Development of Glass Melting Pots by Slip Casting Process
All the coloured glass compositions in Firozabad Glass Industries Cluster, worldwide famous for Producing wide range of coloured glass item, are melted exclusively in hand moulded refectory pots. Due to limitations of hand moulding, process performance of such pots are far from satisfactory which ultimately affects both the product quality and economy adversely.
To overcome this problem the Centre has planned to develop glass meting pots by Slip-casting process due its advantages over hand molding process as mentioned below :
1. Homogeneity of the pot body is much better.
2. Chance of inclusion of trapped air in the pot body during molding is absent.
3. There is no lamination in the pot body.
4. Possibility of development of drying cracks is very low.
Above features are of utmost importance in molding of glass melting pots and extremely difficult to achieve in hand molding process.
Development of Ceramic Shield to Enhance Life to Metallic Recuperator
In Batch type glass melting furnaces difference between the melting temperature and the working temperature is if the order of 200.C and according the variation in exhaust gas temperature is ~150.C. Under such condition if a metallic recuperator is installed for its maximum efficiency during melting hours its is underutilized during working hours and if it is installed for maximum efficiency during working hours it gets overhead during melting hours and suffers with shortage of life.
The centre has planned to develop a ceramic shield to be installed just before the metallic recuperator to take care of overheating and enable ro reap both the advantages of efficiency and life of recuperator simultaneously.
Development of Miniature Day Tank Furnace
Despite passage of a long period since demonstration of a gas fired glass melting Day tank furnace was executed, major reason of the hesitation behind non adoption of this technology by pot furnace units for melting coloured glass has been noticed that significant variation in furnace and high trial cost of tuning of running batch composition for day tank furnace has been a major hindrance in adoption of the technology.
To reduce above trail cost, the Centre has planned to develop a Miniature Day Tank Furnace with behaviour identical to that of commercial capacity.
Heat Treatment of Red Mud for Development of X-Ray & Y-Ray Shielding Material
Technology of development of X-ray shielding material form red mud by heat treatment was developed by CSIR-AMPRI, Bhopal on Laboratory scale. But for field trial & demonstration before adoption this scale to pilot scale by the Centre. Field trials conducted and demonstrated by the parent institution were found successful and approved by the authority.
Development of High Temperature Pot Arch
Technically life of refractory (pot) Depends on difference in its “Sintering Temperature” and the ‘Service Temperature’. Higher the difference in above two temperatures longer is the life of the pot. Practically a sintering temperature of 50.C higher than the service temperature gives satisfactory life of pot. But due to features of existing setup 12-pot furnace in Firozabad. At no. stage throughout the process sintering temperature is achieved and hence no pot is ever sintered.
As a solution to this problem the Centre has planned to develop and demonstrate a High temperature Pot Arch wherein the pots can be sintered before transfer to the melting furnace.
Demonstration of 3-Pot Furnace
More than 90% of pot furnace of Firozabad Glass Industry cluster are 12-pot furnace. With a furnace of such a huge size and the existing work practice individual transfer of pots, in case of failure of running pots cannot be avoided and the complications lying with it have to be borne by the industry.
With a view to eliminate individual hot pot transfer the Centre has planned to develop and demonstrate a 3-pot furnace wherein all the three pot would be placed inside and removed out of the furnace at room temperature. In case of failure of one pot the furnace may be run with two pots and in case of failure of two pots the furnace would be restarted. This will eliminate the thermal shock during transfer of individual pots and the thermal shock to the adjacent pots and the furnace structure during transfer of each pot.