Multilateral Investment Guarantee Agency
Environmental Guidelines for
Glass Manufacturing
Industry Description and Practices used (frequently installed as supplementary
heating). Energy requirements range 3.7-6.0
This guideline describes the manufacture of flat kiloJoules per metric ton (kJ/t) glass produced.
glass, and pressed and blown glass. Flat glass
includes plate and architectural glass, Waste Characteristics
automotive windscreens and mirrors. Pressed
and blown glass includes containers, machine Two types of air emissions are generated, those
and hand-blown glassware, lamps and from the combustion of fuel to operate the glass
television tubing. In both categories a glass melt melting furnaces and fine particulates from the
is prepared from silica sand, other raw vaporization and recrystallization of materials
materials such as lime, dolomite, and soda, and in the melt. The major emissions are sulfur
cullet (broken glass). The use of recycled glass is oxides (SOx), nitrogen oxides (NOx) and
increasing and this requires extensive sorting particulates which can contain heavy metals
and cleaning prior to batch treatment to remove such as arsenic and lead. Note: particulates
impurities. The use of recycled glass reduces the from lead crystal manufacture can have a lead
consumption of both raw materials and energy. content of 20-60 percent and an arsenic content
For the manufacture of special and technical of 0.5-2 percent. Certain specialty glasses can
glass, lead oxide (up to 32 wt. %), potash, zinc produce releases of hydrogen chloride (HCl),
oxide, and other metal oxides are added. hydrogen fluoride (HF), arsenic, boron and lead
Refining agents include arsenic trioxide, from raw materials. Container, press and blow
antimony oxide, nitrates, and sulfates. Metal making operations produce a periodic mist
oxides and sulfides are used as (de-) coloring when the hot gob comes into contact with the
agents. release agent used on the molds.
The most common furnace used to Cold top electric furnaces that operate with
manufacture glass melt is the continuous coverage of the melt surface by raw material
regenerative type with either side or end ports feed release very little particulate matter as the
connecting brick checkers to the inside of the blanket acts as a filter to prevent the release of
melter. Checkers conserve fuel by acting as a particulate matter. Some releases of particulates
heat exchanger--the fuel combustion products will take place when tapping but furnace
heat incoming combustion air. The molten glass releases should be in the order of 0.1 kg/t when
is refined (heat conditioning) and then is either operated this way.
pressed, blown, drawn, rolled or floated, Lead glass manufacture may result in lead
depending on the final product. emissions of the order of 2-5 kg/t.
Damaged/broken product (cullet) is returned to In all cases, the concentration of heavy
the process. metals and other pollutants in the raw flue gas
The most important fuels for glass melting mainly depends on the type of fuel used, the
furnaces are natural gas, light and heavy fuel oil composition of the feed material, and the
and liquefied petroleum gas. Electricity is also portion of recycled glass. High input of sulfates
393
394 Glass Manufacturing
or potassium nitrate may increase emissions of design and firing patterns, higher pre-heater
SO2 and NOx respectively. Where nitrate is temperatures, pre-heating of raw material, and
used, in excess of two-thirds of the introduced electric melting.
nitrogen may be emitted as NOx. Heavy metals Changing the composition of the raw
used as (de)colorizing agents will increase materials can, for example, reduce chlorides,
emissions of these metals. fluorides, and sulfates used in certain specialty
The grinding and polishing of flat glass to glasses. The use of outside sourced cullet and
produce plate glass has become obsolete since recycled glass will reduce energy requirements
the development of the float glass process. The (estimated at two percent savings for each 10
chemical make-up of detergents that may be percent of cullet used in the manufacture of
used by float glass manufacturing could vary melt) and thus air emissions (up to 10% for 50%
significantlysome could contain phosphorous cullet in the mix). Typical recycling rates in the
in hand blown and pressed glass, pollutants in flat glass industry are 10-20%, and over 50% for
effluents are generated by finishing processes the blown and pressed glass industries.
such as cutting, grinding, polishing and etching The amount of heavy metals used as refining
and include suspended solids, fluorides, lead, and coloring or decolorizing agents, as well as
and variations in pH. potassium nitrate, should be minimized to the
Liquid effluents also result from forming, extent possible.
finishing, coating, and electroplating operations. In the furnace, particulates are formed
Heavy metal concentrations in effluents occur through the volatilization of materials and these
where silvering and copper plating processes tend to form condensates, which cause slag
are in use. formation that will clog the furnace checkers.
Disposal of this slag requires testing to
Pollution Prevention and Control determine the most suitable disposal method. It
is important to inspect the checkers on a regular
Oxygen enriched and oxy-fuel furnaces are basis to determine if cleaning is required.
used in specialty glass operations to reduce Particulate matter is also reduced, for
emissions and/or to provide higher production example, through enclosing conveyors, through
rates for the same size furnace. Although pelletizing raw material, through reducing melt
oxyfuel furnaces may produce higher NOx temperatures, and by blanketing the furnace
emissions on a concentration basis, they are melt with raw material.
expected to give very low levels of NOx on a Reductions in wastewater volumes are
mass basis (kg/t of product). Low NOx possible through closed cooling water loops and
furnaces, staged firing, and flue gas improved blow-off techniques.
recirculation are available to reduce NOx
emissions in terms of both concentration and Target Pollution Loads
mass. These techniques are also available for
air-fuel fired furnaces. Levels of NOx can be Modern plants using good industrial practices
controlled to 500-800 milligrams per cubic meter are able to achieve the following in terms of
(mg/m3). pollutant loads. Because of the lack of nitrogen
The type of combustion fuel used affects the in the oxidant, using oxy-fuel fired furnaces
amount of sulfur oxides and nitrogen oxides produces 4-5 times less flue gas volume than
emitted. Natural gas results in negligible sulfur regenerative furnaces. As a result nitrogen
dioxide emissions from the fuel compared with oxides (NOx) are reduced by 80% and
those from high sulfur fuel oils. Fuel oil with a particulates are reduced by 20-80%.
