Treatment plant – water from glass processing
Water Treatment Systems for Glass Processing: Choosing the Right Solution
Glass processing involves various technologies that enhance its durability, strength, and appearance. Techniques such as tempering, painting, bonding, and coating produce little to no waste. However, the situation differs for shape-processing methods like grinding, drilling, milling, edging, and polishing. These processes rely on abrasive machining, generating fine glass dust as excess material is removed.
Abrasive machining requires intensive cooling of both tools and glass surfaces. This is achieved using process water, often enriched with specialized coolants. Consequently, the removed glass particles mix with the cooling water, creating a slurry that needs effective filtration to maintain water quality and ensure efficient production.
Water Consumption in Glass Processing
Glass grinding and milling heads consume between 7-12 liters per minute per head. When multiplied by the number of heads in a typical vertical edging machine, total water usage can reach 150-200 liters per minute. This high demand makes direct municipal water supply impractical, necessitating a closed-loop water system within each machine, with process water circulating through grinding heads and a small settling tank beneath the equipment.
This simple system is widely used in the glass industry, offering continuous cooling via an integrated pump. It requires minimal investment, as the water tank and pump come standard with the machine. However, a significant drawback is the small tank capacity, leading to rapid contamination. Within hours of operation, water becomes dirty, though large contaminants settle at the tank’s bottom, preventing scratches on glass surfaces. Over time, accumulated sludge disrupts operations, requiring frequent shutdowns for tank cleaning and sludge removal.
The Costs of Water Contamination
Regular tank cleaning is labor-intensive and time-consuming. Over weeks or months, these interruptions add up, reducing productivity. Additionally, dirty water affects grinding quality, reduces diamond tool lifespan, and creates disposal challenges for glass sludge.
To maintain consistent water quality, it is essential to remove glass particles continuously. While water doesn’t need to be as clear as drinking water, it must remain free from solid residues that could clog machine nozzles. Many machine manufacturers specify permissible water parameters, including pH, maximum conductivity (µS/cm), and contaminant concentration (ppm, mg/L).
To achieve this, glass processing plants implement water treatment systems that extend water usability in a closed loop for weeks or even months. An efficient filtration system should:
Continuously remove glass particles to maintain water quality.
Minimize manual intervention for sludge disposal.
Reduce waste and water consumption, contributing to sustainability.
Types of Water Filtration Systems for Glass Processing
1. Centralized Water Filtration System
A centralized filtration system processes water from multiple machines through a single, high-capacity treatment unit. It requires collecting dirty water via floor channels or pipelines that transport sludge-laden water to a treatment facility. Once filtered, the clean water is redistributed back to machines via a network of supply pipes.
Advantages:
Efficient large-scale filtration.
Consolidated sludge collection in one location.
High processing capacity (200–6000 liters per minute).
Challenges:
High installation costs due to required drainage infrastructure.
Complex implementation in existing facilities.
Potential system failures due to multiple pumping stations and pipelines.
Because of these factors, centralized systems are mostly used in large-scale glass processing plants, typically integrated during facility design and construction.
2. Individual Water Filtration Systems
Decentralized filtration systems are gaining popularity in glass processing due to their compact size, easy installation, and adaptability. They connect to one or a few machines and come in different types:
Sedimentation Systems
Utilize vertical settling tanks (sedimenters) to clarify water.
Use coagulants or flocculants to accelerate filtration.
Collect sludge in bags for drying.
Quality of filtration varies depending on sludge concentration and chemical additives.
Centrifugal Separators
Installed near machine tanks.
Use high-speed spinning drums to separate contaminants.
Effective for removing larger particles but allow fine residues to remain in water.
Require manual sludge removal and frequent water replacement.
Pressure Filtration (Filcore Filters)
Filcore pressure filters represent the most advanced and efficient water filtration technology for glass processing. Designed for automated operation, they ensure high water quality while minimizing maintenance and labor costs.
Key Benefits of Filcore Filters:
High-performance automatic filtration that operates without chemical additives such as coagulants or flocculants.
Provides exceptional water clarity (10 NTU), ideal for CNC spindle cooling and other precision glass processing applications.
Compact, modular design allows direct installation next to machines, reducing space requirements and simplifying setup.
Fully automated operation, eliminating the need for frequent manual intervention.
Significantly reduces water consumption, lowering long-term operating costs and contributing to sustainability efforts.
Enhanced machine performance by preventing nozzle clogging and maintaining optimal cooling efficiency.
Filcore systems use innovative filter core technology, which continuously separates glass particles from the water and automatically flushes sludge without halting production. This ensures uninterrupted machine operation, improves tool longevity, and reduces downtime caused by contaminated water. As a result, investing in Filcore filters enhances both production efficiency and environmental responsibility, making them a top choice for modern glass processing plants.
Choosing the Right Water Filtration System
Selecting between centralized and decentralized filtration depends on the size and infrastructure of the facility:
For small to mid-sized plants with individual machine tanks, decentralized systems offer lower installation costs and greater flexibility.
For large-scale glass processing plants, centralized filtration may be more efficient but requires careful cost analysis, considering equipment expenses, infrastructure modifications, and operational challenges.
Final Thoughts
Optimizing water filtration in glass processing not only enhances machine performance and product quality but also reduces operational costs and supports environmental sustainability. Investing in the right system ensures uninterrupted production, extends tool lifespan, and minimizes water waste—making it a smart, long-term solution for the industry.