Grand finale

Introduction

The Prime Glass project has been an important part of the last three years of many people’s LIFE, now it has come to its end in the best way: with the great results we achieved and with the excellent final conference that saw about 120 participants, in the wonderful landscape of Rapallo.

To share the celebration with you, we prepared this article that is meant to summarize the great day we all spent, and it includes pictures, videos (in Italian) and all the presentations (in English).

Staraglass rapallo per il sito-18

The audience

Staraglass rapallo per il sito-36

The location and SSV’s Dr. Manoli

Staraglass rapallo per il sito-40

The location. Excelsior Palace Hotel, Rapallo

Mr. Arnaldo Messori’s welcome

Stara Glass’ President, Mr. Arnaldo Messori, introduced the conference and thanked all the involved people.

Staraglass rapallo-10 per il sito

 

Bianca Maria Scalet, (Nicola Favaro) (Ufficio di Gabinetto Ministro per la Coesione Territoriale e il Mezzogiorno / Stazione Sperimentale del Vetro) – Glass melting: emission sources – Implementation of Best Available Techniques (BAT) and Associated Emission Levels

Dr. Scalet, one of our most prestigious speakers, gave us the chance to get a very wide overview of the glass emission regulation nowadays scenario.

Scalet Rapallo 30 marzo 2017

Staraglass rapallo-14 per il sito

Staraglass rapallo-20 per il sito

 

Francesco Prosperi (Stara Glass) – The Prime Glass DeNOx solutions in the present scenario of the glass industry NOx containment technologies

Stara Glass’ technical director proposed a wide and precise analysis of all current technologies for NOx primary and secondary containment in glass industry.

Francesco Prosperi_Primglass_meeting_03-30-17

Staraglass rapallo-27 per il sito

Staraglass rapallo-26 per il sito

 

Ernesto Cattaneo (Stara Glass) – The technologies of the Prime Glass project

The Stara Glass R&D engineer and chairman of the event, that has been deeply involved in most of the project activities, proposed a synthetic overview of the project technologies, thus introducing the successive speeches.

Ernesto Cattaneo_Primglass_meeting_03-30-17

Staraglass rapallo-46 per il sito

Staraglass rapallo-45 per il sito

Simone Tiozzo, (Walter Battaglia, Alessandro Migatta) (Stazione Sperimentale del Vetro)The Multipoint Continuous Monitoring system and its application in the Prime Glass project

The SSV engineer introduced the highly innovative monitoring system that has been utilized to collect the experimental data of the operating glass plant with a multipoint parallel acquisition.

Tiozzo-Battaglia-Migatta SSV_MCM_Primeglass_meeting_03-30-17 FINAL

Staraglass rapallo-59 per il sito1

Staraglass rapallo-42 per il sito

The bow-tied speakers, Giorgio Minestrini (Stara Glass) and Simone Tiozzo (SSV)

Milena Marchegiani, (Luca Tosini, Adelvaldo Bussolati) (Bormioli Rocco)A customer’s experience of the Prime Glass technologies and the open problems in glass furnaces’ emissions control

One of the most interesting parts of the conference has been the opportunity to see the Prime Glass technologies from the point of view of the end-user. It has been a big luck, for the project partners, to test our experimental plants together with the extremely skilled Bormioli Rocco personnel, and Doctor Marchegiani’s brillant presentation has shown another example of the priceless technical sodalice we have been able to develop within the project, and not just among the partners.

Marchegiani-Tosini-Bussolati 2017.03 BR PG

Staraglass rapallo-66 per il sito Staraglass rapallo-68 per il sito 1

(Carlo Cravero), Michele Pallante, Alessandro Spoladore (Università degli Studi di Genova) –   Simulation of glass production system components with gas recirculation using CFD and lower order models

UNIGE Engineers Pallante and Spoladore brillantly exposed the contribution of Professor Cravero’s CFD computing team to the project

Cravero_Pallante_Spoladore_Primeglass_meeting_03-30-17

Staraglass rapallo-70 per il sito Staraglass rapallo-75 per il sito

Staraglass rapallo-87 per il sito

 

Alessandro Mola (Stara Glass) An analysis of the environment and energy performance of the Prime Glass technologies and their future developments

Dr. Mola, the scientific responsible of the project and actual conceiver of the two NOx containment technologies we studied, presented a detailed analysis of the project results and their possible future developments.

