Manufacture of Glass

Transcription

1 Best Available Techniques (BAT) Reference Document for the Manufacture of Glass Industrial Emissions Directive 2010/75/EU (Integrated Pollution Prevention and Control) JOINT RESEARCH CENTRE Institute for Prospective Technological Studies Sustainable Production and Consumption Unit European IPPC Bureau

2 The mission of the JRC-IPTS is to provide customer-driven support to the EU policy-making process by developing science-based responses to policy challenges that have both a socioeconomic as well as a scientific/technological dimension. Acknowledgements This report was produced by the European Integrated Pollution Prevention and Control Bureau (EIPPCB) at the European Commission's Joint Research Centre Institute for Prospective Technological Studies (IPTS) under the supervision of Serge Roudier (Head of the EIPPCB) and Luis Delgado (Head of the Sustainable Production and Consumption Unit). The main EIPPCB author of this report was Ms Bianca Maria Scalet. Mr Marcos García Muñoz and Ms Aivi Sissa Queirolo from the EIPPCB started the work. This report was drawn up in the framework of the implementation of the Industrial Emissions Directive (2010/75/EU) and is the result of the exchange of information provided for in Article 13 of the Directive for the Manufacture of Glass. EU Member States (Belgium, Bulgaria, Denmark, Germany, Ireland, Spain, France, Italy, Luxembourg, Hungary, Netherlands, Austria, Poland, Portugal, Romania, Finland, Sweden United Kingdom), industrial associations representing the European glass manufacturers (CPIV, FEVE, Glass for Europe, APFE, European Domestic Glass, ESGA, EURIMA, ECFIA, ANFFECC) and Ökopol representing the European Environmental Bureau participated in the information exchange. The whole EIPPCB team provided contributions and peer-reviewing.

3 This document is one from the series of foreseen documents listed below (at the time of writing, not all documents have been drafted): Best Available Techniques Reference Document... Ceramic Manufacturing Industry Common Waste Water and Waste Gas Treatment/Management Systems in the Chemical Sector Emissions from Storage Energy Efficiency Ferrous Metals Processing Industry Food, Drink and Milk Industries Industrial Cooling Systems Intensive Rearing of Poultry and Pigs Iron and Steel Production Large Combustion Plants Large Volume Inorganic Chemicals Ammonia, Acids and Fertilisers Industries Large Volume Inorganic Chemicals Solids and Others industry Large Volume Organic Chemical Industry Management of Tailings and Waste-rock in Mining Activities Manufacture of Glass Manufacture of Organic Fine Chemicals Non-ferrous Metals Industries Production of Cement, Lime and Magnesium Oxide Production of Chlor-alkali Production of Polymers Production of Speciality Inorganic Chemicals Pulp and Paper Industry Refining of Mineral Oil and Gas Slaughterhouses and Animals By-products Industries Smitheries and Foundries Industry Surface Treatment of Metals and Plastics Surface Treatment Using Organic Solvents Tanning of Hides and Skins Textiles Industry Waste Incineration Waste Treatments Industries Wood and Wood Products Preservation with Chemicals Wood-based Panels Production Code CER CWW EFS ENE FMP FDM ICS IRPP IS LCP LVIC-AAF LVIC-S LVOC MTWR GLS OFC NFM CLM CAK POL SIC PP REF SA SF STM STS TAN TXT WI WT WPC WBP Reference Document... Economics and Cross-media Effects ECM General Principles of Monitoring MON Electronic versions of draft and finalised documents are publicly available and can be downloaded from

4

5 Preface PREFACE 1. Status of this document Unless otherwise stated, references to the Directive in this document refer to Directive 2010/75/EU of the European Parliament and the Council on industrial emissions (integrated pollution prevention and control) (Recast). The original best available techniques (BAT) reference document (BREF) on the Manufacture of Glass was adopted by the European Commission in This document is the result of a review of that BREF. The review commenced in March This BAT reference document for the Manufacture of Glass forms part of a series presenting the results of an exchange of information between EU Member States, the industries concerned, non-governmental organisations promoting environmental protection and the Commission, to draw up, review, and where necessary, update BAT reference documents as required by Article 13(1) of the Directive. This document is published by the European Commission pursuant to Article 13(6) of the Directive. As set out in Article 13(5) of the Directive, the Commission Implementing Decision (2012/134/EU) on the BAT conclusions contained in Chapter 5 was adopted on 28 February 2012 and published on 8 March 2012 ( 1 ). 2. Participants in the information exchange As required in Article 13(3) of the Directive, the Commission has established a forum to promote the exchange of information, which is composed of representatives from Member States, the industries concerned and non-governmental organisations promoting environmental protection (Commission Decision of 16 May 2011 establishing a forum for the exchange of information pursuant to Article 13 of the Directive 2010/75/EU on industrial emissions (2011/C 146/03), OJ C 146, , p. 3). Forum members have nominated technical experts constituting the technical working group (TWG) that was the main source of information for drafting this document. The work of the TWG was led by the European IPPC Bureau (of the Commission's Joint Research Centre). 3. Structure and contents of this document Chapters 1 and 2 provide general information on the glass industry and on the industrial processes and techniques used within this sector. Chapter 3 provides data and information concerning the environmental performance of installations within the sector, and in operation at the timeof writing, in terms of current emissions, consumption and nature of raw materials, water consumption, use of energy and the generation of waste. Chapter 4 describes in more detail the techniques to prevent or, where this is not practicable, to reduce the environmental impact of installations in this sector that were considered in determining the BAT. This information includes, where relevant, the environmental performance levels (e.g. emission and consumption levels) which can be achieved by using the techniques, the associated monitoring and the costs and the cross-media issues associated with the techniques. ( 1 ) OJ L 70, , p.1 Manufacture of Glass i

