BatchMaker® Suite User Manual
Contents
1. e e S N en 1 e Nh MN wh 1 h gt EM e 9 S e ei ce e ce e M ah i e 0 0578 0 0264 0 0642 0 0132 0 0193 0 1725 0 0335 0 0623 0 0598 0 0182 0 0205 2 0385 0 0063 0 0165 ME e 0 0249 0 0344 0 0002 pu Cr203 N Elo o NOTE You can print the report via the Print button or save it on your hard drive as an HTML file with Save As For instance you can send the report in HTML format by e mail 2 Close the Report window gt Save close the Master Data and Analyses amp Prices windows The master data and the analyses windows are closed but the associated files remain loaded as you can see in the title bar of the main window When you start BATCHMAKER SUITE the next time the master data and analyses that were active on ending BATCHMAKER SUITE are always loaded BATCHMAKER SUITE Example of Application 24 4 2 Opening and Editing Glass Recipe When you create a new glass recipe or open a glass recipe for editing note that the master data and analyses appropriate for the glass recipe must be loaded If the loaded master data and analyses do not fit the opened glass recipe you may not be able to se2. gt Click the Import button to load the master data weights nominal values and tolerances of an existing batch recipe from a batch file gt Select in the Open Batch Recipe window e g the Amber glass batch file from the Samples Container Glass folder and click the Open button The data of the Amber glass batch sample batch recipe are imported NOTE As an alternative to importing an existing batch recipe you can also enter the data manually or else subsequently change manually the data of an imported batch recipe To do this select the wanted plant the furnace and the glass type from the dropdown list box and enter the corresponding data on the Batch Ingredients and Glass Components tab cards BATCHMAKER SUITE Example of Application 40 The raw material and cullet weights of the batch recipe are entered on the Batch Ingredients tab card 7 New Batch Recipe Glass Batch Ingredients Glass Components Ingredient Dry weight Wet weight Ingredient 2 5000 Chromite Sodium sulfate 10 0000 Cobalt oxide Glass sand 554 5084 Dolomite low iran Glass sand low i 554 6084 Feldspar Phonolite 178 8101 Feldspar low iran Limestone 154 5630 Dolomite 250 7562 Soda ash 233 0538 Foreign cullet Am 26559 8141 4 ela f Ara CEN B Limestone low iron Manganese oxide Selenium premix Spodumene The nominal values tolerances saturations and evaporation values of
3. 17 4 1 Opening and Editing Configuration nn 17 4 2 Opening and Editing Glass ReclDe uos esr NR Fe E OE VR E Ve 24 4 3 Calculating Batch Recipe esce d Au Ra RE DRE REDE d a OR AR Rab dv Ru 29 Aa fecalculalig Batek ias VELIT 37 4 5 Calculating Batch Recipe from Raw Material Weights 39 4 6 xomparing BateiReclDe5sie nenunsidd bassa acd 42 Ad Calculating Glass Properti S ive va betae hus 44 4 8 Calculating Raw Material USA eave iii esie PR LM UU Va VES VEO 47 BATCHMAKER SUITE Introduction 4 1 Introduction This user manual describes the installation of BATCHMAKER SUITE and provides an introduction into the use of the software based on an application example New users in particular should work through the application example step by step whilst the program is running This manual is meant as an introduction only it does not describe all of the functions of BATCHMAKER SUITE For more detailed information please see the Online Help All the functions are fully explained there NOTE BATCHMAKER SUITE is constantly being developed and improved The illustrations in this documentation may therefore differ slightly in certai
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5. BATCHMAKER SUITE Example of Application 37 4 4 Recalculating Batch Recipe In the so called correction test the theoretical glass composition synthesis is recalculated and checked against the tolerances on the basis of the current chemical analyses and of the weights contained in the batch recipe Therefore with this function you can check quickly and simply whether a tolerance is exceeded by the change of the chemical analyses e g fora new raw material delivery and due to this a recalculation from the glass recipe is necessary In the following example the chemical analyses are changed so that the tolerance for Fe203 is complied with For instance in practice you have received a new raw material delivery with a changed analysis 2 Open the analyses and prices via the Edit gt Analyses amp Prices menu command or via the Edit Analyses and Prices icon in the toolbar Mark the ingredient Phonolite in the upper table Change in the lower table the Percentage of Fe203 from 3 798 to 0 798 and the percentage of SiO from 52 65 to 55 65 t Analyses amp Prices Demonstration Raw Materials amp Cullet Energy Sources Miscellaneous Analyses for Plant Container Glass Plant Container Glass 4 Ingredient alysis Humidity Price Ingredient Ca en Soda ash 165 00 3 Barium carbonate Erbium oxide Limestone low iron Glass sand Dolomite Hematite Dolomite low iran Q PrP
6. O On the Raw Materials amp Cullet tab card you define the raw materials and types of cullet that you use for glass production O On the Chemical Components tab card you will find a list of all components that you can use for entering chemical analyses If you create a new configuration or master data file a list of all customary components is already predetermined However you can also extend or change this list as you require O On the Energy Sources tab card you define the available energy sources and the corresponding CO emission factors On the Options tab card you define the used currency and various other settings for the opened configuration To open the analyses and prices for display and or editing gt Select the Edit gt Analyses amp Prices menu command The Analyses amp Prices window is opened t Analyses amp Prices Demonstration Raw Materials amp Cullet Energy Sources Miscellaneous Anal for Plant Container Glass Plant Container Glass Ingredient Analysis Humidity Ingredient Glass sand low iron 2 16 2007 450 13 0 xum 3 Glass sand 2 16 2007 E OO Soda ash 2 16 2007 Limestone Erbium oxide Glass sand ultrapure Hematite Limestone low iron Component Percentage gt Component 99 7200 K20 A 203 m 503 Fe203 0 0168 __ PbO Cad 0 0620 n MgO 0 0284 5 CoO 0 0012 A02 Check Iz Save Close You enter
7. Coke powder Limestone ye Nepheline syenite Chemical Composition of Phonolite sum 93 0466 Component Percentage Component gt SiO 55 6500 A203 17 5680 Na20 5 9430 4 0350 7 9500 0 5260 0 2621 TiO2 0 3145 gt Take over your changes with the Save button If necessary use another file name in order not to overwrite the original sample configuration BATCHMAKER SUITE Example of Application 38 gt Select the Batch Recipe Flint glass entry from the Window menu to bring the batch recipe into the foreground Click the Recalculate button in the Batch Recipe window or the icon of the same name in the toolbar The batch recipe is recalculated taking the new analysis into account without changing the raw material and cullet weights An additional Change column which displays the change of the synthesis compared with the originally calculated version of the batch recipe appears on the Glass Components tab card next to the Synthesis column Batch Recipe Flint glass modified General Summary Batch Ingredients Component Synthesis Change Nominal Tolerance Deviation gt 4 abs abs syn Carriers of 5102 TUE 203 1 5000 0 0100 0 0000 Fe203 0 0998 0 0151 0 1000 0 0998 0 20 12 3144 Glass sand 20 9879 2912 K20 0 6856 Factory cullet 7 2662 10 08 Cad 10 5000 10