MOLA_Primglass_meeting_03-30-17 R1

Staraglass rapallo-77 per il sito Staraglass rapallo-82 per il sito

 

(Nicola Favaro), Walter Battaglia (Stazione Sperimentale del Vetro)The Life Cycle Assessment applied to the Prime Glass technologies

The Life Cycle Assessment (LCA) is a standardized procedure that enables an objective evaluation of the environmental impact of a certain product or process by means of the analysis of raw materials and energy flows and the definition of performance indicators. SSV technicians and scientists have been able to perform this detailed analysis to the Prime Glass technologies, here masterfully exposed by Dr. Battaglia.

Battaglia – Favaro PrimeGlass SSV_LCA_03-30-17 ENG

Staraglass rapallo-92 per il sito

Staraglass rapallo-97per il sito

 

Sauro Pasini, (Sandro Merlini) (RJC) – Designing low NOx combustion systems for end port glass melting furnaces using an integrated CFD based approach

Dr. Pasini, one of our most prestigious speakers, applied his extremely wide combustion design expretise to provide us with an analysis applied to regenerative glass furnaces, that included all most important nowadays solutions and winked to the future ones.

Pasini-Merlini-Giovannini Primglass_meeting_03-30-17_Final

Staraglass rapallo-99 per il sito

Staraglass rapallo-90 per il sito

 

(Carlo Cravero), Santo Cogliandro, Alessandro Spoladore (Università degli Studi di Genova)Perspectives from numerical modeling and video data acquisition for glass furnace optimization and management

The less visible, actually infrared, yet very important part of the project regarding thermography and image analysis has been described by the field experts Dr. Cogliandro and Dr. Spoladore.

Cogliandro_Cravero_Spoladore_Primeglass_meeting_03-30-17

Staraglass rapallo-120 per il sito

Staraglass rapallo-119 per il sito

 

Giorgio Minestrini (Stara Glass) – Innovative plant solution connected to the Prime Glass technologies: state of the art and perspectives

The brillant Stara Glass’ R&D Engineer Giorgio Minestrini that has been, among the other things, supervising the installation of every plant of the project, here introduces the future developments of our technologies that proved to be products ready for the glass market, but still have interesting margins of improvement.

Minestrini_Primglass_meeting_03-30-17

Staraglass rapallo-130 per il sito

Staraglass rapallo-121 per il sito

 

Salutations

The project is formally over, strategic waste gas recirculation and high-efficiency air-staging are among the present-big-thing to evaluate, to optimize the operation of regenerative glass furnaces, and our thermography / image analysis activity allowed us to make our design more accurate and our technologies more performing. We are extremely proud of the results we achieved and the entire Prime Glass team wants to thank:

  • All the glass production plants personnell that challenged the tradictional refractoriness to change of glass industry and embraced our proposal, therefore thank you Vetropack (former Bormioli Rocco) – Trezzano, thank you Vetri Speciali – San Vito al Tagliamento, thank you Bormioli Rocco – Altare
  • The EU LIFE instrument that made all of this possible and, as a consequence, glass industry more sustainable
  • All the attentive, technically prepared and always interested audience of the conference.

Personally, after three years of very satisfactory yet hard work, I want to thank all the wonderful Stara Glass, SSV, UNIGE and external people we have been working with, for the passion and the target-oriented mentality everybody has been using.

Last but not least, I want to thank all people that have been following the news of this website: after three years of posting articles for you, I toast to you!

Staraglass rapallo-139 per il sito

Prime Glass final conference

Our project is close to its end, in the last three years we have been working hard and we have reached the important goals we set about the sustainability of the glass production. We are now proud to invite you to the Prime Glass project final conference that will take place in Rapallo (Genova – Italy) on March 30th 2017, where we will expose all the results. The link below allows you to download the conference program and details. The participation is free of charge, just let us know you are coming as described in the program. Thank you for following us, we hope to toast with you in Rapallo to our noticeable achievements!