6 Preface Chapter 5 presents the BAT conclusions as defined in Article 3(12) of the Directive. Chapter 6 presents information on emerging techniques as defined in Article 3(14) of the Directive. Concluding remarks and recommendations for future work are presented in Chapter Information sources and the derivation of BAT This document is based on information collected from a number of sources, in particular, through the TWG that was established specifically for the exchange of information under Article 13 of the Directive. The information has been collated and assessed by the European IPPC Bureau (of the Commission s Joint Research Centre) who led the work on determining BAT, guided by the principles of technical expertise, transparency and neutrality. The work of the TWG and all other contributors is gratefully acknowledged. The BAT conclusions have been established through an iterative process involving the following steps: identification of the key environmental issues for the sector; examination of the techniques most relevant to address these key issues; identification of the best environmental performance levels, on the basis of the available data in the European Union and worldwide; examination of the conditions under which these environmental performance levels were achieved, such as costs, cross-media effects, and the main driving forces involved in the implementation of the techniques; selection of the best available techniques (BAT), their associated emission levels (and other environmental performance levels) and the associated monitoring for this sector according to Article 3(10) of, and Annex III, to the Directive. Expert judgement by the European IPPC Bureau and the TWG has played a key role in each of these steps and the way in which the information is presented here. Where available, economic data have been given together with the descriptions of the techniques presented in Chapter 4. These data give a rough indication of the magnitude of the costs and benefits. However, the actual costs and benefits of applying a technique may depend strongly on the specific situation of the installation concerned, which cannot be evaluated fully in this document. In the absence of data concerning costs, conclusions on the economic viability of techniques are drawn from observations on existing installations. 5. Review of BAT reference documents (BREFs) BAT is a dynamic concept and so the review of BREFs is a continuing process. For example, new measures and techniques may emerge, science and technologies are continuously developing and new or emerging processes are being successfully introduced into the industries. In order to reflect such changes and their consequences for BAT, this document will be periodically reviewed and, if necessary, updated accordingly. ii Manufacture of Glass

7 Preface 6. Contact information All comments and suggestions should be made to the European IPPC Bureau at the Institute for Prospective Technological Studies at the following address: European Commission Institute for Prospective Technological Studies European IPPC Bureau Edificio Expo c/ Inca Garcilaso, 3 E Seville, Spain Telephone: Fax: JRC-IPTS-EIPPCB@ec.europa.eu Internet: Manufacture of Glass iii

8

9 Best Available Techniques (BAT) Reference Document for the Manufacture of Glass Acknowledgements...II PREFACE...I SCOPE... XVII 1 GENERAL INFORMATION Structure of the industry Introduction Characteristics of glass Broad classification of glass types Historical origins Container glass Sector overview Products and markets Commercial and financial considerations Main environmental issues Flat glass Sector overview Products and markets Commercial and financial considerations Main environmental issues Continuous filament glass fibre Sector Overview Products and markets Commercial and financial considerations Main environmental issues Domestic glass Sector overview Products and markets Commercial and financial considerations Main environmental issues Special glass Sector overview Products and markets Commercial and financial considerations Main environmental issues Mineral wool Sector overview Products and markets Commercial and financial considerations Main environmental issues High temperature insulation wools Sector overview Products and markets Commercial considerations Main environmental issues Frits Sector overview Products and markets Commercial considerations Main environmental issues APPLIED PROCESSES AND TECHNIQUES Materials handling Glass melting Raw materials for glass making The melting process Melting techniques Regenerative furnaces Manufacture of Glass v

10 2.3.2 Conventional recuperative furnace Oxy-fuel melting Electric melting Combined fossil fuel and electric melting Discontinuous batch melting Special furnace designs Container glass Flat glass The float glass process The rolled process (patterned and wired glass) Continuous filament glass fibre Domestic glass Special glass Mineral wool Glass wool Stone wool High temperature insulation glass wools (ASW/RCF and AES) Frits The frits production process Melting furnaces used in frits production Frits as raw material in the production of glazes and enamels PRESENT CONSUMPTION AND EMISSION LEVELS Introduction General overview of the glass industry Process inputs Process outputs Emissions to air Emissions to water Emissions of other wastes Energy Noise Container glass Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy Flat glass Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy Continuous filament glass fibre Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy Domestic glass vi Manufacture of Glass