8. O Microsoft NET Framework Version 4 5 2 2 2 Installing the Software The installation of BATCHMAKER SUITE is divided into the following steps O Installation of Microsoft NET framework O Installation of BATCHMAKER SUITE O Installation of the license module NOTE Reference is made several times below to file names with the file extension exe The extension exe may not be visible under certain circumstances according to the settings of your operating system You require at least power user rights and possibly also administrator privileges to your computer for installing software and drivers If you are in doubt please contact your system administrator 2 2 1 Installing the Microsoft Framework Before BATCHMAKER SUITE is installed it is necessary that the Microsoft NET Framework 4 5 2 is installed on your computer otherwise BATCHMAKER SUITE cannot be used To install the Microsoft NET Framework 4 5 2 2 Insert the installation medium gt Open the Microsoft folder BATCHMAKER SUITE Commissioning 7 gt Run the file NDP452 KB2901907 x86 x64 AIIOS ENU exe by double clicking and follow the instructions of the setup program gt To install the German Language Pack for the Microsoft NET Framework 4 5 2 run the file NDP452 KB2901907 x86 x64 AllOS DEU exe from the installation medium und follow the instructions of the setup program If required you can download language packs for other languages at http www microsof
9. Select the Amber glass batch batch recipe from the Samples Container Glass folder and confirm your selection with Open NOTE Alternatively you can drag amp drop batch recipes from the File Manager into the window The batch recipe is loaded and inserted in the Batches and furnace loads list 2 Enter the value 30 as Factor The batch recipe should therefore be used in production for thirty days with an average Load of 340 t 2 Insert in this way one after the other the Flint glass batch sample batch recipe with a factor of 30 and Green glass batch with a factor of 20 BATCHMAKER SUITE Example of Application 2 Click the Calculate button The total usages and the batch costs of all raw materials and cullet used in these batch recipes appear in the right hand table Prices 4 202 097 6 3 147 380 3 1 783 482 2 15017157 1 055 230 8 579 579 7 343 943 3 74 6339 64 4292 20 0833 5 3304 4 1305 7 548 452 5 5 801 664 2 4 414 3123 1 360 546 1 963 333 4 7 20 195 3 23 4 275 0 1 783 482 2 1 501 715 7 1 055 230 8 579 579 7 343 943 3 74 633 9 64 4292 20 083 3 5 330 4 4 730 6 7 430 636 6 5 671 126 9 4 328 822 1 1 360 546 1 969 393 4 720 195 3 33 597 862 0 32 301 277 6 1 686 082 62 48 You can also have the data displayed in report form here with the Report button The results are copied into the Windows clipboard with the Copy to Clipboard button so that you can process them further in other applications
10. 3 1 1 Menu Bar You can use the menu bar to reach all functions of the program To open a menu click on it with the mouse You can select a menu item within a menu by pointing and clicking in a Similar manner For a complete description of all menu commands please refer to the Online Help 3 1 2 Toolbar The most important menu items are combined in the toolbar For example you can open a glass recipe by selecting the Open gt Glass Recipe menu item in the File menu or simply by clicking on the Open Glass Recipe icon in the toolbar If you let the cursor rest on an icon for some time an information text on the function of the icon appears Bat SS oro HP 0 3 1 3 File Manager You see in the File Manager as standard all files and folders in the Samples subfolder of the program folder However you can freely select the master folder the files and folders of which should be displayed here Only the files relevant for BATCHMAKER SUITE are displayed in the File Manager therefore configurations config master data master analyses amp prices analyses glass recipes recipe batch recipes batch and glass compositions comp C Program Files amp 86 ilis B 7 X C Program Files lt 86 ilis B Container Glass Hint glass p Green glas H 5 Float Glass EZ Soda Lime New Folder BS Tableware ag Rename F2 Delete Del Clear Root Folder History Explore Folder Update View Sort
11. 5000 0 0500 0 0000 Glass sand 2 2399 311 2 5000 2 500 00100 0 0000 Feldspar 1 4084 1 95 Cr203 0 0042 Phonolite 0 2801 0 35 MnO 0 0203 Calumite 0 1856 0 26 0 0475 Dolomite 0 0601 0 08 503 0 1500 Selenium pre 0 0338 0 05 PbO 0 0136 Limestone 0 0211 0 03 0 0185 Sodium sulfate 0 0001 0 00 0 0039 0 0088 n nn13 0 1 3 0 0 0 0 0 0 0 0 Recalculate There has been no warning the recalculation since this time all tolerances could be complied with Correspondingly no component is highlighted in red NOTE The Change column appears only directly after the recalculation of the batch recipe If you save and reopen the batch recipe the Change column is no longer displayed BATCHMAKER SUITE Example of Application 39 4 5 Calculating Batch Recipe from Raw Material Weights As an alternative to calculating a batch recipe from a glass recipe you can also calculate a batch recipe directly from specified raw material weights e g if the chemical composition of the glass to be produced is not known To calculate a batch recipe from raw material weights gt Select the New gt Batch Recipe command from the File menu or click the New Batch Recipe icon in the toolbar The New Batch Recipe window opens it New Batch Recipe Plant Fumace Glass type undef atch Ing redients Glass Components Ingredient Dry weight Wet weight Ingredient
12. Order Show File Extensions You have several possibilities of opening a file from the File Manager For instance you can drag it by Drag amp Drop into the working area of BATCHMAKER SUITE use the open command in the popup menu of the File Manager or double click the file Further commands for working with files are available to you in the popup menu of the File Manager for instance for renaming or deleting and for adapting the display A small folder symbol opposite the relevant file symbol indicates that a file is open for processing in BATCHMAKER SUITE BATCHMAKER SUITE Basic Operating Principles 14 You see in a list under the file tree which windows are currently open for processing in BATCHMAKER SUITE and which window is active i Demonstration V Demonstration Amber glass Amber glass As soon as you mark an entry in the window list the corresponding window is brought into the foreground You can show and hide the File Manager using the File gt File Manager menu item or the icon of the same name in the toolbar You can obtain further information on the File Manager in the Online Help 3 2 Obtaining Help You can obtain help on the program features for almost any situation in BATCHMAKER SUITE Pressing the F1 key causes a window to appear with a description of the program window which you are currently located The Online Help of BATCHMAKER SUITE offers step by step explanations for all impor
