone : We receive in powder form. This is coming from

BETHAMCHERLA in KURNOOL.

Dolomite : We receive in powder form. This is coming from

KARNATAKA.

Mine Clay : We receive in powder form. This is coming from

KERALA.

Bhuj Clay : We receive in powder form. This is coming from

GUJARATH.

Soda Ash : We receive in powder form. This is coming from

GUJARATH.

Sodium Sulphate:We recieve in powder form. This is coming from

MUMBAI.
Function of Raw materials is Glass:-
Quartz (SiO2):
Quartz is the glass forming Raw material. SiO2 is the main
glass forming oxide in the composition. Quartz should be free from
iron oxide. Colour of quartz is white in colour and it should have
99% of SiO2. The melting point of Quartz is 17280C. This is used in
major quantity.
Function of SiO2 in Glass:
1. It is the major glass forming oxide.
2. It imparts good mechanical strength.
3. It produces high viscosity.
4. It has low Thermal expansion and Thermal shock
Resistance.
5. It has chemical resistance.
Lime stone (CaCo3):
Lime stone is used for yield of Calcium oxide (CaO). It
decomposed to Calcium oxide (CaO) and Carbon-di-Oxide (CO 2).
CaO imparts 56 parts and CO2 imparts 44 parts. It has high
percentage of Loss on Ignition.
Function of CaO in Glass:

1. It decreases viscosity of glass

2. It acts as Flux.
 3. It gives Mechanical strength to the glass.
4. It acts as strengthening agent.
5. It develops setting property.
6. It gives de-verification to the glass.

Dolomite (CaCo3 MgCo3):

Dolomite decomposes to CaO and MgO at above 800oC
and Co2 will be evaporated. Dolomite is introduced for MgO in
Glass composition.
Function of MgO in glass:
1. To improve working property.
2. It improves Optical properties.
3. It acts as Flux.
4. It gives de-verification to the glass.
5. It has high percentage of Loss on Ignition.
Clay (Al2O3 SiO2 2H2O):
Clay is used to introduce Al2O3 in glass batch. Clay in batch
acts as Suspending agent. Al2O3 in glass increases the Liquidus
temperature. If more amounts added in glass composition then it
increases viscosity more effective than SiO2.
Functions of Al2O3 in Glass:
1. It increases the hardness of the glass.
 2. It increases Mechanical, Tensile, and Crushing strengths.

3. It gives Durability.

4. It prevents De-verification.

5. This increase Acid and Weathering resistance.

Sodium Sulphate (Na2So4):

This is used in batch to introduce Na2O.
This acts as flux. This used to decrease the temperature of the glass
and also acts as Refining agent also. This refines the glass from
gaseous bubbles and blisters. This is very cheaply available and cost
is low.
Function of Na2O in glass:
1. It acts as Oxidizing agent.
2. It acts as Flux.

Soda Ash (Na2Co3):

This is used for yield of Na2O.It is used as a
refining agent. Its melting temperature is very low. It changes the
colour of glass from green to light yellow.
Function of Na2O in glass:
1. It is using to save the fuel consumption.
2. It acts as Flux.
Batch mixing & Transporting:-