11 3.6.1 Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy Special glass Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy Mineral wool Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy High temperature insulation wools Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy Frits Process inputs Emissions to air Raw materials Melting Downstream activities Diffuse/fugitive emissions Emissions to water Other wastes Energy TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT Introduction Melting technique selection Electric melting Operation and maintenance of furnaces Techniques for materials storage and handling Techniques for materials storage Techniques for materials handling Techniques for controlling emissions to air from melting activities Particulate matter Primary techniques Electrostatic precipitators Bag filters Manufacture of Glass vii

12 Mechanical collectors High-temperature filter media Wet scrubbers Nitrogen oxides (NO X ) Combustion modifications Batch formulation Special furnace designs The FENIX process Oxy-fuel melting Chemical reduction by fuel (CRF) Selective catalytic reduction (SCR) Selective non-catalytic reduction (SNCR) Sulphur oxides (SO X ) Fuel selection Batch formulation Dry or semi-dry scrubbing Wet scrubbers Fluorides (HF) and chlorides (HCl) Reduction at source Scrubbing techniques Oxides of carbon Techniques for controlling emissions to air from non-melting activities Container glass Flat glass Continuous filament glass fibre Domestic glass Special glass Mineral wool Forming area Curing oven Product cooling Product machining and packaging Odours arising from mineral wool production High temperature insulation wools Frits Techniques for controlling emissions to water Techniques for minimising other wastes Energy Melting techniques and furnace design Combustion control and fuel choice Cullet usage Waste heat boiler Batch and cullet preheating Environmental management systems BAT CONCLUSIONS FOR THE MANUFACTURE OF GLASS SCOPE DEFINITIONS General considerations Averaging periods and reference conditions for air emissions Conversion to reference oxygen concentration Conversion from concentrations to specific mass emissions Definitions for certain air pollutants Averaging periods for waste water discharges General BAT conclusions for the manufacture of glass Environmental management systems Energy efficiency Materials storage and handling General primary techniques Emissions to water from glass manufacturing processes Waste from the glass manufacturing processes Noise from the glass manufacturing processes BAT conclusions for container glass manufacturing viii Manufacture of Glass

13 5.2.1 Dust emissions from melting furnaces Nitrogen oxides (NO X ) from melting furnaces Sulphur oxides (SO X ) from melting furnaces Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Metals from melting furnaces Emissions from downstream processes BAT conclusions for flat glass manufacturing Dust emissions from melting furnaces Nitrogen oxides (NO X ) from melting furnaces Sulphur oxides (SO X ) from melting furnaces Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Metals from melting furnaces Emissions from downstream processes BAT conclusions for continuous filament glass fibre manufacturing Dust emissions from melting furnaces Nitrogen oxides (NO X ) from melting furnaces Sulphur oxides (SO X ) from melting furnaces Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Metals from melting furnaces Emissions from downstream processes BAT conclusions for domestic glass manufacturing Dust emissions from melting furnaces Nitrogen oxides (NO X ) from melting furnaces Sulphur oxides (SO X ) from melting furnaces Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Metals from melting furnaces Emissions from downstream processes BAT conclusions for special glass manufacturing Dust emissions from melting furnaces Nitrogen oxides (NO X ) from melting furnaces Sulphur oxides (SO X ) from melting furnaces Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Metals from melting furnaces Emissions from downstream processes BAT conclusions for mineral wool manufacturing Dust emissions from melting furnaces Nitrogen oxides (NO X ) from melting furnaces Sulphur oxides (SO X ) from melting furnaces Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Hydrogen sulphide (H 2 S) from stone wool melting furnaces Metals from melting furnaces Emissions from downstream processes BAT conclusions for high temperature insulation wools (HTIW) manufacturing Dust emissions from melting and downstream processes Nitrogen oxides (NO X ) from melting and downstream processes Sulphur oxides (SO X ) from melting and downstream processes Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Metals from melting furnaces and downstream processes Volatile organic compounds from downstream processes BAT conclusions for frits manufacturing Dust emissions from melting furnaces Nitrogen oxides (NO X ) from melting furnaces Sulphur oxides (SO X ) from melting furnaces Hydrogen chloride (HCl) and hydrogen fluoride (HF) from melting furnaces Metals from melting furnaces Emissions from downstream processes Glossary: Description of techniques Dust emissions NO X emissions SO X emissions HCl, HF emissions Metal emissions Manufacture of Glass ix

