BREF revision Domestic Glass Sector ICF EDG – Sienna – November 3rd 2007

1. BREF revision Domestic Glass Sector ICF EDG – Sienna – November 3rd 2007 • LALART • F. DEBLOCK

2. Local considerations according each country : Authorities Arrêté verrier mars 2003 BAT (in BREFs) BAT-based permit or General Binding Rules From BREF to Permit Conditions + Descriptive BAT : BEST AVAILABLE TECHNIQUES Legally binding BREF : Reference Document

3. WHY a REVIEW of the BREF ? • Main concerns of a review : • New information with potential impact on BAT (gaps, emerging techniques) • Actual levels of performance (IMPLEMENTATION LEVEL ?) • Correction of errors • Coherence with other BREFs including horizontal BREFs (others sectors ; cement)

4. BREF revisionDomestic Glass Sector • Work to be done, • Data collection provided from EDG ICF, • Information from other sectors and authorities, • Cost data study, • Water management, • Conclusion.

5. WORK TO BE DONEREQUESTS

6. Kick off meeting in Seville. BREF revision • means : • Overall current glass industry situation in the EU-27, • Specific costs, • Environmental management systems (EMS), • Emission to air and downstream processes, • Dust collection, • Emission to water, • Energy consumption reduction.

7. Data collection provided by EDG - ICF

8. Updating of chapter 1 (general information) : • List of main glass manufacturers • Number of companies per country • Share of sub sector (container - Float - tableware) Increase the number of installation from EU 15 to EU 27 (especially above 100 T/D)

9. Blue : Updated value 2005 Almost reduction of 50 % of major pollutants due to BAT implementation

10. Blue : Updated value 2005 Stability of good situation including the crystal glass

11. Information from other sectors and authorities

12. – The container glass industry, which is the largest group,comprises glass packaging for drinks, food, perfumes,pharmaceuticals FEVE – The flat glass industry float glass. GEPVP – The continuous filaments of glass fibre. APFE – The special glass industry produces mainly glass for technical applications (optics, electronics, lighting, engineering, ophthalmic lenses etc, …). borosilicate glasses are mainly included in this category. ESGA -The Mineral woolStone wool and Glass Wool (EURIMA) - - The frits industryANFFECC Need for a coherence with other sectors

13. Current level of implementation of BAT domestic container

14. 1 float was electric heated in 2000 – correct operation but high operating costs • 7 SCR implemented ! Technique available • FENIX is based on the combination of many primary measures : • reduction of excess air – suppression of hot spot- homogenization of flame temp • Also New design : overall dimension – design of burners port – separate • chamber in regenator • Achievement : 700-800 mg/Nm3 ( 8 % O2) patented by SG

15. "polemique statement" Swedish Glass Industry to IPPC revision  mentions Lead. A new section under 5.6 about raw materials is needed, perhaps even in chapter 2 and 4. BAT should be to use glass without  lead, not even in art glass. Official ICF answer : any official document should be drafted in respect of the laws and legislations … ie Directive 69/493/EEC.

16. There is no need for modication of two relevant references to the BREF • document issued in 2001 : • 122 – Broad classification of Glass type, page 5 on lead crystal and crystal glass • "Lead oxide can be replaced partially or totally by barium, zinc or potassium • oxides in glasses known as crystal glass that have a lower brilliance or • density than lead crystal. Precise definitions associated with • chemical and physical characteristics are set in Directive 69/493/EEC." • 2. 221 – Raw materials for glass melting page 33 • "Lead oxides (PbO and PB3O4) are used to improve the sonority and to improve • the refractive index of the glass to give better brilliance in products such as lead • crystal. Barium oxide (derived from barium carbonate), zinc oxide and • potassium oxide, may be used as alternative to lead oxide, but they produce • lower levels of density and brilliance than those associated with lead Crystal. • There is also a penalty in the workability of handmade glass".

17. Costs data study

18. Cost data study • As Suggested by M Munoz and accepted by the group -> collection of • cost data by an independant expert ( Ruud Beerkens TNO) • Objective : typical costs for air pollution control methods : • - Costs per ton of molten glass • - Costs per kg pollutant removed • Data coming from : • Specific questionnaire • Comparison from other sectors ( perfume bottle for sodalime) • Experience from TNO • Sofar - Preliminary report issued to coordinator

19. Dust treatment : Bag filter + Dry Scrubbing (mostly used in our sector) Heavyburdenapplied on sodalime production Specially for small furnaces (30 tpd)

20. Primary Measures Basic package of primary measures :Adjustables burners Slower mixing of preheated air with fuel ; low fuel injections velocities; fuel rich combustion ; Air tight sealing ; oxygen sensors to control combustion Tableware 180 T/D (investment 123 K€) cost per ton of molted glass 0,7 €/T Package of extended primary measures :adaptations of furnace design Increase the height of the combustion space ; enlarging the size of burner ports, changing slopes of burners ports and position of burners. + electric boosting for tableware Prices are very variable Tableware 150T/D (operational costs 8 € per molten glass) Others sectors 0,8 to 2,33 € per ton of molten glass

21. recuperative regenerative 2 cases : 30 T/D recuperative furnace 70 T/D regenerative furnace Recuperative furnace : conversion oxyfiring might be BAT Regenerative furnace : depends on local O2 price ( 0,06 €/Nm3)

22. Electric melting All electric melting is mainly limited to lead crystal glass or borosilicate glass production or geographical areas enjoying very low electricity prices. The advantage is no direct combustion (CO2, NOx) emissions and very low volume flows of flue gases (batch gases). • 2 cases in contradictory data : • 30 T/D lead crystal : Electrical version is 5,4 M€ more expensive than • recuperative solution • Extra cost of 14 € per ton molten glass • 25 T/D lead free crystal. Electrical version cheaper and 2 €/ ton of • molten glass saved No clear trend because lack of data !