13. guarantee and is subject to change at any time without prior notification The BatchMaker software and the corresponding hardware the license module may only be used on a single computer i e on the central unit in one location By purchasing this package the buyer acquires ownership of the data media and the hardware provided with the software but no rights to the software itself This applies in particular to all rights for duplication processing and rights of usage for commercial gain of the software The software as well as the documentation are protected by copyright law The license holder is permitted to make one reserve copy for backup purposes The copyright protection must be noted on this reserve copy The software and documentation may not in any way be modified duplicated or used to create derived products It is forbidden to decompile the software or to remove the copy protection Based on the current state of the art it is not possible to produce software that works free of errors in all application combinations ilis gmbh is therefore not liable for damages arising through the use of the software or the hardware delivered with it The names of products and companies cited in this documentation may be protected by trademarks of their respective proprietors BATCHMAKER SUITE Introduction 3 Table of Contents 3 1
14. in the Glass 1 column Select the three batch recipes from the Samples Container Glass folder and confirm your selection with Open NOTE Alternatively you can drag amp drop batch recipes from the File Manager into the window The selected batch recipes are loaded and the data is displayed in tabular form Hint glass Green glass Fumace 1 Fumace 2 Fumace 3 Amber Flint Green td 450 t d 360 t d 711 62 2 108 SiO2 40 0918 2 5102 4 0672 SIO 0 1172 39 6273 4 2741 12 3388 5114 47 7711 66 kg 330 57 kg 6 46 476 35 kg 6 18 X 4783 9 kg 7235 32 kg 65 4 65 3522 07 kg 188 73 kg 5 36 3333 33 kg 70 2 27 2008 5 39 05 PM 2 27 2008 5 39 05 PM 2 27 2008 5 39 05 PM BATCHMAKER SUITE Example of Application 43 gt Under Compare select the desired data category you want to compare e g Batch Ingredients Dry weight kg 554 6084 1517 0022 25075452 3815 88 116 1007 kg 173 9101 90 7333 kg 184 3363 kg 554 6084 168 5558 683 9190 kg 154 5630 2364645 131 7001 kg 9 2978 kg 40 0000 kg 15 0000 7 0000 kg kg 2004 0823 kg You can also have the data displayed in report form here with the Report button The results are copied into the Windows clipboard with the Copy to Clipboard button so that you can process them further in other applications such as Microsoft Excel BATCHMAKER SUITE Example of Application 44 4 7 Calculating Glass Properties BATCHMAKER SUITE contains a glass property
15. mols mol Mg 0 0000 0 0000 01156 In this example the value for the Young s modulus is highlighted in yellow since the validity limits defined for this property have been exceeded If you mark the corresponding row with the mouse you will see in the lower table the violated validity limits for this property and the calculated value for these BATCHMAKER SUITE Example of Application 35 4 3 6 Functional Glass Properties If functional glass properties are activated in the options further tab cards e g for viscosity or electrical conductivity appear as appropriate For instance the temperatures calculated for the specified viscosity fixed points are listed and displayed graphically on the Viscosity tab card You can select arbitrary points on the viscosity curve The associated values are displayed in the boxes below the table login dPas T 2 00 1460 12 400 1038 10 7 60 738 7 13 00 564 7 14 50 537 7 a H En a I a hi Temperature T 922 Viscosity log r dPas 5 00 BATCHMAKER SUITE Example of Application 4 3 7 Displaying Report The report display for batch recipes can be configured so that for instance you can generate a reduced report without price information gt Click the Report button gt Select the elements that should be contained in the report from the Configure Report window You can show or hide all price information via the Include
16. price information element By using the Pagebreak element you can insert a pagebreak before the glass property tables 2 Calumite Factory cullet Flint 728 8940 728 8940 Batch Ingredients Glass Components Pagebreak Glass Properties v With diagram s Include price information After you click the OK button the report elements you have selected are displayed in a separate window Batch Recipe Flint glass Wet melting loss kg eio 57 5 3 313 5 2 3 AE a 2 2 Siz IP am iS 8 T9 zx Glass amount kg 2531 35 4701 08 3977 84 723 24 1232 44 167 48 262 86 262 86 17 43034 Glass price 67 3634 5950 Batch Ingredients E 2 Glass R Wet weight Dry weight Glass Batch costs Glass price Glass sand low iron 1593 9282 1522 2014 1521 3490 52 60 Soda ash 456 6290 2 97 1042 Dolomite 3806255 28290 28 2 16 1325200 183 580 048 396 505 3 042 imestone 2318391 178 9772 334699 138 og 6290 6255 178 9772 169 1335 eldspar 145 6040 0000 Phonolite 4010 0000 9805 8940 Selenium premix 258 003 084 011 723237 oreign cullet Flint 3 380 6255 6040 40 0000 36 4010 15 0000 980 8944 728 8940 380 40 40 0000 364010 36400 Sodium sulfate 150 15 0000 40439805 39808944 128 gt Close the Report window
17. such as Microsoft Excel
18. the plant are not available in the glass recipe O Under Batch Type you can select whether the batch recipe should be calculated related to a mixer batch to the glass amount to be produced with or without cullet additives or to a certain raw material BATCHMAKER SUITE Example of Application 25 O You enter in the Batch size box according to selection in the Batch Type dropdown list box the amount in kg that should be used as basis for the calculation of the batch recipe O You enter in the Furnace Load box optionally the average glass amount produced per day The required batches per day are calculated from this in the batch recipe O You select from the Nominal adjustment dropdown list box a component that should be used for automatic nominal value adjustment Example You specify in the glass recipe a nominal composition that results in total in 99 in order to leave some play namely 1 for impurities that are necessarily brought into the glass by raw materials and cullet However in fact 1 25 impurities are brought in so that the total sum would be 100 25 In this case the nominal value of the component selected here is adjusted so that the sum of the nominal composition results in 98 75 therefore 100 including the 1 25 impurities If you do not want to perform an automatic nominal value adjustment select the None entry In this case the components are adjusted proportionately so that the sum of the calculated glass comp
19. your operating system is used gt Inthe Stylesheet directory box you can state a folder with XSL stylesheets which BATCHMAKER SUITE should use for displaying reports If you leave the box empty the standard templates provided with BATCHMAKER SUITE are used gt If you activate the Store master data and analyses in separate files option the master data and the analyses are not stored as in version 2005 and older in a common configuration file file extension config but in two separate files with the extensions master and analyses 2 6 2 Selecting Glass Properties On the Glass Properties tab card you can select the glass properties that should be calculated and displayed in the batch calculation and in the glass properties calculator and register additional glass property libraries Preferences Glass Properties Fixed Points Registered glass property libraries Batch Maker GlassProps dil Remove Available glass properties Group lass property Symbol Unit Author a BatchMaker Themoshock resistance BatchMaker Density BatchMaker Refractive index n v BatchMaker Dispersion d 1E 4 Vl BatchMaker Abbe number V 4 n k Move Down Select all Select None Calculate even if the predicted eror is exceeding the model limits To register a new glass property library gt Click the Add button gt Select the required library in the Add Glass Property Librar