Batch maxing and transporting is very important to get

Homogeneity in the Batch melting. If Batch is not mixed well then
the Homogeneity will not be there in the batch and results in
formation of melting problems and defects like cords etc.
For good mixing of the batch here we use
special equipment called as BLENDER. Blender is made with thick
Iron sheet, cylindrical at the top and conical at the bottom. The
capacity of the Blender is 1.5kl. Blender contains 12 Air nozzles, 20
air pads are arranged in three rows in triangular sequence from top
to bottom. There is a level indicator at the top of the Blender. There
are four trees at the side of the blender will supply air to the pads
and nossils. There is a discharge (Pinch) valve at the bottom of the
blender.
After completion of weighing Major and
Minor discharge values are open then batch is transferred in to
BLENDER. When Hoppers are reached zero weight then the Major
and Minor hopper values closed. After closing the valves only
Blender starts Blending for predetermined time. In blending
pressurized air passed through the pads and pushes the batch
material in side. All the pads and air nozzles are operated sequencly
for predetermined time and results in good mixing of the batch.
After well mixing for predetermined time the Blender get
pressurized up to 25psi then the pinch valve get open and with that
pressure the material get transported to the Furnace silos.
Screw conveyor:
Screw conveyor is used to transport the raw
materials from silos to weighing hoppers. This is in circular shape,
outer case of the conveyor is made with a thick metal sheet and it
contains a heavy screw in the middle with a heavy threadings made
of cast iron. Raw material from silo falls at one end of the screw due
to threadings the material is transported to other end. Electrical
motor is used to rotate the conveyor. At the other end it contains a
Butterfly valve.
Butterfly valve:
This is a pneumatic operated. This contains a metal
plate made with caste iron. When the valve in close condition the
plate will be in horizontal position and when opened it turns to
vertical position.
 Pinch valve:

Pinch valve also operated with fully pneumatic air.

The outer case of the valve is made with caste iron. Inside two
rubber tubes are present. When the valve in close condition the
tubes are filled with pneumatic air and when in open condition the
air is removed from the tubes. In this way the Pinch valve works.

Bin vent filter:

These are present the top of the each Raw material

silo. These are operated at the time of silo loading. The main
function of this Bin vent filter is to create suction from the inside the
silo using suction fan at the top of the filter and to make loading
easy. The dust sucked by the suction fan moves to top wards and
dust particles are arrested by the cloth inside the Bin vent filter. The
all suction fan collectors are connected to Central Dust Collector.

Major Hopper:

The Major Hopper is a made with thick iron sheet

cylindrical at the top and conical at the bottom. The capacity of the
Hopper is 1500kgs. This is holded on three load cells for weighing of
the hopper. Heaters are provided at the bottom of the hopper to heat
up the hopper to prevent the sticking of raw material to the hopper
walls. Butterfly valve present at the bottom of the hopper to
discharge the weighed material.

Minor Hopper:
 Minor hopper also made with thick iron sheet
cylindrical at the top and conical at the bottom. The capacity of the
hopper is 150kgs. This is also holded by the three Load cells for
weighing of the hopper. Heaters are provided at the bottom of the
hopper to prevent the sticking of raw material to the hopper walls.
Slide gate valve present at the bottom of the hopper to discharge the
weighed material.

Silo:

Silo is constructed with heavy metal sheet cylindrical at the

top and conical at the bottom. The capacity of each silo is 30KL.
vibrator is arranged at the bottom of the silo for easy flow. Rotary
van feeder also arranged at the bottom of the silo to regulate the
material flow in to the screw conveyor. Fluidizers are arranged at
the bottom before cone formation to get good flow in the material of
low bulk density.

Silos are divided into two types based on the raw material loading.

They are:
1. Major silos
2. Minor silos

Major silos:
These silos are used to store and discharge major raw
materials into Screw conveyor.
Raw Materials Silo Capacity
1. Quartz 30 m3
2. Lime stone 30 m3
3. Dolomite 30 m3
4. Mine chem Clay 30 m3
5. Bhuj clay 30 m3

Minor silo:
These are used to store and discharge minor raw
materials into Screw conveyor.
Raw Materials Silo Capacity
1. Sodium sulphate 0.150 MTS
2. Soda ash 2 MTS

Homogenization Process:
This is very important process in the
batch house. It is done for proper mixing of raw materials loaded
inside the Silo. Homogenization is done for the following reasons
They are:
1. To minimize the oxide variation from bag to bag.
2. To maintain equal Granulometry.
This homogenization process is done by air mixing process. A
series of air pipes are present at the bottom of the silo which
provides air for mixing. For each raw material different number of
air pulses are given with different air pressures as following
 Raw materials No. of pulses Air pressure
(Kg/cm2)
1. Quartz ------ -------
2. Lime stone 50 1.2
3. Mine chem clay 75 5
4. Bhuj clay 75 5
5. Dolomite 50 2.8

This homogenization is done after each raw material loaded into

Silo.