23. DUST • Some techniques with very low application in our sector : • Electrostatic precipitator ( ESP) plus dry scrubber : few equipped ; very high cost for small furnaces • Exemple 35 T/D tableware : 15-16 €/ ton of molten glass ( 4 times more than • container or float) • Bag Filter + semi dry scrubber : very effective for SO2 reduction but very expensive (4,5 M€ to 7 M€) – Problem of filter dust recycling • Simulation for our sector : + 30 € per ton of molten glass • Wet scubber : hardly applied in glass industry 16 € per ton of molten glass (issue of the water treatment).

24. NOx reduction • Some techniques with very low application in our sector : • SCR Denox : No SCR ; by extrapolation 5 to 8 € for 100 et 35 T/D (note in Float and container 1,8 to 3,3 €/ per ton of molten glass) • SNCR Denox : hardly used ; no stable conditions of temperature • 3 R process : mainly applied in Float glass industry . Cross media effect : increase of energy 7 to 12 %

25. Conclusions of the report : Becoming aware of our difficulties "Specific air pollution control costs expressed in extra costs as Euro per ton molten glass, are very high for furnaces with production capacities below 100 tons glass per day". "Flue gas filtration and scrubbing for small tableware furnaces can add more than 10 Euro to the melting costs per ton molten glass". Similar to the conclusion of the competitiveness study (carlbro) : "It was also found that environmental pressure was one of many competitive pressures faced by the domestic glass industry"

26. Water management

27. EIPPC bureau from SEVILLE is expecting : • Methods and techniques to minimize the water consumption • (assessment and perspectives) • Environmental Management System applied for water. • Information about water management for Pb crystal. • We are assisted in this approach by an expert M. Deffontaines from the Université of Littoral Côte D’Opale DIVERGENT.

28. Cleaning and purges of closed water process Polishing ( acid, dissolved salts…) Cutting, grinding ( particles, lubrifiant Oil, …) Cooling ( chemical Product…) Wastewater More water for crystal than sodalime ( cutting ; grinding ; acid polishing)

29. Préparation ( unit opération, mixing…) Fresh water stream 10%-40% Glass processing : Cooling 30%-40 % Forming, Cleaning and Utilities … 60%-70% BAT water use in domestic glass recycle water Stream 60%-90% Séparation ( purges , supernatant …) output wastewater 10%-40% Sludge, residue Vapour…

30. Issue of lead concentration Lead (Note 2)<0.5 mg/l (table 3) (Note 2) - For domestic glass installations utilising significant amounts of lead compounds, 1.0 mg/l is currently considered to be more appropriate. There are no overriding technical obstacles to the achievement of 0.5 mg/l, and given the necessary time for the development and implementation of appropriate techniques this figure will be achievable. Problem of level and method of analysis !

31. Recommendation from the expert : • Does it take into account the total lead or only the dissolved part ? • taking sample at pipe outlet after decantation – precipitation (neutralization • after acid polishing), • - filtration on 1µm paper, • - the dissolution in acidic medium, • - the analysis. • the “total dissolved“ lead without the redissolution of precipitated part • Also higher lead concentration levels might be considered as acceptable when the total amount of lead is under control in discharge. • Means level of pollution depends on the quantity of lead and its compounds discharged and not only on the concentration of lead in wastewater • (in the range of 0,1 to 0,3 Kg of lead per melted ton of glass). • The minimization of water use with the implementation of closed • system is crucial

32. Environmental Management System (applied to water) The implementation of an environmental management system (EMS) according to the rules of ISO 14001 permits to the company to have guidelines : - system to detect defaults and to correct them reliably  - system to improve factory performance (concrete targets) Some companies have implemented the ISO 14001 or internal EMS ; Those that experienced the ISO 14001 observe a higher cost due to external audit of certification without any benefit compared to the internal system.

33. CONCLUSION FROM EXPERT Use of water is high in the glass industry but the production of waste water is limited with the implementation of closed water system. Technology of wastewater treatment uses physical and chemical operations well-known and not specific to the glass manufacturing. The glass manufacturing companies made great effort and progress in order to reduce the flow rate of water per ton of glass melted. Ex : In some crystal plants, there is a trend where acid polishing is replaced by fire polishing and mechanical polishing, with the possible consequence that water consumption decrease.

34. Conclusion

35. Kick off meeting in seville. BREF revision means : • Overall current glass industry situation in the EU-27 • data provided (july) + competitiveness study • Specific costs • TNO study in process of validation) • Environmental management systems (EMS) • Discussed in water report • Emission to air and downstream processes • Charts updated • 5 Dust collection • Charts updated • Emission to water • report finished and sent • energy consumption reduction • Wide range ; no change

36. Conclusion :Next steps • Validate the cost data report with TNO and integrate the • main points in the BREF ( in common with others sector) • Provide the water assessment document to Batis forum • (availibility to the working group). • Discussion about the possible changes to be proposed by • Marcos Munos toward a new version of BREF.