20. Batch Ingredients Glass Properties Fumace lass type Fumace load Batches per day Nominal value adjustment Redox number Dry melting loss Glass amount Cullet percentage Batch costs Total costs Analyses as of Calculated on Valid from Software version Fumace 2 450 td 622 SiO 0 071 40 2731 7709 79 kg 477 35kg 6 19 7232 44 kg 65 59 5 amp t glass 59 5 amp t glass 2 5 2014 3 30 35 PM 2 5 2014 3 30 37 PM 2 5 2014 3 30 37 PM v2013 1 5147 30 You see in the Analyses as of row the date and the time of the last saving of the associated analyses file The Valid from row states the time from which this batch recipe should be used in production You can change this value using the Valid From button The nominal value correction performed in the calculation is stated in the Nominal value adjustment row In this example the nominal value for SiO was increased by 0 071 The Redox number of the batch was calculated from the weights on the basis of the Redox factors filed in the master data BATCHMAKER SUITE Example of Application 31 4 3 2 Summary The summed weights humidities melting losses glass percentages glass amounts and price percentages of raw materials factory cullet and foreign cullet are listed on the Summary tab card In addition information on the total amount of glass produced is displayed the total cullet percentage and the glass price percentages for the raw materials an
21. BatchMaker Sui User Manual Version 2014 1 2 iis BatchMaker Suite 2014 File Edit Tools Window Help C SS ero HW C Program Files 86 ilis Batcl B C Program Files 86 ilis Batcl Analyses amp Prices Demonstration i ae Amber glass a Amber glass G amp Fint glass Ingredient Glass sand low iron Glass sand Soda ash Name Amber glass Glas 2 Load Load Load Save Save Save Clear Clear Clear Glas 3 Unit At cursor position 7 60 738 6 710 8 689329 TC Melting point 2 1460 12 1419 18 1407 17 C A E 0000 0000 Mesi 4 1038 10 1003 14 985 14 YT YU 5 922 9 889 13 870 12 Io 13 565 8 543 7 519 16 12 2357 16 0000 14 0000 a 14 5 537 9 516 7 492 18 0 7643 10 5000 10 0000 10 0000 2 5000 1 0000 Viscosity 0 0349 0 0343 0 0669 0 0800 0 0082 0 0046 Viscosity log n dPas zB ESRB E 8 Auto adjust Temperature C Columns wt md ilis gmbh Konrad Zuse Str 22 D 91052 Erlangen Phone 49 91 31 9747790 Fax 49 9131 9747799 E Mail info ilis de Internet www ilis de Copyright 2003 2014 ilis gmbh All rights reserved Version 2014 1 November 2014 The information and data included in this documentation is provided without
22. Minimum Maximum Amber glass mol mol 0 0000 0 0772 0 6010 Sum 902 203 203 20 K20 CaO MgO Cr203 MnO TiO2 S03 PbO a CoO 2102 NiO BaO Se quem Columns 3 4 wt md The glass properties for the two compositions are displayed on the tab cards in the right hand area of the window You define in the Options of BATCHMAKER SUITE which properties are calculated here gt Switch to the Viscosity tab card Name Amber glass Glass 2 Glass 3 Load Load Load Save Save Save Clear Clear Clear Value Amberglass Glass2 Unit Atcursorpostion 7 60 738 6 71038 2 1460 12 1419 18 100 0000 100 0000 4 1038 10 1003 14 74 0000 5 922 9 889 13 lt ton point 7 6 73826 71038 NEN 0 4299 13 565 8 54337 122357 16 0000 145 53739 51627 C 0 7643 am E Viscosity 0 0349 0 0343 0 0669 0 0800 0 0082 0 0120 0 0046 0 0075 0 0017 0 0373 Viscosity log n dPas Auto adjust Temperature T C Columns 3 2 wt md BATCHMAKER SUITE If you select a viscosity fixed point in the upper table the corresponding values are Example of Application marked in the graphs By using the mouse wheel or the context menu you can enlarge or reduce the visible diagram area To pan the diagram hold down the right mouse button and move the mouse 46 gt Select the Standard view command from the context menu to return to the original scale gt Click the Report button
23. R20 13 0000 0 0500 Component Main Carrier s of MgO sum 100 Ingredient Ratio 2 100 Nominal Glass Composition sum 99 501 Saturation abs Component Evapor K20 0 203 MnO TiO PbO CoO Ls 202 gt NiO Ingredient um MgO 3 Dolomite low iron 21 6030 EB Calumite Chromite Limestone 8 2400 11 5440 0 2805 A Repot 4 Calculate Check Iz Save Close 26 You see in the upper main table the components that should be contained in the glass They were transferred with the arrow buttons from the upper selection list into the table Nominal Tolerance Saturation and Evaporation can be entered for each component in the columns When the batch recipe is calculated the tolerances are checked automatically There is a corresponding warning if a tolerance is exceeded You can state one or several carrier raw materials for each component in the lower table If you have stated more than one carrier raw material for a component you define in the Ratio column the relative percentages for which the stated raw materials should be used related to the dry weights sum of the percentages must always be 100 NOTE A carrier raw material is a raw material that introduces a chemical component expressed as a percentage of its total chemical composition For example glass sand is normally used a
24. ade available to you file extension v2c The ilis SoftwareManager program opens 2 Click on Update License The license is updated BATCHMAKER SUITE Commissioning 8 2 4 Uninstalling the Software 2 4 1 Uninstalling BatchMaker Suite To uninstall BATCHMAKER SUITE gt Open the Windows Control Panel gt Select the Uninstall a program option gt Mark the BatchMaker Suite entry in the list of installed programs 2 Click on Uninstall The program files are removed from your computer NOTE The data files you have created such as glass recipes batch recipes etc are not removed by the uninstall program and must be deleted manually if necessary 2 4 2 Uninstalling the License Module To uninstall the ilis SoftwareManager and the driver of the license module gt Open the Windows Control Panel 2 Select the Uninstall a program option gt Mark the ilis SoftwareManager entry in the list of installed programs 2 Click on Uninstall The program and driver files are removed from your computer 2 5 Starting and Ending BatchMaker Suite To start BATCHMAKER SUITE gt Open the Windows Start menu gt Open the ilis BatchMaker Suite program folder in the Programs menu gt Select the BatchMaker Suite entry NOTE The first program start of BATCHMAKER SUITE after booting your computer can take few seconds depending upon the performance of the computer As an alternative you can double click the program icon D on your desktop t
25. aw material of Al2035 in the lower table table amp Glass Recipe Flint glass modified General Fixed Ingredients Meting Energy Glass Components Component Saturation abs Tolerance abs 0 1000 0 0100 0 0500 0 0100 0 0001 Nominal 5 1 5000 10 5000 2 5000 0 0010 502 Cad 5 503 Fe203 R20 0 1000 13 0000 0 0500 Ingredient Feldspar Phonolite Ratio 80 amp Report amp Calculate You add Phonolite as second carrier raw material from the ingredient list to the You change the ratio of feldspar to phonolite in the Ratio column to 80 to 20 Component K20 Cr203 Evapor CoO 2102 BaO Ingredient A203 x Spodumene 26 5000 B Feldspar low iron gt Chromite 16 5400 14 1520 BATCHMAKER SUITE Example of Application 28 4 2 3 Fixed Ingredients The Fixed Ingredients tab card is divided into the four Fixed Additives Glass Percentages Relative to Ingredients and Relative to Components subareas Sodium sulfate Fixed ingredients are amounts of raw materials or cullet that are not calculated through the nominal chemical composition of the glass but are added to the batch absolutely in kg or relatively in weight related to the glass amount a certain ingredient or a component As a rule raw materials are stated as fixed additives in kg cullet as glass percentage You leave the glass recipe open to calcula