FURNACE

Introduction:
The word Furnace is delivered from the Latin word
FORNEX, which means an enclosed structure in which Fuel is
burned to produce heat. Simply called as FURNACE.
The continuous tank furnace whose walls serve as a container to
produce a good quality glass for continuous production at low cost.
The furnace is oil and LPG fired, side Recuperative type,
Electrically boosted.
FURNACE DESIGN:
The furnace is designed to melt and refine glass easily, and
for the proper combustion of fuels and proper utilization of heat.
The holding capacity of the furnace is 70MT. Proper design
increases the life of Furnace. Furnace length is 9mts and width is
3mts and the furnace total area is 27sq.mts.
Furnace used in the industry is recuperated type of
continuous tank furnace. The furnace is divided into 3 zones.
They are:
1. Recuparator zone.
2. Melting zone (Melter).
3. Fore hearth.
RECUPERATOR:
Recuparator is a system of construction used for
recover waste heat. The Recuparator made with stainless steel. The
main function of the Recuparator is to exchange the Heat. The
Recuparator is double shale type their by exchanging heat from
waste gases and used for combustion in the furnace.
Recuparator was arranged with
Steel pipes atmosphere air is passing through the steel pipes. Air is
heat up with waste gases temperature coming from the furnace. The
recovered heat from the Recuparator is sent to the furnace as a
secondary air or Combustion air with the help of a blower.
MELTING CHAMBER (Melter):
 Melter is a continuous tank in
which the Batch are charged and melted. From the Dog house the
Batch are charged in to the Tank and melted due to heat produced
by the Burners arranged at both the sides. Burners are fired with
Heavy fuel oil. These burners are continuous. Bubblers are
arranged for Refining of glass and Electrical boosters are arranging
at the bottom of the glass to maintain temperature at the bottom of
the tank.
CHARGING OF BATCH INTO FURNACE:
After Blending the material is transferred
to Furnace silos. Day hoppers are arranged which takes material
from Furnace silos. The Screw feeders are used for charging of
batch materials continuously into tank from both the sides. The
charging port of the batch into furnace is called Dog House. These
feeders are automatic and feed the material according to the glass
level. These feeders are provided with water jacket for water
circulation to prevent melting of screw due to furnace temperature.
MELTING PROCESS:
The batch after charging into the Furnace
is contacted with the heat produced by the Burners. In contact with
the heat the raw materials get decomposed and then melted. The
melted (or) molten glass flows throughout the length of the Melter
contacting with the heat. The molten glass is refined by using
Bubblers at the middle of the Furnace.
HOMOGENIZING:
Due to the conventional currents inside the
molten glass results in getting homogeneity in glass. These currents
are caused due to Bubblers action and due to E-Boosters at the
bottom of the Furnace. After getting good homogenized and refining
then the glass flows to the channel to Fore Hearth.
FORE HEARTH:
Fore hearth is nothing but the Glass conditioning
chamber. In this chamber glass is conditioned to required viscosity
and work ability to get the final shape of the glass product. Fore
hearth is a glass flow channel from the Melter is fired with LPG.
Bushings are arranged at the bottom of the Fore hearth through
which the glass fibers are dragged out.
BURNERS:
V4 burners are used to fire the heavy fuel oil on
both sides of the Furnace. Pencil burners are used to fire LPG at
Fore Hearth. Some time these create like blocking of nuzzles
creating improper combustion. Care is taken and every week the
burners are replaced one by one after cleaning.
FURNACE PRESSURE:
Furnace pressure is very important to maintain
consistent temperatures inside the furnace. Furnace pressure is
maintained little positive side. This is maintained by using
dampening air blow from the top of the Furnace.
To maintain consistent condition on tank and to get good
combustion and good quality of glass the following areas are to be
checked daily.
1. Combustion and atomizing blowers running.
2. Burners condition and their replacements.
3. Any air leakage present in Recuparator.
4. Recuparator cooling and bottom condition.
5. Cleaning of oil filters.
6. Cleaning if combustion air filters.
7. Flux line cooling.
8. Flame conditions.
9. Oxygen percentage in the Furnace.
10. Crown cooling.
11. Screw charger conditions.
12. Damper positions.
13. Bubblers and E-Boosters conditions.
14. Furnace pressure.
15. Refractories conditions.

