Pilkington浮法玻璃生产介绍

AmemberofNSGGroup2ApplicationofInorganicChemistryinIndustryFlatGlassandCoatingsOnGlassDrTroyManningAdvancedTechnologist,On-lineCoati[e-mail]3Outline•OverviewofFlatGlassindustryandNSG/Pilkington•FlatGlassmanufacture–FloatGlassProcess•Coatingtechnologywithintheglassindustry–ChemicalVapourDeposition•Examplesofonlinecoatingapplications–LowEmissivity/SolarControl–SelfCleaning•Summary•SuggestedReading4GlobalFlatGlassMarketGlobalMarket37milliontonnes(4.4billionsq.m)BuildingProducts33mtonnes-Automotive4mtonnesOfwhich–24million=highqualityfloatglass–3million=sheet–2million=rolled–8million=lowerqualityfloat(mostlyChina)GlobalValueAtprimarymanufacturelevel€15billionAtprocessedlevel€50billion5NSGandPilkingtoncombined•Aglobalglassleader–thepureplayinFlatGlass•Combinedannualsalesc.£4billion•EqualtoAsahiGlassinscale,mostprofitableinFlatGlass•Ownership/interestsin46floatlines•6.4milliontonnesannualoutput•WidenedAutomotivecustomerbase•36,000employeesworldwide•Manufacturingoperationsin26countries•Salesin130+countries6ManufactureofFlatGlass•Fourmainmethods–PlateGlass(1688)–moltenglasspouredontoaflatbed,spread,cooledandpolished–SheetGlass(1905)–continuoussheetofglassdrawnfromtankofmoltenglass–RolledGlass(1920)–moltenglasspouredontototworollerstoachieveaneventhickness,makingpolishingeasier.Usedtomakepatternedandwiredglass.–FloatGlass(1959)–moltenglasspouredontobedofmoltentinanddrawnoffincontinuousribbon.Giveshighqualityflatglasswitheventhicknessandfirepolishfinish.~320float-glasslinesworldwide7MeltingfurnaceFloatbathCoolinglehrContinuosribbonofglassCrosscuttersLargeplatelift-offdevicesSmallplatelift-offdevicesRawmaterialfeedTheFloat-GlassProcess•Operatesnon-stopfor10-15years•6000km/year•0.4mm-25mmthick,upto3mwide8TheFloatGlassProcess9Rawmaterials10MeltingFurnace11FloatBath12FloatGlassPlant13TheFloat-GlassProcessFine-grainedingredients,closelycontrolledforquality,aremixedtomakebatch,whichflowsasablanketontomoltenglassat1500ºCinthemelter.Thefurnacecontains2000tonnesofmoltenglass.Afterabout50hours,glassfromthemelterflowsgentlyoverarefractoryspoutontothemirror-likesurfaceofmoltentin,startingat1100ºCandleavingthefloatbathasasolidribbonat600ºC.Despitethetranquillitywithwhichfloatglassisformed,considerablestressesaredevelopedintheribbonasitcools.14RawMaterials•Oxide%inglassRawmaterialsource•SiO272.2Sand•Na2O13.4SodaAsh(Na2CO3)•CaO8.4Limestone(CaCO3)•MgO4.0Dolomite(MgCO3.CaCO3)•Al2O31.0Impurityinsand,FeldsparorCalumite•Fe2O30.11ImpurityinsandorRouge(Fe2O3)•SO30.20Sodiumsulphate•C0.00Anthracite15Rawmaterials•SiO2Verydurable,BUThighmeltingpoint(1700°C)!•+Na2OMeltsatalowertemperature,BUTdissolvesinwater!•+CaOMoredurable,BUTwillnotforminbathwithoutcrystallisation•+MgOGlassstaysasasuper-cooledliquidinbath,nocrystallisation•+Al2O3Addsdurability•+Fe2O3Addsrequiredlevelof‘green’colourforcustomer16ChemistryofGlassImportantglassmakingchemistry:basicreactionsNa2CO3+SiO21500ºCNa2SiO3+CO2Na2SiO3+xSiO2Na2SO4(Na2O)(SiO2)(x+1)Digestion17CompositionofGlass18StructureofGlassRandomnetworkof[SiO4]-tetrahedralunits.Na-OenterSi-Onetworkaccordingtovalency–NetworkFormersCaandMg–NetworkModifiers–makestructuremorecomplextopreventcrystallisation19Body-tintedGlassIonResultingColourofGlassFerrous(Fe2+)BlueFerric(Fe3+)YellowFe2++Fe3+GreenSelenium(SeO2)BronzeCobalt(Co2+)Grey/BlueNickel(Ni2+)Grey20CIELa*b*colourspace21CIELa*b*colourspace22FunctionsofaWindow•Lightin–homes,offices•Lightout–shops,museumdisplays•Heatin–heatingdominatedclimates•Heatout–coolingdominatedclimates•Canchangepropertiesofglassbyapplyingcoatingstothesurface23Makingawindowfunctional-coatings•Awidevarietyofcoatingtechnologiesareutilisedbytheglassindustry–SprayPyrolysis–PowderSpray–ChemicalVapourDeposition–SputterCoating–ThermalEvaporationCoatings–SolGelCoatings•Theseareapplied–OnLinei.e.astheglassisproducedonthefloatline–OffLinei.e.coatingnotnecessarilyproducedatthesamelocation24VariationsofCVD•AtmosphericPressure–APCVD•LowPressure-LPCVD•AerosolAssisted-AACVD•Metalorganic–MOCVD•Combustion/Flame–CCVD•HotWire/Filament–HWCVD/HFCVD•PlasmaEnhanced-PECVD•LaserAssisted–LACVD•MicrowaveAssisted–MWCVD•AtomicLayerDeposition–ALD25ChemicalVapourDeposition26ChemicalVapourDepositionMaingasflowregionGasPhaseReactionsSurfaceDiffusionDesorptionofFilmPrecursorByProductsDiffusiontosurface27ChemicalVapourDepositionAnimationkindlysuppliedbyDr.WarrenCross,UniversityofNottingham28CVDprocessesandparametersProcessParametersTransportPrecursorsGasphasereactionPressure,temperature,flowconditions,boundarylayerthickness,gasphaseconcentration,precursors,carriergasDiffusionPressure,temperature,flowconditions,boundarylayerthickness,gasphaseconcentrationAdsorptionTemperature,gasphaseconcentration,numberandnatureofsitesSurfacereactionTemperature,natureofsurfaceDesorptionofby-productsTemperature,pressure,natureofsurfaceDiffusiontolatticesiteTemperature,surfacemobility,numberofvacantsites29CVDPrecursorProperties•Volatile–gas,liquid,lowmeltingpointsolid,sublimabl