26. calculator with which you can calculate from their chemical composition and compare the glass properties of different glasses gt Select the Glass Properties command from the Tools menu or click the icon of the Same name in the toolbar The Glass Properties window opens ered Sum 5102 AI203 Fe203 Na20 K20 CaO MgO Cr203 MnO TiO2 503 PbO CoO 2 2 5 quem Columns 3 wt md Repon Click the Load button in the Glass 1 column Select the Amber glass batch sample batch recipe from the Samples Container Glass folder and confirm your selection with Open NOTE Alternatively you can drag amp drop batch recipes from the File Manager into the window The calculated glass composition of the batch recipe is loaded into the first column on the table on the left hand side of the window 2 Enter a glass composition of 16 gt 2 10 CaO and 74 SiOz manually into the second column of the table by default the SiO2 percentage is calculated automatically Enter Sample in the column heading as the name for this composition 2 Click the Calculate button BATCHMAKER SUITE Example of Application 45 2 Amber glass Glass 2 9 02 0 35 9893036 1E6 K fon 251140010 249350008 g cm 100 0000 100 0000 ivei 1 5236 0 0023 1 5181 0 0018 aor 501 ug Na20 g mess GPa GPa GPa Glass Load Save Clear J kg K J kg K mJ m
27. d cullet used BATCHMAKER SUITE 4 3 3 Batch Ingredients The individual raw material and cullet weights dry and wet as well as the relevant melting losses glass cost and price percentages are listed on the Batch Ingredients tab card The oxide balance of the raw material marked in the left table in each case is shown in the detail Example of Application table in the right part of the window weight 1593 9282 15222014 456 6290 380 6255 231 8391 178 9772 145 6040 40 0000 36 4010 15 0000 2 5665 4043 3805 728 8340 liem kg 456 6290 380 6255 231 8391 169 1335 145 6040 40 0000 36 4010 15 0000 2 5665 BATCHMAKER SUITE Example of Application 23 4 3 4 Glass Components You see the calculated composition of the glass compared to the nominal composition on the Glass Components tab card Batch Recipe Flint glass modified General Summary Batch Ingredients Glass Components Component Synthesis Nominal Tolerance Deviation Molar Ri CJ abs synthesis Carriers of 72 0710 72 0710 00000 716555 A1203 1 5000 15000 00100 00000 08788 iiis doin ER Fe203 0 1149 0 1000 01149 0 0430 Na20 12 3144 11 8691 Glasssand o 20 9879 29 12 20 0 6856 0 4348 Factory cullet 7 2662 10 08 Cad 10 5000 105000 0 0500 0 0000 11 1854 Gs sed 22399 311 25000 2500 00100 37054 Feldspar 1 4084 1 95 0 0042 0 0016 Phonolite 0 2650 0 37 0 0209 0 0176 Calu
28. h recipe is displayed in its own window You see which windows are currently opened in the window list of the File Manager and in the Window menu If you open several windows at one time note that only the topmost window is active If you select one of the entries the corresponding window is activated and brought into the foreground Please note also that the commands in the menu bar and in the toolbar always refer to the active window in each case For instance if you have opened the master data and a glass recipe and the glass recipe is active certain commands in the File and Edit menus may not be available In another example if you have opened several glass recipes the commands in the File and Edit menus act only on the glass recipe in the currently active window BATCHMAKER SUITE Example of Application 17 4 Example of Application The objective of this section is the calculation of a batch recipe with reference to the sample files supplied with BATCHMAKER SUITE For this purpose the sample configuration is firstly opened and edited An existing glass recipe is then adapted with this configuration data A batch recipe is then calculated from the glass recipe data and displayed as a report Finally you learn to compare batch recipes and to work with the glass property calculator and the raw material usage calculator NOTE All parts of the individual windows are not discussed in detail in this manual You will find a detailed descrip
29. ion of a glass Glass compositions can be saved and loaded within the glass property calculator 3 3 5 Storage Location of Files By default the public documents folder C Users Public Documents ilis BatchMaker Suite Samples is suggested as storage location for all data that you produce with BATCHMAKER SUITE You can and should store your own files in different folders e g ona network drive BATCHMAKER SUITE notes for every type of file the folder last used You can handle BATCHMAKER SUTTE files in Windows Explorer just like other files e g copying renaming 3 3 6 Sample Files A set of sample files consisting of a configuration Demonstration config several glass recipes and the batch recipes of the same name calculated from them is delivered with BATCHMAKER SUITE You will find these files in the default storage folder see above NOTE Please note that the sample files in BATCHMAKER SUITE are only provided as examples and cannot be applied to the production unchanged 3 4 Working with Windows In BATCHMAKER SUITE several windows can be opened simultaneously e g the master data a glass recipe and a batch recipe The following rules apply here O Only one configuration or one master data and analyses file each can be opened and loaded simultaneously O Several glass recipes can be opened simultaneously Each glass recipe is displayed in its own window O Several batch recipes can be opened simultaneously Each batc
30. ion of glass recipes with statement of the wanted chemical glass composition and if necessary definition of fixed ingredients such as cullet or refining agents O Calculation of batch recipes based upon the desired glass recipes in particular the computation of the raw material weights Moreover BATCHMAKER SUITE offers many useful and practical tools such as an integrated File Manager a glass property calculator for predicting and for comparing important glass properties such as viscosity and thermal expansion and a usage calculator for determining the monthly requirement of raw materials and cullet Data storage in the open XML format facilitates easy interfacing with laboratory information systems and batching plants BATCHMAKER SUITE Introduction 5 1 2 Overview of Sections The Commissioning section contains instructions for installing BATCHMAKER SUITE You must work through this section if BATCHMAKER SUITE is not yet on your computer system or you want to install a more recent version of the software In Basic Operating Principles the most important operating and display elements such as windows menus and buttons are described You also find out here how to obtain assistance for the individual program functions The Example of Application section deals with a typical application of BATCHMAKER SUITE by reference to sample files supplied with the software You are guided step by step through the program from editing the configurati