Furnace contents:
• Melter, Furnace, or Tank
• Sidewall or Side rails
• Bottom
• Front wall
• Rear wall
• Breast wall
 • Superstructure - refractory above glass
• Crown - furnace top
• Skew block - holds crown in place
• Tuck stone - supports breast wall
• Glass line - glass surface
• Flux line - underside of tuck stone
• Port -combustion exhaust gases escape
• Stack -flue or chimney
• Recuparator -heat recovery device
• Skimmer -skims glass at furnace outlet
• Throat -glass exit area of furnace
• Doghouse -batch feeding pocket
• Front-end -channel and fore hearth system
• Channel -glass delivery trough
• Fore hearth -glass existing trough
• Flow block -bottom of fore hearth
• Bushing block -glass exit point
• Bubblers -air nozzles in the Melter bottom
• Thermocouple -temperature measuring device

TANK:
 The tank is a Melting chamber. The length of the tank
determines the path of glass batch for melting and refining, while
the width determines the length of the flame and convention flow of
molten glass.

Throat:
Throat is a channel proved at the front end bottom of the
tank for flow of molten glass from melting chamber to the working
chamber. The area of the throat depends on the rate of flow of
molten glass and heat conditioning.
Tuck stone:
The blocks sated above the tank blocks on which the
Brest wall is constructed.
Crown:
The Crown is arranged on jamb wall. This crown also serves to
reflect heat which is coming from flames to the glass level. The lower
limit of crown depends on the flame and upper limit depends on the
combustion space. The entire crown is constructed with silica bricks.
Peep holes:
The peep holes are arranged to furnace. These holes are
provided for observing the batch melting and burner flames.
Thermocouple:
Thermocouples are which indicating temperature in
furnace. Thermocouples are made with Platinum-Rhodium alloy. It
with stand at 1800-2200C.
Common Raw Materials Used in Refractories:
• Clay family
• Quartz sand
• Corundum
• Chromite
• Chromic Oxide
• Zircon
• Sillimanite, kyanite
• Magnesite and periclase

Refractories Used in furnace:

• Mullite
• Insulating fire bricks(IFS)
• Silica
• Fusion-cast AZS
• Dense zircon
• Super structure TZB
• Basic chrome magnesite
• Chromic oxide
• Chrome alumina
 • Clay flux – used to back up glass contact refractory
• Mullite – used as a standard super structure refractory
• Insulating fire bricks(IFB) – used as an insulating refractory to
reduce heat loss in side walls
• Silica – used as a standard superstructure material especially
for crowns
• Fusion-cast (AZS) – used as superstructure material especially
for tuck stone and dog house
• Dense zircon – used at melting or fore hearth
• Super structure (TZB) – used at marble furnace paving
• Basic chrome mangnesite – used as a standard stack material
• Chromic oxide – used as co standard glass contact refractory
• Chrome alumina - used as the standard wool furnace glass
contact material and as recuperator ring and liners for
Composites furnaces.

These are the common Refractives used for the

construction of various types of furnaces. These Refractives have the
all properties that are required to withstand the working conditions
in the Furnace.
 GRM LAB

The following tests are going to be done every day in the GRM Lab.
They are divided in to two types based on the properties.
They are:
1. Physical tests.
2. Chemical tests.

1. Physical Tests:
 These physical tests are done to check the
Physical properties of the Raw materials are as following;

1. Colour verification.
2. Bulk density.
3. Moisture content.
4. Viscosity of Glass.
5. Dry sieve.
6. Wet sieve.
2. Chemical tests:
Chemical tests will be carried out in the
chemical lab are as following.
They are:
1. XRF.
2. COD.
3. FeO.
4. Wet analysis of Glass.
5. Wet analysis of each Raw material.
 CONTENTS

1. BATCH HOUSE.
2. FURNACE.
3. GRM-LAB.