GLASS WOOL

[CODE NO.4069]

Glass wool is an insulating material made from fibres of glass arranged using a binder into a texture similar to wool. The process traps many small pockets of air between the glass, and these small air pockets result in high thermal insulation properties. Glass wool is produced in rolls or in slabs, with different thermal and mechanical properties. It may also be produced as a material that can be sprayed or applied in place, on the surface to be insulated.

Gases possess poor thermal conduction properties compared to liquids and solids and thus make good insulation material if they can be trapped in materials so that much of the heat that flows through the material is forced to flow through the gas. In order to further augment the effectiveness of a gas (such as air) it may be disrupted into small cells which cannot effectively transfer heat by natural convection. Natural convection involves a larger bulk flow of gas driven by buoyancy and temperature differences, and it does not work well in small gas cells where there is little density difference to drive it, and the high surface area to volume ratios of the small cells retards bulk gas flow inside them by means of viscous drag.

In order to accomplish the formation of small gas cells in man-made thermal insulation, glass and polymer materials can be used to trap air in a foam-like structure. The same principle used in glass wool is used in other man-made insulators such as rock wool, Styrofoam, wet suit neoprene foam fabrics, and fabrics such as Gore-Tex and polar fleece. The air-trapping property is also the insulation principle used in nature in down feathers and insulating hair such as natural wool.

Natural sand and recycled glass are mixed and heated to 1,450°C, to produce glass. The fiberglass is usually produced by a method similar to making cotton candy, by forcing it through a fine mesh by centrifugal force, cooling on contact with the air. Cohesion and mechanical strength are obtained by the presence of a binder that “cements” the fibers together. A drop of binder is placed at each fiber intersection. The fiber mat is then heated to around 200°C to polymerize the resin and is calendered to give it strength and stability. Finally, the wool mat is cut and packed in rolls or panels, palletized, and stored for use.

Glass wool is a thermal insulation material consisting of intertwined and flexible glass fibers, which causes it to "package" air, resulting in a low density that can be varied through compression and binder content (as noted above, these air cells are the actual insulator). Glass wool can be a loose-fill material, blown into attics, or together with an active binder, sprayed on the underside of structures, sheets, and panels that can be used to insulate flat surfaces such as cavity wall insulation, ceiling tiles, curtain walls, and ducting. It is also used to insulate piping and for soundproofing.

"Fibrous glass," until relatively recently called fibre glass-and still the same material-is not new. Coarse filters were used by the early Egyptians before the time of Christ. Thirteenth-century Vinetian glassmakers used then quite extensively for the decoration of artware. At the Columbian Exposition of 1893, eorgia Cayvan, an actress, wore a dress in which glass fibres were used as the weft and silk as the warp. During World War I the allied blockade cut off most of the asbestors supply to Germany and the germans began to make fibrous glass as a substitute.

Glass Wool:-

(Glass Fibre)

Glass fibre is a collective term for glass processed into fibres which have diameters between 0.1 mm and is few thousandths of a mm. The development of techniques for drawing fibres from a glass mass has opened the way for additional, wide-ranging future appliations.

For a long time, two main groups have been recognised insulating fibre glass and textile fibreglass both have different applications and characteristics and are made of different type of glass.

Insulating Glass Fibres (Glass Wool):-

These are normally made of soda-lime glass by the centrifugal process using a rotating disk. Glass droplets are drawn into endless fibres by centrifugal force (rotation). The fibres cool in air and are hardened. The same effect is actived by air-jets, whereby the airstreams cause the formation of fibres from molten glass. The individual fibres immediately matt together. This is sometimes called "glass wadding" and it can be used as it is or can be further processed.

The actual weight of loosely piled, insulating glass fibres is between 30 and 200 kilogrames per cubic metre. Therefore, they are particularly suited for building insulation, since they add no significant load to the structure. Fibreglass insulation can be easily combined with other construction materials, such as mortar and plaster. The durability of the glass ensures a long life for fibre glass (Glass Wool) insulating products.

COST ESTIMATION

Plant Capacity 13.8889 MT/Day

Land & Building (8000 sq.mt.) Rs. 2.87 Cr

Plant & Machinery Rs. 2.88 Cr

Working Capital for 2 Months Rs. 1.47 Cr

Total Capital Investment Rs. 7.65 Cr

Rate of Return 28%

Break Even Point 63%

INTRODUCTION

GLASS WOOL

INSULATING GLASS FIBRES (GLASS WOOL)

CHARACTERISTICS OF GLASS WOOL

USES AND APPLICATION

B.I.S. SPECIFICATION

GLOBAL MARKET OVERVIEW OF GLASS WOOL

COMPETITORS IDENTIFIED IN THIS MARKET INCLUDE, AMONG OTHERS

OVERVIEW OF FIBER GLASS MARKET

DEMAND- SUPPLY GAP

EXPORT POSSIBILITY

DOMESTIC/ EXPORT MARKET

BONDED FIBER GLASS

BONDED FIBRE GLASS WOOL CONFIRMS TO IS 8183

MANUFACTURING PROCESS OF GLASS WOOL

FORMULATION OF GLASS WOOL

FIBRES GLASS FORMING

ROTARY FIBERIZING

MANUFACTURING METHODS & PRODUCTS

SUBSEQUENT FABRICATION

LUBRICANTS, BINDERS ETC.

GLASS WOOL PRODUCTION LINE

TYPE OF GLASS WOOL PRODUCTS:

PRODUCT FEATURES:

PROCESSING DETAILS OF GLASS FIBER MANUFACTURING

RAW MATERIALS HANDLING -

GLASS MELTING AND REFINING -

FIGURE: TYPICAL FLOW DIAGRAM OF THE GLASS FIBER

PRODUCTION PROCESS

WOOL GLASS FIBER FORMING AND FINISHING -

FIGURE: A TYPICAL SPIN PROCESS.

FIGURE: SIDE VIEW OF CURING OVEN (INDIRECT HEATING)

AND COOLING SECTION

GLASS TANK MELTING SODA LIME GLASS

A. THE MELTING CHAMBER CROWN:

B. THE BREAST WALLS AND CHARGING-END:

C. PORTS AND REGENERATOR CHAMBERS:

D. CHECKERS:

E. RIDER ARCHES:

THE FOLLOWING PROPERTIES IN REFRACTORIES TO BE SIGNIFICANT

IN ACHIEVING LONG LIFE:

TANK CROWNS & WALLS

REGENERATOR CROWN, WALLS, PORTS & CHECKERS

THE WEAR MECHANISMS ARE DIVIDED INTO FOUR GROUPS ACCORDING

TO CHECKER ZONES:

REFRACTORIES FOR SODA LIME GLASS TANKS

A. TANK CROWNS & WALLS

B. REGENERATOR PORTS

C. REGENERATION CROWNS

D. REGENERATOR WALLS

E. REGENERATOR CHECKERS

F. INTERMEDIATE CHECKERS

G. BOTTOM CHECKERS

H. RIDER ARCHES & CHECKER SUPPORTS

PROCESS FLOW DIAGRAM FOR GLASS WOOL

BLOCK DIAGRAM OF GLASS WOOL MANUFACTURE

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE

SERVICE ARE

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT & MACHINERY SUPPLIERS (IMPORTED)

COMPLETE GLASS WOOL MFG. PLANT.

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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