31. iron 2220107 Hematite Chromite 2 16 2007 316 00 Lead oxide Manganese oxide 2 16 2007 328 00 Cobalt oxide 28750 00 Nepheline syenite Spodumene Potash m MgO 11 Cr203 PbO a Cl CoO 2102 NOTE You mark several entries the selection lists and add them to the table at the same time by holding the SHIFT or CTRL key down The entries that you have already added to the tables are no longer displayed in the corresponding selection list BATCHMAKER SUITE Example of Application 23 gt Click the Report button to have all analyses clearly displayed a table E Save As Print Print Preview Page Setup Analyses for Plant Container Glass Raw Analysis CaO Cr203 02 CI material date Glass sand 77 22 46 4 50 3300 997200 0 0580 0 0168 0 0620 0 0284 0 0012 0 0126 0 0450 low iron nae roa Soda 010276 1640 0018 0005587500 00072 00095 00080 0000 000 osos Limestone 2007 02 16 1500 0 6582 0 1685 0 1258 0 0436 0 4523 55 3580 02805 00580100180 Limestone 5907 02 16 0 2550 0 0850 0 0750 4560 0 0 0085 low iron Dolomite orar zoo 11429794448 94484 998 0045000325 Dolomite 70246 46 00 0 0230 0 013 21 6030 0 008410 0032 low iron Poe vmi ram sso 02621 Ca
32. lating batch recipes in the master data and in the analyses and prices At any point in time a configuration or a master data and analyses file the name of which is displayed in the title bar of the main window is active in BATCHMAKER SUITE The first time BATCHMAKER SUITE is started the supplied sample configuration Demonstration config is loaded automatically BATCHMAKER SUITE notes the currently used configuration or master data and analyses file and loads this automatically the next time the program is started 3 3 2 Glass Recipes A glass recipe in BATCHMAKER SUITE contains the specification for the glass to be produced e g the nominal chemical composition the raw materials used and the cullet added Several glass recipes can be opened simultaneously in BATCHMAKER SUITE 3 3 3 Batch Recipes A batch recipe can be entered manually or calculated automatically from the data in a glass recipe and the current raw material analyses A batch recipe contains the weights of raw materials and cullet for production as well as the glass composition calculated from these Furthermore a batch recipe in BATCHMAKER SUITE contains additional data such as glass properties which are also calculated from the raw material weights As for glass recipes several batch recipes can be opened simultaneously in BATCHMAKER SUITE BATCHMAKER SUITE Basic Operating Principles 16 3 3 4 Glass Compositions A glass composition contains the chemical composit
33. lect certain raw materials or plants or you will use the incorrect analyses for later calculation of the batch recipe open the sample glass recipe for white container glass gt Select the Open gt Glass Recipe entry from the File menu or click the Open Glass Recipe icon in the toolbar gt Select the Flint glass recipe file from the Samples Container Glass folder and click the Open button The file is loaded and displayed in the Glass Recipe window amp Glass Recipe Flint glass General Glass Components Fixed ingredients Melting Energy Plant Container Glass Batchtype Mixerbatch Fumace Fumace 2 Batch size 3000 kg Nominal adjustment 502 Fumace load Empty weights Eliminate and notify I Accept nominal values for components without carrier Comment A Repot 4 Calculate 5 Cose 4 2 1 General The master data of the glass recipe are summarized on the first General tab card O Plant Furnace and Glass type describe for which furnace in which plant and for which glass type the glass recipe should be valid Here you can select the data that you have defined in the currently loaded master data under Plants Furnaces amp Glass Types NOTE So that you can enter the glass composition and the fixed ingredients the plant at least must be selected on the General tab card Otherwise the raw materials and cullet assigned to
34. mis 8 ral sa Feldspar 2007 02 16 8100699560 000300065 Sodium 2007 02 16 0 052 43 4700 0 042 56 0520 0 0065 sulfate Selenium 5007 02 46 302 00 95 3220 0 0965 0 0210 premix Feldspar 5007 02 46 132 00 67 3400 16 5400 0 0 5678 14 6850 0 04 Low Chromite 2007 02 16 31600 21356 141520275400 1 0 2007 02 16 328 00 2 8790 3 6120 4 3990 0 1322 oxide oxide tote 64 5000 0 0700 0 1500 0 0800 Foreign Analysis cullet date 2007 02 1 EE 58 00 71 5400 1 8400 0 3390 12 8450 0 8156 10 0580 2007 02 16 EL 71 2930 1 8323 0 3574 12 8398 0 8145 10 1689 Foreign 2007 02 16 71 9500 1 4584 0 0785 13 1003 0 6950 10 2840 0 1513 0 02250 0304 cullet Flint Factory Analysis CaO kw date 2007 02 16 BET 71 3121 2 0120 0 4131 ales 0 7471 10 4850 2 5024 0 0780 0 0087 2007 02 16 IEEE 0 5335 11 7098 0 7902 10 9560 2 2513 0 2467 0 0366 0 0662 0 1930 0 0109 0 0124 ies 2007 02 16 72 0989 1 5023 0 0977 12 1908 0 0809 10 5123 2 4879 0 0039 0 0200 0 0462 0150 0 0124 0 0168 Demonstration config 2014 02 05 15 21 38 J b H h y e NR ho p gt to co tn alo m 151 S TR eo ce h
35. mite 0 1856 0 26 0 0475 0 0355 Dolomite 0 0601 0 08 0 1500 01119 Selenium pre 0 0338 0 05 0 0136 0 0036 Limestone 0 0211 0 03 0 0185 0 0312 Sodium sulfate 0 0001 0 00 0 0039 0 0031 0 0088 0 0043 _0 0013 n The specifications from the glass recipe are listed once again in the Nominal and Tolerance columns The percentages of the components in the glass calculated from the raw material weights are listed in the Synthesis column The Deviation column states the absolute deviation of the calculated percentage from the nominal value The raw materials which according to chemical analysis contain the component marked in the left table in each case are listed in the detail table in the right part of the window BATCHMAKER SUITE Example of Application 34 4 3 5 Glass Properties The glass properties calculated from the glass composition are listed on the Glass Properties tab card You can configure in the Options window which glass properties are calculated here Batch Recipe Flint glass modified Glass Components Glass Properties lass property Value Unit Thermal expansion 9 01 0 35 1E 5 K Density 2502 0011 Refractive index 1 5220 0 0022 Dispersion 87 82 1 22 1 4 Abbe number 59 44 Chemical resistance 188 ug Ma20 g Hydralytic class 3 Shear modulus 30 39 0 92 GPa Bulk modulus 44 25 GPa Poisson s ratio 0 2206 Specific heat 20 801 39 J kg Validity limit Minimum Maximum Value
36. n circumstances from how they will appear on the screen It is also possible that according to the ordered scope of functions some of the functions described here are not applicable in your version 1 1 Introduction The objective of batch calculation in glass production is compliance with a defined chemical glass composition which determines the properties of the final product e g thermal expansion and refractive index but also has a decisive influence on the melting properties and processability e g viscosity Thus batch calculation also has a substantial influence on another large cost factor in glass manufacture the energy costs Great economic importance is attached to the prediction of glass properties since this can drastically reduce the number of trial melts and thus the expense of time and costs in new and further developments of glasses In addition many glass properties such as viscosity can be determined physically only by much experimentation and measurement BATCHMAKER SUITE assists you in the development and production of glasses by the automatic calculation and optimization of raw material weights for the glass composition you specify The work with BATCHMAKER SUITE can be broken down roughly into four steps O Definition of the master data such as the raw materials types of cullet and chemical components used O Entry and maintenance of the chemical analyses and prices for all raw materials used O Product