Prime Glass meeting Mar 30-2017 Rapallo r1

Prime Glass scientific conference in Savona

The conference has been a great success and the whole Prime Glass group wants to thank the speakers and the audience.

The presentations are available for download at the following links, that report the names of the authors.

Arensi_Ansys Battaglia_SSV Cravero_Cogliandro_Unige Fricker_IFRF Minestrini_StaraGlass Mola_StaraGlass Nilberto_Cattaneo_Unige_StaraGlass Pallante_unige Pasini_Merlini_RJC Spoladore_Unige 20170124_101945 20170124_170205 IMG-20170125-WA0004

Prime Glass scientific conference in Savona – 01/24/2017

We are proud to invite you to our “PRIMEGLASS PROJECT: EXPERIMENTAL EVIDENCE AND FLUID DYNAMICS MODELLING ISSUES FOR THE GAS RECIRCULATION TECHNOLOGY” conference that will take place in the Savona Campus of the Unifersity of Genova.

Download the complete program following the link below.

scientific_conference_PRIMEGLASS

The conference is aimed at presenting and discussing the strategic gas recirculation technology developed within the PRIME GLASS framework.
Several modelling issues have been tackled to develop a fluid-dynamic model for both recirculation systems and combustion analysis.
The resulting models have been set up and finalised using experimental campaigns on the pilot plants.
Invited lectures from Accademia and Industry give an additional contribution to the meeting with an overview over the state of the art in this challenging simulation topic.

Regeneration chambers CFD

The University of Genova, partner of the Prime Glass project, has published an interesting article about the CFD analysis of the chambers of a regenerative glass furnace on the on-liner magazine Energies. The models that have been utilized for the article are the same that helped us in the design of our strategic waste gas recirculation systems.

You can find the article here.

Prime Glass meeting in Murano – presentations

The Prime Glass meeting in Murano (Venice – Italy) has been a great success. All the staff involved wants to thank the wide audience that attended the meeting. Both for the present and for who missed it, here below you cand find all the presentations that have been held.

IMG_4001 IMG_4002

Esperienze PRIME GLASS R2

PRIMEGLASS PRE MURANO R4

seminario PrimeGlass

SSV_26.02.2016_AMS UNI EN 14181_2015

SSV_26_Feb2016

SSV_Seminario 26.02.2016_Ottizzazione combustione(1)

Primary techniques for NOx abatement: an analysis by SSV

The Prime Glass project’s aim was to develop two technologies for the abatement of NOx emission from glass furnaces and, at the same time, to reduce the energy consumption.

The main driving force of the project was the new European Legislation which foresee new ambition limit values for NOx: from March 2016 all glass industries in Europe have to comply with new emission limits.

The permits of the glass industries in Europe are now under revision and should be updated by March 2016 from the local authority. Glass industries are making a big effort to implement and develop a new technology in order to guarantee the compliance with the new limit values; however the results are not always satisfactory.

Based on the information available at SSV and its project partners, it is confirmed that Primary Measurements, which means modification or optimization of the furnace, are still preferred compared to the secondary measurements which foresee the installation of new secondary abatement systems (SNCR or SCR). It is also confirmed that the new limit values will be for the majority of plant very ambitious and difficult to reach.

Glass industry is indeed involved in exploring the possibility of reducing the emissions of oxides through primary techniques with the purpose of combustion optimization (stage combustion, flue-gas recirculation, adoption of low-NOx burners, changing fuel, new furnace designs, etc..) for several reasons:

– first of all, because the furnace is working and they do not require a significant financial commitment with respect to a secondary abatement system;

– secondly, because, in any case, the optimization of combustion provides useful information for the feasibility study and the design of the secondary system. It is necessary, in order to consider also that these systems, while allowing to obtain high performance in terms of reduction of pollutants emitted into the atmosphere imply significant Cross-media effects.