low sulfur content is preferable to fuel oil with a For furnaces which operate with a cover of
high sulfur content if natural gas is not raw material, a target of 0.1 kg/t for particulates
available. is realistic. Reductions in SO2 are achieved by
An efficient furnace design will reduce choosing natural gas over fuel oil where
gaseous emissions and energy consumption possible.
examples include modifications to the burner
395 Glass Manufacturing
Treatment Technologies Air Emissions from Glass Manufacturing
Parameter Maximum value in
ESPs are the preferred choice for removing milligrams per
particulates, although fabric filters are also normal cubic meter
used. Dry scrubbing using calcium hydroxide is (mg/Nm3)
used to reduce SO2, HF, and HCl. Secondary
NOx 1,000 (up to 2,000
measures for NOx control include selective
may be acceptable
catalytic reduction (SCR), selective non-catalytic
depending on
reduction (SNCR), and certain proprietary
furnace technology
processes such as the Pilkington 3R process.
and if justified in
Emissions Guidelines the EA)
SOx
Emission levels for the design and operation of
Gas fired 700
each project must be established through the
Oil fired 1800
Environmental Assessment (EA) process, based
Particulates 50 (20 where toxic
on country legislation and the Pollution
metals are present)
Prevention and Abatement Handbook as applied to
Lead and cadmium (total) 5
local conditions. The emission levels selected
Arsenic (As) 1
must be justified in the EA and acceptable to the
Total of other heavy 5
World Bank Group.
metals
The following guidelines present emission
Fluoride (F) 5
levels normally acceptable to the World Bank
HCl 50
Group in making decisions regarding provision
of World Bank Group assistance; any deviations
from these levels must be described in the Liquid Effluents
World Bank Group project documentation.
The guidelines are expressed as For glass manufacturing plants, the following
concentrations to facilitate monitoring. Dilution effluent levels should be achieved:
of air emissions or effluents to achieve these
Effluents from Glass Manufacturing
guidelines is unacceptable.
All of the maximum levels should be Parameter Maximum value
achieved for at least 95% of the time that the PH 6-9
plant or unit is operating, to be calculated as a Total suspended 50 milligrams per
proportion of annual operating hours. solids liter (mg/L)
Chemical oxygen 150 mg/L
Air Emissions demand (COD)
Oil and grease 10 mg/L
For glass manufacturing plants, the following Lead (Pb) 0.1 mg/L
air emissions should be achieved: Arsenic (As) 0.1
Antimony (Sb) 0.5
Fluorides (F) 20
Total metals 10 mg/L
Note: Effluent requirements are for direct
discharge to surface waters.
Ambient Noise
Noise abatement measures should achieve
either the following levels or a maximum
increase in background levels of 3 dB(A).
396 Glass Manufacturing
Measurements are to be taken at noise receptors Key Issues
located outside the project property boundary.
The following box summarizes the key
production and control practices that will lead
to compliance with emission requirements:
Ambient Noise
Maximum Allowable Consider using oxy-fuel fired furnaces for
specialty glass manufacturing
Leq (hourly), in dB(A)
Use low-NOx burners, staged firing, and flue gas
Daytime Nighttime recirculation.
Receptor 07:00 - 22:00 -
Consider natural gas rather than oil as the fuel of
22:00 07:00 choice.
Residential; 55 45 Select raw materials to minimize emissions of
institutional;
fluorides and other pollutants such as chlorides
educational
and sulfates.
Industrial; 70 70 Maximize water reuse.
commercial
For reductions in particulate emissions, pelletize
The emission requirements given here can be raw materials, enclose conveyors, reduce melt
consistently achieved by well-designed, well- temperatures, and blanket the melt surface with
operated and well-maintained pollution control raw material.
systems.
Further Information
Monitoring and Reporting
The following are suggested as sources of
Frequent sampling may be required during additional information (these sources are
start-up and upset conditions. Once a record of provided for guidance and are not intended to
consistent performance has been established, be comprehensive):
sampling for the parameters listed above should Bounicore, A.J. and W.T. Davis. 1992. Air
be as detailed below. Pollution Engineering Manual. New York: Van
Establish a maximum opacity level that Nostrand Reinhold.
corresponds to 50 mg/Nm3 then continuosly Sittig, Marshall. 1975. Pollution Control in
monitor opacity. Other air emission parameters Asbestos, Cement, Glass, and Allied Mineral
should be measured annually. Liquid effluents Industries. London: Noyes Data Corporation.
should be continuously monitored for pH and World Bank, Environment, 1996. Pollution
other parameters should be tested weekly. prevention and Abatement: Glass Manufacturing
Monitoring data should be analyzed and Plants. Technical Background Document.
reviewed at regular intervals and compared World Health Organization. 1993. Assessment of
with the operating standards so that any Sources of Air, Water, and Land Pollution. A Guide
necessary corrective actions can be taken. to Rapid Source Inventory Techniques and Their Use
Records of monitoring results should be kept in in Formulating Environmental Control Strategies.
an acceptable format. These should be reported Part One: Rapid Inventory Techniques in
to the responsible authorities and relevant Environmental Pollution by Alexander P.
Economopoulos. Publication No.
parties, as required, and provided to MIGA if
WHO/PEP/GETNET/93.
requested.
Emission Control at Stationary Sources in the
Federal Republic of Germany. Prof. Otto Rentz at al,
January 1997.