14 Combined gaseous emissions (e.g. SO X, HCl, HF, boron compounds) Combined emissions (solid + gaseous) Emissions from cutting, grinding, polishing operations H 2 S, VOC emissions Dust emissions NO X emissions SO X emissions HCl, HF emissions Metal emissions Combined gaseous emissions (e.g. SO X, HCl, HF, boron compounds) Combined emissions (solid + gaseous) Emissions from cutting, grinding, polishing operations H 2 S, VOC emissions EMERGING TECHNIQUES Glas Flox high-temperature combustion system Advanced cullet and batch preheaters PRECIOUS-project PRAXAIR-BCP project New product formulations Waste injection in the stone wool production process Submerged combustion melting technology Flue-gas treatment with dry sodium bicarbonate and chemical valorisation of gas treatment residues Application of ceramic and catalytic ceramic filters for the removal of multiple pollutants from process waste gases NASU electrostatic precipitator for nanoparticles Charged cloud scrubber CONCLUDING REMARKS AND RECOMMENDATIONS FOR FUTURE WORK ANNEXES Annex I: Method of estimation of air pollution control costs and cross-media effects Costs included in the economic evaluation Comparison of costs of different technologies Air pollution control cost data Distribution of APC costs in combined systems, among more than one pollutant species Cross-media effects Example cost calculation Cost data for APC systems applied to glass melting furnaces Annex II: Example sulphur balances for industrial glass furnaces Annex III: Emission Monitoring Main pollutants Monitoring of emissions Annex IV: Calculation of conversion factors for the determination of mass emissions from concentrations GLOSSARY REFERENCES x Manufacture of Glass

15 List of tables Table 1.1: Approximate sector-based breakdown of glass industry production for the years 1996 (EU- 15) and 2005 (EU-25)... 4 Table 1.2: Distribution of container glass installations and production in Member States Table 1.3: Number of container glass installations in specified production ranges Table 1.4: Owners and locations of float tanks in the EU-27 in Table 1.5: Joint ventures of float tanks in the EU-27 in Table 1.6: Number of float tanks in Member States in 2007 in the EU Table 1.7: Percentage of float capacity in specified ranges Table 1.8: Estimated evolution of the capacity utilisation and surplus float glass production within the EU Table 1.9: Number of continuous filament installations and furnaces in Member States Table 1.10: Number of continuous filament furnaces in specified production ranges Table 1.11: Number and distribution of IPPC domestic glass installations in Member States in Table 1.12: Number of domestic glass installations in specified production ranges in 2006 (estimated) Table 1.13: Special glass sector breakdown for the year Table 1.14: Geographical distribution of main special glass production in EU Table 1.15: Investment costs for special glass installations Table 1.16: Number of mineral wool installations in the EU Table 1.17: Number of mineral wool installations in specified production ranges Table 1.18: Distribution of HTIW installations in Member States Table 1.19: Distribution of frits installations with a total capacity of >20 tonnes/day (2008 estimation) Table 1.20: Number of frits installations located in Spain in specified production ranges (estimates).. 36 Table 2.1: Important glass making raw materials Table 2.2: Elements used to impart colour to silicate glasses Table 2.3: Estimate of EU furnace types in 2005 (for installations >20 t/day) Table 2.4: Typical container glass composition Table 2.5: Typical soda-lime silica flat glass composition Table 2.6: Typical E-glass composition for glass fibre products used in general applications Table 2.7: Typical E-glass composition for glass fibre yarn products used in printed circuit boards and aerospace Table 2.8: Chemical composition of the main products of the special glass sector Table 2.9: Typical mineral wool compositions Table 2.10: Typical chemical composition ranges for ASW/RCF and AES, in mass percentage Table 3.1: Common raw materials utilised in the glass industry Table 3.2: Reference conditions of emission data Table 3.3: Summary of emissions to atmosphere arising from melting activities Table 3.4: Classification of metals and their compounds Table 3.5: Potential heavy metal emissions from glass processes without abatement Table 3.6: Table 3.7: Theoretical energy requirements for the melting of common glasses from batch formulations without cullet recycling Examples of energy output distribution for the production of the most common industrial glasses Table 3.8: Examples of specific energy consumption for a range of glass furnaces Table 3.9: Overview of major container glass production inputs and outputs Table 3.10: Materials utilised in the container glass sector Table 3.11: Statistical data on furnace sizes and type from the FEVE survey (2005 values) Table 3.12: Table 3.13: Table 3.14: Table 3.15: Table 3.16: Table 3.17: Statistical data on total cullet rates for the EU container glass furnaces, reported from the FEVE survey for different glass colours (2005 values) Specific melting energy for different furnace types and size ranges from the FEVE survey (2005 data) Dust emissions from container glass furnaces with and without abatement systems from the FEVE survey (reference year 2005) SO X emissions from container glass furnaces with and without abatement systems, from the FEVE survey (reference year 2005) NO X emissions from container glass furnaces for different fuel types and furnace techniques, from the FEVE survey (reference year 2005) HCl and HF emissions from container glass furnaces with and without abatement systems, from the FEVE survey (reference year 2005) Manufacture of Glass xi

