• It will take a million years for glass to decompose.
• Glass is recycled without loss of quality.
• The thickest glass in the world is the 26 cm screen of the Sydney Aquarium.

What is glass made from?

To make glass, craftsmen take: quartz sand (the main component); lime; soda;

Interesting Facts:

• Murano glass is considered the most expensive in the world. Products made from it cost millions of dollars. Since ancient times, Venice has been famous for the production of high-quality glass. It is reliably known that in the 13th century the state government moved production to the large island of Murano, and the craftsmen were strictly forbidden to leave it. The punishment is a death sentence. In addition, entry to the island was also closed to tourists or other residents of Venice. Such strict measures made it possible to maintain the secret of production.
• One of the most interesting mental illnesses of the Middle Ages is the “glass disease.” A person with such a disorder thought that he was made of glass and was afraid of breaking. The French king Charles VI suffered from this disease. The monarch always wore several layers of clothing and forbade anyone to touch himself.

What functions do soda and lime perform in the production process?

Baking soda helps reduce the melting point by 2 times. If you do not add it, it will be very difficult to melt the sand, and, accordingly, to connect individual grains of sand with each other. Lime is needed so that the mass can withstand water. If it were not in the composition, the window, for example, would dissolve immediately after the first rain, and the glass would burst after contact with water.

Related materials:

How and what are chips made from?

Interesting Facts:

1. China did not produce glass for more than 500 years, from the 14th to the 19th centuries. Now the state is one of the leaders in production and controls a third of the world glass market.
2. 1994 was a very active year for glass recycling in the United States. If you put all the glass products recycled during that year in one line, you will get a kind of “road” to the Moon.

How is colored glass made?

Not only colorless glass is produced. To obtain a colored product, in addition to the main components, chemical compounds are added to the melting furnace:

1. Iron oxides give glass a rich red tint.
2. Nickel oxides – brown, purple (depending on quantity).
3. To get a bright yellow tint, add uranium oxides to sand, soda and lime.
4. Chrome makes glass green.

Related materials:

How and what are sausages made from?

What characteristics and properties does glass have?

The proportions of components for the manufacture of glass goods are selected depending on their purpose. They are distinguished: household glass - that which is then used to make dishes, glasses, jewelry; construction – shop windows, windows, stained glass;

Technical glass is the densest. Used in heavy industry. The main property of glass is the ability to transmit sunlight through it. But not completely. Thus, standard window glass allows only 85% of sunlight to pass through. Glass has low thermal conductivity; in other words, it does not get too hot from other products. This property is widely used for the use of glass in fireplaces ( household appliances– stoves and ovens).

Interesting fact : Everyone has heard about armored (bulletproof) glass. The process of its production looks like this: several glass layers are connected to each other, fixed with polymer films and sent to the oven. The first bulletproof glass was installed on the windows of the White House in 1941.

Glass is an amazing material. The process of its creation is complex and traumatic, but interesting and very necessary.

Related materials:

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• What is Venetian glass and...

Glassmaking is a very ancient process. There is archaeological evidence that people were making glass as early as 2500 BC. Retrieving glass, once a rare and valuable work of art, is now common production process. Glass products are used as industrial and household containers, insulators, reinforcing fibers, lenses and decorative arts. The materials used to make different types of glass may differ, but general process its receipt is described below.

Steps

Using the oven

Buy quartz sand. Quartz sand is the main ingredient for glass production. Iron-free glass is prized for its clarity because if the glass contains iron, the glass will appear greenish.

• Wear a mask if you are working with very fine quartz sand. If inhaled, it may irritate the throat and lungs.
• Quartz sand can be purchased in online stores. It is quite cheap, a bag weighing 25 kg costs around 200 rubles. If you want to work on an industrial scale, then for large quantities specialized sellers can offer good prices - sometimes less than 2,000 rubles per ton.
• If you cannot find sand that contains few impurities, the greenish tint effect can be compensated for by adding small amounts of manganese dioxide. And if you want greenish glass, leave the iron as is!

