GLASS PRODUCTION PROCESS IN GLASS FACTORY | The basic raw material is sand

Summary

This video explores the fascinating process of glass manufacturing, focusing on the float glass method, which is responsible for 90% of global glass production. The journey begins with raw materials like sand, lime, and soda, which are carefully blended and melted at high temperatures. The liquid glass then floats on molten tin to form flat sheets, before being cooled, cut, and subjected to rigorous quality checks. Finally, the glass is packed and shipped for use in industries such as automotive, solar panels, and architecture, showcasing its indispensable role in modern life.

Takeaways

• 😀 Glass plays a significant role in modern life, being used in windows, smartphone screens, skyscrapers, solar panels, and car sunroofs.
• 😀 The majority of glass (90%) is produced through the Float Glass manufacturing process, which results in a flat, transparent surface.
• 😀 Float Glass production takes place 24/7, producing hundreds of tons of glass daily for various industries like automotive, construction, and solar panels.
• 😀 The main raw material for glass is sand, which accounts for 60% of the ingredients, with lime, soda, and broken glass (cullet) also playing key roles.
• 😀 Cullet, or broken glass, is recycled in the production process to reduce energy usage and speed up the melting process.
• 😀 Raw materials for glass manufacturing are carefully inspected for purity before entering the factory, ensuring high-quality output.
• 😀 The raw materials are melted in large furnaces, reaching temperatures as high as 1648°C to combine and form the liquid glass.
• 😀 Natural gas and large fans are used to heat the furnace and melt the raw ingredients, facilitating a fast melting process.
• 😀 Once melted, the liquid glass floats on molten tin, creating a flat sheet, while its thickness is controlled using a stretching machine.
• 😀 After the glass is cooled using water and air fans, it undergoes quality checks before being cut into smaller sheets with a carbide cutting wheel.
• 😀 The finished glass is packed and shipped globally after being inspected for quality and ensuring it meets consumer requirements.

Q & A

What are the main raw materials used in glass production?

The main raw materials used in glass production are sand (60%), lime, soda, and broken glass (called callet). These materials are combined to form the glass mixture.

Why is callet (broken glass) added during glass production?

Callet helps speed up the melting process and reduces the amount of energy required for melting. It can reduce the energy consumption by up to one-fifth.

How does the melting process work in glass production?

The raw materials are melted in a large furnace that reaches extremely high temperatures (over 1648°C) to liquefy the ingredients, which then form the molten glass.

What is the significance of the term 'float glass'?

Float glass refers to the manufacturing process where molten glass floats on a molten tin surface, forming a smooth, flat, and transparent surface. The method accounts for 90% of global glass production.

How does the float glass process affect the glass's properties?

The float glass process ensures the glass has a flat and transparent surface with a natural greenish hue. It also allows for precise control over the thickness of the glass.

What role does the stretching machine play in glass production?

The stretching machine regulates the thickness and width of the glass as it moves through the molten tin container. It ensures the final product meets the required specifications.

At what temperature does the glass start to solidify after being formed?

After being formed in the float process, the glass cools to about 537°C and then continues to be cooled at a controlled rate until it reaches around 93°C.

How is the quality of glass ensured during production?

The glass is checked automatically and manually during production. Automatic checks identify any defects, while manual quality control involves sampling to ensure the glass meets required standards.

What happens to glass that does not meet the required quality standards?

Glass that doesn't meet the standards is removed from the production line and sent to the recycling section, where it is processed for reuse as callet in future batches.

How is glass transported after production?

Once the glass is cut and packed, it is transferred to a vacuum transfer system, which helps carry and stack the glass for final shipping to consumers worldwide.