16 Table 3.18: Emissions of metals from container glass furnaces with and without abatement systems, from the FEVE survey (reference year 2005) Table 3.19: Typical unabated emission values from surface coating activities with tin chloride for container glass Table 3.20: Typical unabated emission values from surface treatment of container glass with SO Table 3.21: Total direct energy consumption (plant) per net tonne of product from the FEVE survey for bottle/jars and flaconnage production Table 3.22: Materials utilised in the flat glass sector Table 3.23: Overview of air pollution control (APC) systems installed in the flat glass sector in Europe Table 3.24: Emission levels from flat glass furnaces with and without abatement systems Table 3.25: Overview of the continuous filament glass fibre sector inputs and outputs Table 3.26: Materials utilised in the continuous filament glass fibre sector Table 3.27: Distribution of boron compounds at different temperatures and treatment stages of the fluegases Table 3.28: Emission levels from continuous filament glass fibre furnaces Table 3.29: Overview of domestic glass sector inputs and outputs Table 3.30: Materials utilised in the domestic glass sector Table 3.31: Summary of emissions to air from domestic glass furnaces Table 3.32: Typical concentrations measured in water at discharge point, after treatment Table 3.33: Materials utilised in the special glass sector Table 3.34: Overview of inputs and outputs for example glass ceramic, borosilicate glass tubes and soda-lime glass lamp bulbs processes Table 3.35: Materials utilised in the mineral wool sector Table 3.36: Waste gas volumes for the main process activities in the mineral wool sector Table 3.37: Full range of emissions from mineral wool melting furnaces in the EU-27, for Table 3.38: Dust emissions from melting furnaces for glass wool production (year 2005) Table 3.39: SO X emissions from melting furnaces for glass wool production (year 2005) Table 3.40: NO X emissions from melting furnaces for glass wool production (year 2005) Table 3.41: HCl, HF and CO emissions from melting furnaces for glass wool production Table 3.42: Dust, SO x, NO x, HCl and HF emissions from melting furnaces for stone wool production (year 2005) Table 3.43: Emissions of H 2 S, CO, CO 2 and metals emissions from melting furnaces for stone wool production (year 2005) Table 3.44: Full range of emissions from downstream activities in the glass wool production sector for the year Table 3.45: Full range of emissions from downstream activities in the stone wool production for the year Table 3.46: Mineral wool sector solid waste generation and disposal Table 3.47: Energy use in mineral wool production Table 3.48: Materials utilised in the high temperature insulation wools sector Table 3.49: Main raw materials utilised in frit production Table 3.50: Typical emission levels from melting furnaces for the frits sector Table 3.51: Examples of NO X emission levels from frit production installations operating with different combustion conditions and batch formulations Table 4.1: Information for each technique described in this chapter Table 4.2: Main advantages and disadvantages of electric melting Table 4.3: Example installation for the application of electric melting in the domestic glass sector (crystal and lead crystal glass) Table 4.4: Example installation for the application of electric melting in the special glass sector Table 4.5: Main advantages and disadvantages of primary techniques for dust reduction Table 4.6: Main advantages and disadvantages of electrostatic precipitators Table 4.7: Dust emission levels associated with the use of ESPs for example installations Table 4.8: Summary Examples of actual costs of electrostatic precipitators applied to the glass manufacturing of flat, container, special glass and mineral wool Table 4.9: Main advantages and disadvantages of bag filters Table 4.10: Examples of actual costs of bag filters applied to the special glass sector in two installations Table 4.11: Main advantages and disadvantages of cyclones Table 4.12: Main advantages and disadvantages of high-temperature filters Table 4.13: Main advantages and disadvantages of wet scrubbers Table 4.14: Main advantages and disadvantages of combustion modifications xii Manufacture of Glass