1. Add sodium carbonate and calcium oxide to the sand. Sodium carbonate (called soda ash) reduces the temperature at which industrial glass is produced. However, it causes water to corrode the glass. Therefore, in order to neutralize this phenomenon, calcium oxide, or lime, is additionally introduced into the glass. In order to make glass more resistant, magnesium and/or aluminum oxides are introduced into it. Typically, these additives occupy no more than 26–30 percent of the glass composition.

   Depending on the purpose of the glass, add other chemicals. The most common additive for decorative glass is lead oxide, which provides the shine of crystal, as well as its low hardness, making it easier to cut, and its low melting temperature. Eyeglass lenses may contain lanthanum oxide, which is used for its refractive power, while iron promotes the absorption of iron by the glass.

   • Lead crystal can contain up to 33 percent lead oxide, but the more lead, the more experience it takes to shape the molten glass, so many glassmakers choose low lead content.

2. Add components to obtain the desired glass color, if necessary. As noted above, iron impurities in quartz glass give it a greenish appearance, so iron oxide is added to enhance the greenish tint, as is copper oxide. Sulfur compounds give yellowish, amber, brownish and even black tints, depending on how much additional carbon or iron is added to the glass charge.

   Place the mixture in a good temperature-resistant crucible. The crucible must withstand the exceptionally high temperature that is reached in the furnace. Depending on the additives, it can range from 1500 to 2500 degrees. The crucible should be such that it is not difficult to grasp it with metal tongs and rods.

   Melt the mixture until liquid. For industrial silicate glass this is done in a gas-heated furnace; special glasses can be melted in an electric, pot or muffle furnace.

   • Quartz and sand without impurities transform into a glassy state at a temperature of 2300 degrees Celsius. The addition of sodium carbonate (soda) reduces the temperature required for glass formation to 1500 degrees Celsius.

3. Homogenize the molten glass and remove bubbles from it. This involves stirring the glass until it is evenly thick and adding substances such as sodium sulfate, sodium chloride or antimony oxide.

   Mold the molten glass. Glass can be formed using one of the following methods:

   • The glass melt can be poured into a mold and allowed to cool. This method was used by the Egyptians and is how most optical lenses are created.
   • A large amount of molten glass can be collected at the end of a hollow pipe and then blown out by turning the pipe. Glass is formed by the air blown into the pipe, the force of gravity acting on the molten glass, and any tools the glassblower uses to work the molten glass.
   • Molten glass can be poured into a bath of molten tin used as a substrate and blown with compressed nitrogen to form and polish it. Glass formed using this method is called float glass, and this is how flat glass has been produced since the 1950s.

4. Cool the glass slowly in the oven. This process is called annealing, and it removes any point sources of stress that may form as the glass cools. Unannealed glass is much less durable. Once the process is complete, the glass can be coated, laminated, or otherwise treated to increase strength and durability.

   Using a Charcoal Fryer

   1. Make a makeshift oven out of a charcoal-fired barbecue grill. This method uses the heat generated by flames from burning charcoal to melt quartz sand into glass. The materials used are relatively cheap and available - theoretically, to prepare everything you need to make glass, you only need to run to a hardware store. Use a large barbecue grill - a rotisserie will do standard size"dome" models. It should be as thick-walled and durable as possible. Most BBQ grills have a vent on the bottom - open it.

      • Even at the extremely high temperatures achieved with this method, it can be very difficult to melt sand on a grill. Before you begin, add a small amount (about 1/3-1/4 of the sand's volume) of washing soda, lime and/or borax to the sand. These additives reduce the melting point of sand.
      • If you're going to blow glass, have a long, hollow metal tube handy. If you are going to pour glass into a mold, prepare it in advance. You need a shape that won't burn or melt from the heat of the molten glass, graphite works great for this purpose.