The main problem is not only the absence of a specific technology able to guarantee in all the cases the compliance, but also the difficulties to guarantee the stability of the emissions below the limit value over the time (aging of the furnace) and/or during the change of production (color or pull change). The complessity of the issue is well demonstrated by the important number of technical articles or oral presentations dealing with the NOx issue and also by the different projects in place in Europe.

Today we have several different techniques that allow us to face the problem of nitrogen oxides containment, which can be used separately or in parallel. It must always be taken in account that in both new and existing furnaces, the first step always consists in an optimization of the current situation, a fine combustion tuning, involving the air/fuel ratio and the setup of burners, which must be performed after any change of working condition: this and the new generations of glass furnaces will not just have to guarantee a good product, they will also have to be extremely reliable on an ambient point of view, and this goal is achievable by the usage of different devices.

In this context, the PRIME GLASS PROJECT maintains its importance as new state of art technology to reduce the NOx emission by primary measurements. The relevance of the project is confirmed by the interest recently demonstrated by some technical NGOs like the ICG (International Commission of Glass) which required a presentation to be added at the ICG webpage and the TC13 which will be updated during the next meeting scheduled in Paris on November 2015.

The second aim of the project is the reduction of the energy consumption. This topic is becoming always more relevant. The glass industry has already made a big effort to reduce the energy needed to produce a final glass article; from the beginning of the 19th century up to nowadays the energy required has been reduced of more than 5 times and it actually reaching the thermodynamic limit. However, the reduction of 1-2 % is still possible by technology able to recover energy from the waste flow gas. This small number in term of percentage means a big reduction in terms of tone of CO2 emitted by the glass industry in Europe.

The importance of the specific topic is well recognized by the new European Roadmap which setup ambitious reduction of the CO2 emitted by the industry. The last documents provide figures suggesting a reduction of at least 30 % by 2030. The reduction of the energy consumptions means also a reduction of the primary raw materials used as fuel (methane or fuel oil), another of the important focus of the European Commission managed by the so call Circular Economy.

It should finally noted that there is not a single solution available for the reduction of NOx emission and for energy saving; the easy things has been already done in the pass. The challenges of the future research is provide different new technologies to improve the situation; the application of different technologies will provide the solution to reach the ambitious reduction required by the European Commission. In this context, the PRIME GLASS PROJECT maintains and confirms its importance.

Inside the furnace

endo

This is an image that has been captured from a HD endoscopic video we have filmed inside an operating furnace. Coupling at least two of such videos we want to develop an image analysis tool to define a mathematical flame presence probability function.

PRIME GLASS project LIFE12 ENV/IT/001020 – Public supply request

Stara Glass selects one or two companies to 1) supply and 2) install the following items for an end-fired regenerative glass furnace, that will allow us to test an experimental high temperature air-staging technique:

– No. 2 fused-cast AZS (min 33% ZrO2) ports – About 11500 kg

– No. 2 fused-cast AZS (min 33% ZrO2) burner zones – About 750 kg

– No. 2 fused-cast AZS (min 33% ZrO2) chamber penertration zones – About 9500 kg

– No. 1 zirconium-mullite connection duct

We ask the companies that are interested at supplying and/or installing the said items to contact us at staraglass@hydragroup.it in order to ask us for the technical specifications that can not be reported here in order to protect the reserved data of the plant

A CFD model for end port glass furnaces’ combustion

trz3_sxFlame_2Bruc_Um81_P1WSGG_8901

The CFD activity is currently focused on the assesment of a reliable combustion model for End Port furnaces.
Preliminar investigations on the state of the art for turbulent combustion modelling led to chose the so called “flamelet approach” as best compromise between accuracy and computational costs.
Thanks to the partnership with MOXOFF, based in Milan, it is possible to develope in parallel several branches within the main worflow:

– In depth analysis of advantages/disadvantages offered by commercial software (Fluent, ICEM) and open-source software (OpenFOAM, SnappyHexMesh) in terms of grid generation and physical simulation.

– Simulation set-up and validation of experimental data for different furnaces under different working conditions.

Encouraging results have been already achieved for Trezzano 3 (Fluent simulation).
The concentration of chemical species (including minor species like NO and CO) and temperature levels are quite close to the real values.