17 Table 4.15: Examples of NO X emission levels associated with the application of combustion modifications Table 4.16: Main advantages and disadvantages of oxy-fuel melting Table 4.17: NO X emission levels associated with the use of oxy-fuel melting in example installations Table 4.18: Examples of actual and estimated costs of oxy-fuel melting applied to the container and special glass sectors Table 4.19: The main advantages and disadvantages of the 3R technique Table 4.20: NO X emission levels associated with the use of the SCR technique in example installations Table 4.21: Results of discontinuous NO X emissions measurements from a float glass furnace equipped with SCR Table 4.22: Main advantages and disadvantages of the SCR technique Table 4.23: Cost data associated with the use of SCR technique for example installations producing container, flat and special glass Table 4.24: Plants operating with the SCR technique and operating parameters Table 4.25: Main advantages and disadvantages of the SNCR technique Table 4.26: Indicative ranges of SO X emissions from soda-lime glass furnaces for different fuels Table 4.27: Indicative dry absorption efficiencies with Ca(OH) Table 4.28: Indicative SO X abatement rates for dry scrubbing with Ca(OH) Table 4.29: Indicative SO X abatement rates for dry scrubbing with Na 2 CO Table 4.30: Actual removal efficiencies of acid gaseous pollutants for dry scrubbing with different type of absorption reagent and operating conditions Table 4.31: Indicative SO X abatement rates for semi-dry scrubbing with Na 2 CO 3 solution Table 4.32: SO X abatement rates for semi-dry scrubbing with Ca(OH) Table 4.33: Main advantages and disadvantages of dry and semi-dry scrubbing techniques Table 4.34: Table 4.35: Table 4.36: Emission levels associated with the use of dry scrubbing combined with a filtration system in example installations Emission levels associated with the application of wet scrubbing to an electric furnace producing special glass in an example installation Solid and gaseous emissions from the forming area of a glass wool installation where a WESP is used Table 4.37: Main advantages and disadvantages of wet electrostatic precipitators (WESPs) Table 4.38: Main advantages and disadvantages of stone wool filters Table 4.39: Main advantages and disadvantages of waste gas incineration Table 4.40: General achievable values for emissions to air from non-melting activities in the mineral wool sector, applying different techniques Table 4.41: Investment and operating costs of abatement techniques for non-melting activities in the mineral wool sect Table 4.42: List of potential waste water treatment techniques for use in the glass industry Table 4.43: Typical specific energy consumption values achieved by applying available techniques/measures for minimising the use of energy Table 4.44: Example installations of waste heat boilers applied in different sectors of the glass industry Table 4.45: Example installation for the application of a direct batch and cullet preheater to a container glass furnace Table 5.1: Reference conditions for BAT-AELs concerning air emissions Table 5.2: Indicative factors used for converting mg/nm 3 into kg/tonne of melted glass based on energy efficient fuel-air furnaces Table 5.3 BAT-AELs for carbon monoxide emissions from melting furnaces Table 5.4: BAT-AELs for ammonia emissions, when SCR or SNCR techniques are applied Table 5.5: BAT-AELs for waste water discharges to surface waters from the manufacture of glass. 336 Table 5.6: BAT-AELs for dust emissions from the melting furnace in the container glass sector Table 5.7: BAT-AELs for NO X emissions from the melting furnace in the container glass sector Table 5.8: BAT-AEL for NO X emissions from the melting furnace in the container glass sector, when nitrates are used in the batch formulation and/or special oxidising combustion conditions in cases of short campaigns or for melting furnaces with a capacity of <100 t/day Table 5.9: BAT-AELs for SO X emissions from the melting furnace in the container glass sector Table 5.10: BAT-AELs for HCl and HF emissions from the melting furnace in the container glass sector Table 5.11: BAT-AELs for metal emissions from the melting furnace in the container glass sector Table 5.12: BAT-AELs for air emissions from hot-end coating activities in the container glass sector when the flue-gases from downstream operations are treated separately Manufacture of Glass xiii