   2. Know the dangers of this method. This method involves heating the barbecue grill beyond its normal temperature limits - so much so that it may even melt the grill itself. Careless operation using this method poses a risk severe injuries or even death. Work with caution. Keep a large amount of soil, sand, or a fire extinguisher designed for high temperatures on hand in case you need to reduce the intensity of the fire.

      Take all possible precautions to protect yourself and your belongings from high temperatures. Work using this method on a concrete surface outdoors, with sufficient space around. Do not use irreplaceable equipment. Stay away from the grill when you cook glass. You will also need to wear as much protective clothing as possible, including:

      • high-strength gloves or oven mittens;
      • welding mask;
      • high-strength apron;
      • fire resistant clothing.

   3. Buy a home workshop vacuum cleaner with a long hose attachment. Using duct tape or some other means, bend the hose so that it blows directly into the vent hole on the bottom without touching the body of the grill. You'll probably need to attach a hose to one of the grill's legs or wheels. Place the vacuum cleaner itself as far away from the grill as possible.

      • Make sure that the hose is secure and does not move: if it comes loose during glass melting, Not approach the grill if it is very hot.
      • Turn on the vacuum cleaner to check the position of the hose. A precisely placed hose will blow directly into the vent.

   4. Line the inside of the grill with charcoal. Use more charcoal than you would for roasting meat. Successful results are observed when the grill is filled almost to the brim.

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We will finally answer the question that haunts many: “How is transparent glass made from opaque sand?”
Let's start with the fact that some time ago glass did not exist in principle, and people lived in caves. And with the advent of this fragile and transparent material, life changed radically. Think for yourself how many glass things surround us today: shop windows, telescopes, computer screens, glasses, various containers, even people have learned to build houses from glass.

Imagine how much glass a person produces and how much sand he uses. As with any production, the plant first receives raw materials - sand. And this sand, not just any sand, but special sand - quartz. When compared with marine, quartz is much smaller and whiter.

The first stage of production is the oven. Up to 170 tons of sand are placed in this furnace at a time, and the temperature is raised to 1500 degrees. The formula of glass is not only sand (although it is the majority), but also some substances that enhance its strength. Note - strength, but not transparency. Here are the names of some of the components: sulfate, field twine, soda, saltpeter, dolomite. Soda, for example, is only needed to make the sand melt faster.

Already in the furnace, this entire mixture turns into glass. It's just that it's still liquid. Next, until the glass has cooled and hardened, it is poured into molds (for example, for making bottles). A special automated installation cuts the plastic glass mass pouring out of the furnace into equal pieces and sends these pieces to the molding machine. Since the main production functions are carried out by machines, it quickly takes on the desired shape without having time to harden first.

So the secret is in the oven itself? Is it possible that high temperature can make an opaque thing transparent? No!

You will be surprised, but the sand was actually transparent even before arriving at the factory. To verify this, we need a microscope.

What is sand made of? That's right, from grains of sand. These are the ones you need to look at under a microscope. In fact, every grain of quartz sand is transparent! “Why then, when you pick up sand in your palm, it doesn’t shine through like water?”

And here the laws of physics come into force. The fact is that grains of sand are separate elements with several faces. It is these very edges that refract the ray of light falling on them. This is how a feeling of “opacity” is created.

For even greater understanding, let's conduct an experiment. Let's take a transparent bottle and break it with a hammer. Grind the fragments further in a mortar. Now we pour them onto the table, and what do we see? And we see an opaque pile of glass.

In the oven, everything happens with precision, but quite the opposite than in our experiment. The oven combines the “cracked” grains of sand into one whole. Here the geometric parameters of each individual grain of sand are no longer important, since they will all melt and merge into one whole. You will get one large grain of sand, which will easily transmit light, i.e. Made to order glass.

As soon as people learned to make transparent glass and use it in life, the need for opaque glass arose. Special powders have been invented that can not only darken transparent material, but also give it the desired color. This is how custom glass is created in a seemingly uncomplicated way.

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Why do you need furnaces for glass melting? The fact is that in order to make something useful out of glass, you must first melt it, and it melts at temperatures neither more nor less, 1400-1600 ° C.

