Nickel Sulphide risk mitigation in Float glass

manufacturing
Agenda

01 Introduction to Nickel Sulphide inclusions

02 Causes of Nickel Sulphide inclusions

03 Consequences of Nickel Sulphide inclusions

04 Risk mitigation strategies

Introduction
What is Nickel Sulphide inclusions & its consequences?
Nickel sulphide inclusions are microscopic particles that can be present in float
glass. They are formed during the manufacturing process and can cause the glass
to break unexpectedly, posing a safety risk to users and leading to costly product
failures.
These inclusions can cause significant issues during the manufacturing process, as
well as after the glass has been installed. When the glass is heated or cooled, the
nickel sulphide particles can expand or contract at a different rate than the
surrounding glass, causing the glass to fracture or break unexpectedly.
Nickel sulphide inclusions can have serious consequences for float glass
manufacturing. When these inclusions are present in glass, they can cause
product failure, leading to costly recalls and reputational damage for
manufacturers. In addition to product failure, nickel sulphide inclusions can also
pose safety risks. Glass with inclusions may shatter unexpectedly, causing injury or
even death. This can lead to product failure, safety risks, and financial losses. The
impact of nickel sulphide inclusions on float glass manufacturing cannot be
overstated.
How does Spontaneous breakage occur due to NiS
NiS inclusions are very small, spherical shape, opaque solids, typically 0.1 to 0.5 mm dia (0.005” to 0.020”) and which change
their crystalline phase (Alpha to Beta) and size long after the tempering process. This Alpha to Beta change makes them expand
slightly. When glass is tempered a NiS stone inclusion actually shrinks more on than the surrounding glass during the quench
cooling. This sudden quench catches the inclusion in its smaller, hot, Alpha phase, not giving it time to make its usual transition
to the slightly larger, cold, Beta phase.

With time(months or years), the phase change and growth of the inclusion, take place in the cold glass. The changes take place
faster if the glass is warmer, such as in insulated spandrel panels exposed to sunlight. At first there is little stress on the
surrounding glass while the stone slowly expands to fully occupy the cavity. With further growth in size, as the phase change is
completed, the surrounding glass is subjected to an increasing tensile stress. There are many different compositions of a NiS
inclusion. The exact composition of a NiS inclusion is a factor in determining when the full expansion and possible breakage
occur. It can take many months or years, and even then, breakage may not happen at all. Typically, such expansion and the first
occurrence of breakage will not happen until at least a year has passed from the date of tempering.
Reasons for Spontaneous Breakage due to Nickel Sulphide
inclusions
• Nickel sulphide inclusions are a critical factor contributing to spontaneous glass breakage, especially in
facade applications.
• These inclusions consist of nickel and sulfur compounds trapped within the glass during the
manufacturing process.
• They are typically in the form of nickel sulphide crystals, which can have a detrimental impact on the
structural integrity of the glass.

Formation of Nickel Sulphide inclusions:

• Batch Materials : Nickel and Sulphur impurities in raw materials

• Melting Furnace: The high temperature environment can promote the formation of these inclusions.
• Cooling Process: Rapid cooling can trap these impurities within the glass structure.
Causes of Nickel Sulphide inclusions
Contamination is one of the primary causes of nickel sulphide inclusions.
This can occur when foreign materials, such as dust or debris, come into
contact with the glass during the manufacturing process. Even small
amounts of contamination can lead to significant defects in the final
product.

Impurities in the raw materials used to make float glass can also contribute
to nickel sulphide inclusions. These impurities can be introduced at various
stages of the production process, including during the melting and refining
of the glass. It is important to carefully monitor the quality of raw materials
to minimize the risk of impurities.