18 Table 5.13: BAT-AEL for SO X emissions from downstream activities when SO 3 is used for surface treatment operations in the container glass sector, when treated separately Table 5.14: BAT-AELs for dust emissions from the melting furnace in the flat glass sector Table 5.15: BAT-AELs for NO X emissions from the melting furnace in the flat glass sector Table 5.16: BAT-AEL for NO X emissions from the melting furnace in the flat glass sector, when nitrates are used in the batch formulation for the production of special glasses in a limited number of short campaigns Table 5.17: BAT-AELs for SO X emissions from the melting furnace in the flat glass sector Table 5.18: BAT-AELs for HCl and HF emissions from the melting furnace in the flat glass sector..348 Table 5.19: BAT-AELs for metal emissions from the melting furnace in the flat glass sector, with the exception of selenium coloured glasses Table 5.20: BAT-AELs for selenium emissions from the melting furnace in the flat glass sector for the production of coloured glass Table 5.21: BAT-AELs for air emissions from downstream processes in the flat glass sector, when treated separately Table 5.22: BAT-AELs for dust emissions from the melting furnace in the continuous filament glass fibre sector Table 5.23: BAT-AELs for NO X emissions from the melting furnace in the continuous filament glass fibre sector Table 5.24: BAT-AELs for SO X emissions from the melting furnace in the continuous filament glass fibre sector Table 5.25: BAT-AELs for HCl and HF emissions from the melting furnace in the continuous filament glass fibre sector Table 5.26: BAT-AELs for metal emissions from the melting furnace in the continuous filament glass fibre sector Table 5.27: BAT-AELs from downstream processes in the continuous filament glass fibre sector, when treated separately Table 5.28: BAT-AELs for dust emissions from the melting furnace in the domestic glass sector Table 5.29: BAT-AELs for NO X emissions from the melting furnace in the domestic glass sector Table 5.30: BAT-AELs for NO X emissions from the melting furnace in the domestic glass sector, when nitrates are used in the batch formulation for a limited number of short campaigns or for melting furnaces with a capacity <100 t/day producing special types of soda-lime glasses (clear/ultra-clear glass or coloured glass using selenium) and other special glasses (i.e. borosilicate, glass ceramics, opal glass, crystal and lead crystal) Table 5.31: BAT-AELs for SO X emissions from the melting furnace in the domestic glass sector Table 5.32: BAT-AELs for HCl and HF emissions from the melting furnace in the domestic glass sector Table 5.33: BAT-AELs for metal emissions from the melting furnace in the domestic glass sector with the exception of glasses where selenium is used for decolourising Table 5.34: BAT-AELs for selenium emissions from the melting furnace in the domestic glass sector when selenium compounds are used for decolourising the glass Table 5.35: BAT-AELs for lead emissions from the melting furnace in the domestic glass sector when lead compounds are used for manufacturing lead crystal glass Table 5.36: BAT-AELs for air emissions from dusty downstream processes in the domestic glass sector, when treated separately Table 5.37: BAT-AELs for HF emissions from acid polishing processes in the domestic glass sector, when treated separately Table 5.38: BAT-AELs for dust emissions from the melting furnace in the special glass sector Table 5.39: BAT-AELs for NO X emissions from the melting furnace in the special glass sector Table 5.40: BAT-AELs for NO X emissions from the melting furnace in the special glass sector when nitrates are used in the batch formulation Table 5.41: BAT-AELs for SO X emissions from the melting furnace in the special glass sector Table 5.42: BAT-AELs for HCl and HF emissions from the melting furnace in the special glass sector Table 5.43: BAT-AELs for metal emissions from the melting furnace in the special glass sector Table 5.44: BAT-AELs for dust and metals emissions from downstream processes in the special glass sector, when treated separately Table 5.45: BAT-AELs for HF emissions from acid polishing processes in the special glass sector Table 5.46: BAT-AELs for dust emissions from the melting furnace in the mineral wool sector Table 5.47: BAT-AELs for NO X emissions from the melting furnace in the mineral wool sector Table 5.48: Table 5.49: BAT-AELs for NO X emissions from the melting furnace in glass wool production when nitrates are used in the batch formulation BAT-AELs for SO X emissions from the melting furnace in the mineral wool sector xiv Manufacture of Glass

19 Table 5.50: BAT-AELs for HCl and HF emissions from the melting furnace in the mineral wool sector Table 5.51: BAT-AELs for H 2 S emissions from the melting furnace in stone wool production Table 5.52: BAT-AELs for metal emissions from the melting furnace in the mineral wool sector Table 5.53: BAT-AELs for air emissions from downstream processes in the mineral wool sector, when treated separately Table 5.54: BAT-AELs for dust emissions from the melting furnace in the HTIW sector Table 5.55: BAT-AELs from dusty downstream processes in the HTIW sector, when treated separately Table 5.56: BAT-AELs for NO X emissions from the lubricant burn-off oven in the HTIW sector Table 5.57: BAT-AELs for SO X emissions from the melting furnaces and downstream processes in the HTIW sector Table 5.58: BAT-AELs for HCl and HF emissions from the melting furnace in the HTIW sector Table 5.59: BAT-AELs for metal emissions from the melting furnace and/or downstream processes in Table 5.60: the HTIW sector BAT-AELs for VOC emissions from the lubricant burn-off oven in the HTIW sector, when treated separately Table 5.61: BAT-AELs for dust emissions from the melting furnace in the frits sector Table 5.62: BAT-AELs for NO X emissions from the melting furnace in the frits sector Table 5.63: BAT-AELs for SO X emissions from the melting furnace in the frits sector Table 5.64: BAT-AELs for HCl and HF emissions from the melting furnace in the frits sector Table 5.65: BAT-AELs for metal emissions from the melting furnace in the frits sector Table 5.66: BAT-AELs for air emissions from downstream processes in the frits sector, when treated separately Table 6.1: Environmental performance overview for catalytic ceramic filter installations Table 7.1: Split views Table 8.1: Indirect emissions related to the consumption of chemicals and electricity Table 8.2: Example cost calculation (ESP plus Ca(OH) 2 scrubber) for a 700 tonnes/day Table 8.3: Table 8.4: Table 8.5: Table 8.6: Table 8.7: Table 8.8: Table 8.9: Table 8.10: Table 8.11: Estimated costs for air pollution control systems with electrostatic precipitators plus dry scrubbing, applied to the flue-gases of glass melting furnaces Estimated costs for air pollution control systems with bag filters plus scrubbing, applied to the flue-gases of glass melting furnaces Comparison of methods for the removal of SO X, HCl, HF and other gaseous pollutants from flue-gases of glass melting furnaces Overview of specific costs for different air pollution control (APC) techniques applied to glass furnaces for the abatement of dust and SO X Estimated example costs and associated direct and indirect emissions associated with the application of primary measures for NO X emissions reduction Estimated example costs for the application of secondary measures for NO X emissions reduction Additional costs associated with the application of DeNO X techniques (in EUR/tonne melted glass) Estimated specific indirect emissions per tonne melted glass for different glass furnaces and for different air pollution control (APC) techniques Raw materials and typical sulphur content in the mineral wool manufacturing production Table 8.12: Typical SO 3 content of common cullet types Table 8.13: Main pollutants likely to be considered for measurement in the glass industry Table 8.14: Continuous monitoring techniques Table 8.15: Mass flow thresholds for continuous monitoring of emissions Table 8.16: Discontinuous monitoring techniques Table 8.17: Table 8.18: Example of detection limit values for the measurement of emissions from glass melting furnaces Example of detection limit values and expanded uncertainties for the measurement of emissions in the glass industry sector Manufacture of Glass xv