The raw material for glass production is mainly quartz sand (silicon oxide SiO2)

Quartz sand

To give the glass the necessary properties, quartz sand is mixed with various additives, mainly limestone (the kind that is shell rock, from the facades of buildings), feldspar, dolomite, soda and dyes (metal oxides)

Limestone

Feldspar

Dolomite

There are up to 20-30% of such additives in glass. In general, the more additives, the lower the viscosity of the melt (roughly speaking, it is “more fluid”) and the lower the melting point, i.e. it is easier to process, for example, you can blow bottles, etc., already at 800 °C. But it can be different: if, for example, boron oxide is added to the mixture, the result will be borosilicate glass, heat-resistant and resistant to temperature changes - to the delight of housewives. Glass made from pure silicon oxide will be refractory; in order to blow anything out of it, you will have to heat it to 1600 °C.

In general, we have sorted out the raw materials. Everything that is needed is thoroughly cleaned, crushed (this is usually done by special enrichment factories/productions), mixed and poured into a glass furnace through a special window. Inside the furnace in a huge pool, an almost infernal fire takes over and turns the sand into liquid in a few hours.

Flame inside the oven.

By the way, heating such a furnace to the required temperature is a difficult, long, and most importantly, expensive process (how much fuel is needed to heat such a huge fool for 2-9 thousand tons of glass!), therefore, having lit it once, they try not to extinguish it again: During the 10-15 years of glass melting, the furnace service is interrupted only a couple of times for cold repairs.

Naturally, the mixture does not melt all at once, but gradually; As it melts, it mixes and air bubbles come out of it. What is already well melted collects at the bottom of the pool (the density of the melt is higher) and, according to the law of communicating vessels, flows under the wall passing through the pool to another part of it, away from the flame and the not yet molten mixture.

The temperature is a little lower here, and liquid glass from here it goes into the next working bath outside the furnace, and from there it goes for processing. To produce sheet glass for windows and mirrors, for example, it is cast and rolled almost like metal.

To obtain a perfectly flat surface, in modern factories molten glass is first poured into a pool full of molten tin, and the glass, floating on the surface of the tin, is distributed over it in an even thin layer and cools from about 1000 to 600 ° C, so the so-called float glass.

As I already said, this process is continuous, and the output after cooling is an endless glass ribbon. But before cutting it into pieces, the surface is heated again with gas burners: in this way, microcracks are sealed, which still form even despite gradual cooling due to the difference in stress inside the glass during hardening. As a result, the glass comes out especially transparent.

Float glass production

The old technology used in Soviet factories involved vertically pulling a glass ribbon while intensively cooling the mass coming from the furnace. Glass produced in this way has significantly greater optical distortion.

Well, it looks like we’ve sorted out almost everything. In the picture, only one more incomprehensible part of the furnace remains: the regenerator. The thing is wonderful and ingenious in its simplicity. For its invention back in 1856, the youngest of the Siemens brothers, Friedrich, received English nobility. The point is to save fuel for the glass melting furnace by heating the air supplied to the furnace for combustion. And fuel savings can reach 40%!

Operating principle of the regenerator

The regenerator consists of two identical shafts filled with heat-resistant ceramic assemblies, forming many small channels for air inside the shafts. Air enters through the first shaft, enters the furnace through the window, mixes with fuel (gas) and burns. The hot combustion products go through another window into the second shaft, and before coming out, they heat the mentioned ceramic assemblies. Then, as soon as they are sufficiently hot, after about twenty minutes, an air flow is released through the second shaft, it warms up in it before entering the furnace, and the exhaust gases begin to heat up the assemblies in the first shaft. Then the cycle repeats.

Beyond the scope of this story are various heat-resistant ceramic coatings inside the furnace (metal is not suitable for this temperature). Everything with them is also quite entertaining: physical and chemical processes, occurring during glass melting, lead to amazing formations: stalactites begin to grow inside the furnace!

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