Temperature changes can also play a role in the formation of nickel sulphide
inclusions. Rapid cooling or heating of the glass can cause thermal stress,
which can create microscopic cracks that can trap nickel sulphide particles.
These cracks can then expand over time, leading to visible defects in the
glass
How Nickel Sulphide can be detected?
One of the most effective ways to reduce the risk of nickel sulphide inclusions in float glass manufacturing is through glass
testing. By identifying any potential inclusions early on, manufacturers can take steps to prevent them from causing product
failure or safety risks. There are various testing methods available, such as ultrasound, X-ray, and visual inspection, each
with its own benefits and limitations. For example, ultrasound testing can detect inclusions that are too small to be seen by
the naked eye, while X-ray testing can provide a more detailed analysis of the inclusion's location and size. By implementing
regular glass testing, manufacturers can ensure that their products meet the highest standards of quality and safety.

Another important best practice for reducing the risk of nickel sulphide inclusions is through quality control measures. This
involves monitoring the manufacturing process at every stage to identify any potential issues before they become major
problems. Quality control measures can include anything from inspecting raw materials for impurities to ensuring that the
production process is operating within the correct temperature range. By implementing these measures, manufacturers can
reduce the likelihood of inclusions occurring and improve the overall quality of their products. Production process
optimization is also key to reducing the risk of nickel sulphide inclusions. By adjusting various process parameters, such as
temperature, pressure, and speed, manufacturers can optimize the production process to minimize the risk of inclusions.
For example, by carefully controlling the cooling rate of the glass, manufacturers can reduce the likelihood of inclusions
forming during the manufacturing process. By implementing these best practices, manufacturers can significantly reduce
the risk of nickel sulphide inclusions and improve the quality and safety of their products.
 Quality Control

Quality control plays a critical role in reducing the risk of nickel

sulphide inclusions in float glass manufacturing. By implementing
quality control measures, manufacturers can detect and address
potential issues before they become major problems. Quality control
measures can include regular inspections of raw materials, monitoring
of production processes, and testing of finished products.

To ensure that quality control measures are effective, they must be

implemented consistently and monitored closely. This requires a
commitment to quality from all levels of the organization, from senior
management to line workers. Quality control measures must also be
regularly reviewed and updated to reflect changes in production
processes or new technologies.
Glass Testing
Glass testing is a critical step in identifying nickel sulphide inclusions that
can compromise the quality and safety of float glass products. By
subjecting glass samples to various testing methods, manufacturers can
detect the presence of these inclusions and take appropriate measures to
address them.

There are several testing methods available, including visual inspection,

ultrasonic testing, and X-ray diffraction. Each method has its benefits and
limitations, and manufacturers often use a combination of methods to
ensure accurate results. Visual inspection is the most basic form of
testing and involves examining the glass for visible inclusions. Ultrasonic
testing uses high-frequency sound waves to detect inclusions that may
not be visible to the naked eye. X-ray diffraction is a more advanced
technique that can identify the chemical composition of inclusions. While
these methods can be effective, they also have their limitations and may
not detect all types of inclusions. It is important for manufacturers to
understand the strengths and weaknesses of each method and choose
the most appropriate approach for their specific needs.
Production Process Optimization
Optimizing the production process is crucial in reducing the risk of
nickel sulphide inclusions. By adjusting various process parameters,
manufacturers can significantly improve product quality and reduce the
likelihood of defects. One key parameter that can be adjusted is the
temperature of the glass during production. Higher temperatures
increase the likelihood of nickel sulphide inclusions, so careful
monitoring and control of temperature is essential.

Another important process parameter is the speed of the cooling

process. Rapid cooling can cause thermal shock, which can lead to the
formation of nickel sulphide inclusions. By carefully controlling the
cooling rate, manufacturers can minimize the risk of thermal shock and
reduce the likelihood of defects. Additionally, the use of high-quality
raw materials and strict adherence to production protocols can further
reduce the risk of nickel sulphide inclusions.
 Nickel Sulphide Inclusion Lifecycle

Small, spherical, opaque solids

Undergo a crystalline phase
change (Alpha to Beta) and
01
expansion long after tempering

05
02
Typically 0.1 to 0.5 mm in
diameter

Expansion occurs more quickly in 04

warmer conditions 03
Often occurs at least a year after
tempering
Mitigation Measures

● Quality control measures during

manufacturing
● Magnetic and nonferrous separators to
remove metallic materials
● Onsite inspections to ensure absence of
Nickel-bearing metals
● Heat Soaking