20 List of figures Figure 1.1: Graph on production development by sector (data from 2004 onwards refer to...4 Figure 1.2: Most popular high temperature insulation wools for above 600 C and up to 1800 C...34 Figure 2.1: A cross-fired regenerative furnace...47 Figure 2.2: Cross-section of a regenerative furnace...48 Figure 2.3: Single pass end-fired regenerative furnace...48 Figure 2.4: Plan view of an end-fired regenerative furnace...49 Figure 2.5: Blow and blow forming and press and blow forming...55 Figure 2.6: The float glass process...58 Figure 2.7: The rolled glass process...59 Figure 2.8: The pressing process for the formation of glass articles...63 Figure 2.9: The spinning process for the formation of glass articles...63 Figure 2.10: A typical glass wool plant...68 Figure 2.11: Typical glass wool process water circuit...70 Figure 2.12: A typical stone wool plant...71 Figure 2.13: A typical hot blast cupola furnace...72 Figure 2.14: Parallel blowing method...75 Figure 2.15: Horizontal blowing method...75 Figure 2.16: Spinning process...75 Figure 2.17: Schematic representation of the frits production process...77 Figure 2.18: Schematic representation of typical melting furnaces for frits production with oxygenenriched fuel/air combustion and heat recovery...79 Figure 2.19: Schematic representation of typical melting furnaces for frits production with oxy-fuel combustion...79 Figure 3.1: Typical water distribution in a container glass plant...89 Figure 3.2: Trend curves for the total melting energy in flaconnage production from the FEVE survey (2005 data primary energy for electric boosting or oxygen production is not included) Figure 3.3: Energy usage in a typical bottle/jar container glass plant (not representative of perfume/cosmetic ware production) Figure 3.4: Mean energy consumptions in glass container furnaces expressed in GJ/tonne melted glass and standardised to 50 % cullet (2005) Figure 3.5: Energy usage distribution for a typical float glass process Figure 3.6: Example of water balance for a continuous filament glass fibre installation Figure 3.7: Direct energy usage in a typical continuous filament glass fibre production process Figure 3.8: Energy usage in soda-lime-silica glass tableware production Figure 3.9: Expected concentration of SO 2 depending on the percentage of cement briquettes recycled with the batch charge in the cupola furnace Figure 4.1: Electrostatic precipitator Figure 4.2: Results of dust emissions (monthly spot measurements) from an oil-fired float glass furnace equipped with an ESP and dry scrubbing with Ca(OH) Figure 4.3: Specific costs per tonne molten glass for air pollution control by dry scrubbing and filters, with total disposal of filter dust, for float glass furnaces depending on melting pull Figure 4.4: Bag (fabric) filter scheme Figure 4.5: Estimated costs for dry scrubbers in combination with bag filters for container glass furnaces, assuming a complete filter dust disposal and 25 % SO X removal Figure 4.6: NO X emissions from the FENIX process Figure 4.7: Difference in specific melting costs after conversion from conventional furnaces to oxygenfiring for different glass production installations (container, float,continuous filament glass fibre and tableware) Figure 4.8: Variation of NO X concentration over time for a float glass furnace equipped with SCR..248 Figure 4.9: Continuous improvement in an EMS model Figure 6.1: Schematic diagram of the advanced batch and cullet preheater Figure 6.2: Schematic diagram of the submerged combustion melter Figure 6.3: Schematic representation of a sonic jet charger Figure 6.4: Schematic diagram of the charged cloud scrubber system Figure 8.1: Sulphur balance for a float glass furnace with complete filter dust recycling Figure 8.2: Sulphur balance for a container glass furnace with partial filter dust recycling Figure 8.3: Schematic sulphur balance for an oxy-fuel glass wool furnace with filter dust recycling.438 xvi Manufacture of Glass