37. o start BATCHMAKER SUITE Once you have completed your work with BATCHMAKER SUITE you exit the program in the File menu with Exit As an alternative you can click on the Close button of the main window BATCHMAKER SUITE Commissioning 2 6 Setting up BatchMaker Suite At the first start of BATCHMAKER SUITE you are requested by a message to check the preferences in the Options dialog and if necessary to adapt them to your requirements iis BatchMaker Suite 201 File Edit Tools Window Help aem ado C Program Files 86 No option file could be found Please check your preferences and configure the desired glass properties and fixed points if available in the Options window The Options dialog is opened automatically after you confirm this message Only the most important settings are described in the following sections for a complete reference of the dialog please refer to the Online Help 2 6 1 Adapting Preferences You can make basic settings in BATCHMAKER SUITE on the Preferences tab card language Multilingual names for plants fumaces glass types and raw materials File Options Stylesheet directory Store master data and analyses in separate files Append date time to batch recipe file name Confirm before overwriting a file BATCHMAKER SUITE Commissioning 10 gt Select the wanted language of the user interface from the Language dropdown list box If you select Automatic the language setting of
38. o view edit composition limits and raw matenaltelated evaporations 2 Click the Save button to accept your changes Use if necessary another file name in order not to overwrite the original sample configuration BATCHMAKER SUITE Example of Application 21 4 1 2 Entering Chemical Raw Material Analysis After you have created a new raw material you can enter a chemical analysis for this raw material gt Select the Edit gt Analyses amp Prices menu command or click the Edit Analyses and Prices icon in the toolbar The Analyses amp Prices window is brought into the foreground t Analyses amp Prices Demonstration Raw Materials amp Cullet Energy Sources Miscellaneous Analyses for Plant Glass Ingredient Analysis Humidity Price Ingredient oe oe 2 16 2007 4 50 33 00 Barium carbonate Glass sand 2 16 2007 LS 29 00 Soda ash 2 16 2007 Limestone Erbium oxide Glass sand ultrapure Hematite Limestone low iron ila Chemical Composition of Glass sand low iron sum 39 944 Component Percentage gt Component 33 7200 0 0580 0 0168 0 0620 0 0284 0 0012 K20 503 PbO Cod 702 Repot Copy Data Rrcek isave Ge The entry area consists here of a main table upper half of the window for the assignment of raw materials and cullet to the selected plant and for entry of the associated p
39. on file through producing a glass recipe up to calculating the corresponding batch recipe and thus you become acquainted with the most important functions of the program 1 3 Conventions To make distinctions clearer different fonts and icons are used in the text Labels and file names User input Cross references Enumerations 2 actions 1 4 Customer Support If you have questions on installing or operating BATCHMAKER SUITE please contact us at the following address We will be pleased to provide you with further assistance ilis gmbh Konrad Zuse Strabe 22 91052 Erlangen Germany Phone 49 9131 9747790 Fax 49 9131 9747799 E Mail support ilis de Internet www ilis de BATCHMAKER SUITE Commissioning 6 2 Commissioning In this section you will learn what the minimum requirements of BATCHMAKER SUITE are for your computer system and how to install the software on your computer 2 1 System Requirements In order to operate BATCHMAKER SUITE your computer system must meet the following requirements O PC with Intel Pentium 4 processor or compatible Core i5 or better recommended 1 GB RAM 4 GB recommended 1 GB free hard disk storage Color monitor resolution min 1024 x 768 1280 x 1024 or higher recommended Mouse keyboard USB 2 0 interface Oo OF OF Operating system Microsoft Windows 7 or Windows 8 1 with current Service Pack and current update status O Microsoft Internet Explorer
40. osition results in 100 NOTE The tolerances in the calculation of the batch recipe are always checked on the basis of the corrected nominal composition O You select from the Empty weights dropdown list box how raw materials that were Stated as carrier raw material but are not required in the batch recipe to achieve the required glass composition should be handled in the calculated batch recipe For instance with the Eliminate and notify setting raw materials without weights are removed from the batch recipe However you will be advised by a corresponding message which raw materials are affected in the calculation of the batch recipe O You activate the Accept nominal values for components without carriers checkbox if you want to specify nominal values for components that are not brought into the batch by carrier raw materials O You can enter a comment in the Comment box which is also taken over in the batch recipe You can subsequently change this comment in the calculated batch recipe BATCHMAKER SUITE 4 2 2 Glass Components You define the wanted chemical composition of the glass to be produced on the Glass Components tab card amp Glass Recipe Flint glass General Glass Components Fixed ingredients Metting Energy Example of Application f fe Nominal Tolerance X 2 abs 502 72 0000 0 1000 203 1 5000 0 0100 Cad 10 5000 0 0500 2 5000 0 0100 Se 0 0010 0 0001 503 Fe203 0 1000
41. plant related the chemical analyses for the raw materials and types of cullet that you have defined in the master data in the Analyses amp Prices window You enter data in the tables in two different ways To become familiar with both types of entry you create a new raw material in the next steps and enter a chemical analysis for this raw material BATCHMAKER SUITE Example of Application 19 4 1 1 Creating a New Raw Material To create a new raw material gt Activate the Raw Materials amp Cullet tab card in the Master Data window gt Place the cursor with the mouse or the cursor keys in the upper table in the first cell of the last still empty row marked with a Pars Fumaces amp Glass Types Raw Materials amp Cult Name Type Redox Emission factor factor t CO2 1 Foreign cullet Hint Farei 0 0020 Acat cullet Green Hoat cullet Superwhite Foreign cullet Factory Amber Fano ane 7 ac Factory cult Green faao one Sas Click here to viewedit composition limits and raw matenal elated evaporatians 2 Enter a meaningful Name for the raw material e g Spodumene 20 BATCHMAKER SUITE Example of Application gt Select the Raw material entry from the Type dropdown list box to classify the new raw material Name Redox Emission factor factor t CO2A Hoat cullet Green Hoat White Factory cullet Amber Factory cullet Green Factory cullet Hint Click here t
