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Glass and Ceramics Factory Production Line

Glass and Ceramics Industry

The glass and ceramics industry is a vast sector that creates value by processing raw materials such as silica, soda, feldspar and limestone at high temperatures. High purity is the key to product quality.

Core Processes of the Glass and Ceramics Industry

The glass and ceramics industry is an energy-intensive, chemistry-driven sector that supplies the construction, packaging, automotive and white goods sectors by processing mineral raw materials such as silica, soda, feldspar and limestone at high temperatures (1000-1600 °C). In this sector, calcium-based minerals are both a key component of the formulation and the main input for emission control.

Glass production consists of five main stages: batch preparation, melting (1450-1600 °C), forming, annealing and finishing. In flat glass production, the molten glass spreads over a tin bath on the float line to form an optical surface. Ceramic production, on the other hand, comprises slip preparation, forming, drying, biscuit firing and glaze firing.

In both sectors, the chemical purity, particle size and moisture of the mineral raw materials are the key variables that determine the transparency, mechanical strength and thermal shock resistance of the final product.

Modern Glass Production Line

The Effect of Raw Material Selection on Product Quality

Soda-lime-silica glass accounts for approximately ninety percent of the world's glass production, and its typical formula contains 70-74% silica, 12-16% soda and 8-14% calcium oxide (CaO) by mass. CaO is the main stabiliser that increases the glass's resistance to water and stabilises the softening temperature. Small deviations in the stabiliser ratio can cause colour defects on the float line.

In ceramic formulations, calcium carbonate and calcium oxide are used to control the degree of whiteness, pore distribution and thermal expansion coefficient. They are preferred as a flux source in glazed tiles, porcelain (granite) tiles and sanitaryware.

Dolomitic lime: Used as an MgO source in some glass formulations to reduce devitrification (crystallisation). If not optimised, it can increase the furnace's energy consumption.

Modern Ceramic Tile Production
Glass Manufacturing Glow
Ceramic Raw Material
flare WHY CHOOSE US

In Raw Material Quality Parameters,
Our Focus Is Product Quality

We offer high-purity raw materials and reliable supply systems designed to reduce the scrap rate in your production processes and maximise final product quality.

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Maximum Purity

Industrial quality standard with a CaCO₃ content between 95-99% for your glass and ceramic formulations.

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Homogeneous Melting

Reduces the risk of thermal shock by optimising the batch moisture between 3-5% (ideal particle size 0.1-1.0 mm).

  • check_circle Colour Defect Prevention (Fe₂O₃ < 0.1%)
  • check_circle Sophisticated Formulations (1-4% MgO)
  • check_circle Reducing Furnace Energy Consumption
  • check_circle Optical Surface Quality Guarantee

The Role of Lime-Based Solutions in Glass and Ceramic Production

  • Aggregate (Limestone): The starting raw material of the glass batch. It absorbs heat in the melting furnace and converts into CaO form; in the glass batch, the homogeneity of the limestone directly affects energy consumption.
  • Quicklime (CaO): Since it is pre-calcined, adding it to the formulation in special glasses reduces the furnace's decarbonisation load by a percentage. It is also critical in process water conditioning and hard water softening.
  • Hydrated Lime (Ca(OH)₂): The ideal reagent for heavy metal precipitation in wastewater treatment units (pH 5-9) or for acid neutralisation processes in furnace flue gases (SO₂, HF, HCl).
  • Lime-Based Desiccant: With its high capacity, it prevents packaging deterioration and ceramic staining during long sea shipments (container rain, etc.).

Waste Management and Emission Control Standards

Glass and ceramic furnaces are among the industries that are specifically monitored in the EU BAT (Best Available Techniques) reference documents.

Application AreaSolution & Critical Parameter
Flue Gas (SO₂ & HF)Ca(OH)₂ powder or suspension; Ca/S molar ratio typically 1.5 - 2.5 (can rise to 3 in fluoride-rich environments)
Wastewater NeutralisationPrecipitation of heavy metals via automation (0.5-2.0 kg/m³) by keeping the pH of ceramic glazing acids between 5-9.
NOx Emission SystemsThe reagent acting as a particulate protective layer in SNCR/SCR systems, preventing wear with a lime shield.
Next-Generation TrendsAchieving energy efficiency by increasing recycled glass (cullet) to 90%, while being required to update the fresh lime dosage with new XRF analyses.

Frequently Asked Questions

Limestone (CaCO₃) serves as the calcium oxide (CaO) source in the glass batch. It breaks down in the melting furnace to form CaO and stabilises the chemical durability, softening temperature and mechanical strength of the glass. In the soda-lime-silica glass formula, the CaO content is kept between 8-14% by mass.
Calcium oxide is used in the ceramic body as a flux and to adjust whiteness. In glazed tiles, porcelain (granite) tiles and sanitaryware it regulates pore distribution and, by reacting with silicates during firing, supports vitrification. The desired whiteness is achieved when the Fe₂O₃ content is kept below 0.1%.
Dry or semi-dry desulphurisation is common for SO₂ control in glass furnace flue gases. High-reactivity hydrated lime (Ca(OH)₂) is dosed into the reactor, reacts with SO₂ to form CaSO₃ and CaSO₄, and these salts are captured in the bag filter. The Ca/S molar ratio is generally kept between 1.5-2.5.
The CaCO₃ content of the limestone used in the glass batch should generally be between 95-99%. To prevent colour defects, the Fe₂O₃ content should be below 0.1% and the SO₃ impurity below 0.05%. Homogeneous melting is achieved by keeping the particle size in the 0.1-1.0 mm range and the moisture content below 4%.
Wastewater from the glazing and washing lines of ceramic factories can be acidic and contain heavy metals. Hydrated lime (Ca(OH)₂) is added via an automatic dosing system linked to a pH sensor, raises the pH to the 5-9 range and precipitates metals such as copper, zinc and lead in hydroxide form. The typical dosage is 0.5-2.0 kg/m³.
In standard soda-lime-silica glass, limestone is the primary raw material because it calcines naturally during the melting process. Quicklime (CaO) can be used in special glass types or to reduce the decarbonisation load in order to increase furnace efficiency. The choice is made according to the furnace design and energy strategy.
Hydrogen fluoride (HF) in glass furnace flue gases reacts with calcium-based sorbents to form water-insoluble CaF₂, which is easily captured in the bag filter. Compared with alkali-based sorbents, lime-based sorbents are more economical, less corrosive and more manageable in terms of disposing of the resulting waste.
During long sea voyages, temperature differences cause condensation inside the container (container rain); this leads to deterioration of cardboard packaging and staining on glazed surfaces. Lime-based desiccants reduce this risk with their high moisture absorption capacity and increase shipment safety.
Every 10% increase in the use of recycled glass (cullet) reduces the batch energy consumption by approximately 2.5-3%. However, since cullet itself carries a calcium component, the fresh limestone dosage must be recalculated using XRF analyses; otherwise the chemical stability of the glass may drift.
In semi-dry FGD systems, the Ca/S molar ratio is typically kept between 1.5-2.5. In the presence of HF or when an SO₂ treatment efficiency above 95% is targeted, this ratio can rise to 3. The reactor inlet temperature, the Ca(OH)₂ BET surface area and the moisture content are also parameters that directly affect efficiency.