42. rices and humidities as well as a detail table lower half of the window in which a chemical analysis is assigned to each raw material or each type of cullet You will see in list form in each case on the right next to the tables all available raw materials and chemical components as they were defined in the master data in the Raw Materials amp Cullet and Chemical Components areas gt Mark in the right upper selection list the Spodumene entry and add it with the button to the main table As an alternative you can transfer individual entries by double click with the mouse Enter if necessary the analysis date or the date of delivery under Analysis date Enter a Humidity in weight if necessary Enter the Price if necessary 08 O Now mark the 6102 entry in the right lower selection list and move it with the button into the detail table NOTE Alternatively you can double click the entry or use drag amp drop to move the entry to the left table BATCHMAKER SUITE Example of Application 22 2 Enter as Percentage of SiO the raw material Spodumene 64 5 wt gt Inthe same way you can enter the other constituents of spodumen and their percentages in the lower table Raw Wales amp Cue Ingredient Analysis Humidity Price Ingredient gt 22 EY Feldspar 2 16 2007 81 00 a EE Sodium sulfate 2 16 2007 113 00 E a Erbium oxide Selenium premix 2 16 2007 307 00 Feldspar low
43. s This section explains the basic principles required to operate BATCHMAKER SUITE The user interface consists essentially of standard elements such as windows menus and buttons and you will be familiar with the way they are used from other Windows programs The following section assumes that you are familiar with basic information on how to work with the Windows operating system If you are not familiar with this information you should first consult the Windows documentation 3 1 User Interface After the program has started the main window of BATCHMAKER SUITE appears Tools Window Help 2 5929 C Program Files 86 ilis B The main window consists of four areas O You can reach all program functions through the menu bar at the upper edge of the window O The most important program functions are accessible via large icons in the tool bar underneath the menu bar O The File Manager in the left margin of the window provides you fast access to your data O The remaining area is available for entry and evaluation windows Like most of the other windows the main window has buttons in the top right corner to maximize minimize or close the window You can move the window to any position on your screen and change the size of the window BATCHMAKER SUITE takes note of the position and size of the window and restores these the next time you open the program BATCHMAKER SUITE Basic Operating Principles 13
44. s of BatchMaker you may no longer change its ID However the name can be changed later on without danger You can enter a localized name for the relevant raw material in the Name lt language column The displayed language corresponds to the current Windows language setting To enter a name in several lanquages set the wanted language in your Windows interface and then enter a corresponding name in BATCHMAKER SUITE Basic Operating Principles 15 3 3 Working with Files There are essentially the following types of files with which you work in BATCHMAKER SUITE O Configurations file extension config Master Data file extension master Analyses amp Prices file extension analyses Glass Recipes file extension recipe Batch Recipes file extension batch Oo OF 0 Glass Compositions file extension comp NOTE It is possible to save the master data and the analyses in separate files file extension master and analyses instead of in a common configuration file config You can activate this setting in the Options window As standard the data are saved as in the previous versions in a file with the extension config Independently of the selected saving option the data are edited in two separate Master Data and Analyses amp Prices windows 3 3 1 Master Data and Analyses You define all master data and all chemical analyses that you require for producing glass recipes and calcu
45. s the carrier raw material for SiO2 When calculating a batch BATCHMAKER SUITE automatically takes into consideration other raw materials that also bring significant amounts of SiO into the glass for example feldspar as the main carrier of Al203 and allows for this Only a tolerance but no nominal value is stated in this glass recipe for the oxide Fe203 If you mark the row with the mouse you also see that no carrier raw material was defined in the lower table In this way the percentage of Fe203 which is necessarily brought into the glass as impurity by the raw materials can be monitored If the percentage in this example exceeds 0 1 weight 96 there is a warning in the calculation of the batch recipe and you can correct the excess by using an alternative raw material for instance BATCHMAKER SUITE Example of Application 27 Only a saturation value is specified in this glass recipe for the oxide SO3 No carrier raw material is stated therefore SO is brought into the glass only indirectly by the other raw materials A maximum of 0 15 weight 9o SO in the glass is taken into account by the statement of the saturation value that which is brought in above this amount is considered to be evaporated You can also state only an evaporation value for a component for instance without defining a carrier raw material 2 You mark the component 2 the Nominal Glass Composition table Feldspar is shown as sole carrier r
46. t com en us download details aspx id 42641 2 2 2 Installing BatchMaker Suite NOTE You can install and use BATCHMAKER SUITE parallel to BATCHMAKER EXPRESS or BATCHMAKER 2005 2004 To install BATCHMAKER SUITE on your computer 2 Insert the installation medium gt Runthe BatchMaker Suite setup msi file and follow the instructions of the setup program 2 2 3 Installing the License Module BATCHMAKER SUITE is delivered with a license module dongle which is plugged into a USB port of the computer The license module contains your customer data and protects the software against unauthorized access NOTE If the license module is lost the license to use the software expires To install the ilis SoftwareManager and the driver of the license module on your computer gt Insert the installation medium gt SoftwareManager Setup exe file and follow the instructions of the installation program NOTE To ensure that the USB license module is correctly recognized you must be logged in with local administrator rights when it is plugged in Do not remove the license module as long as the computer is switched on 2 3 Updating the License The license module is provided with an operating time limit on delivery The license module and thus the software can be used for an unlimited time only after importing a special activation file which will be sent to you by email To update the license 2 Double click the license file m
47. tant operating processes Cross references also allow you to find related topics You also have access to the classified table of contents and the index through the Contents and Index menu items in the Help menu gt Ausblenden unick Vorwarts Drucken Raw Materials and Cullet General Operation You define raw materials foreign and factory cullet that you want to use as File Manager ingredients in your Glass Recipe and Batch Recipes on the Raw Materials amp E i Edit Master Data Cullet tab card in the Master Data window Plants Fumaces and Glass C Raw Materials and Cullet Note Chemical Components All purchased cullet is designated as foreign cullet in BatchMaker Factory cullet Edit Analyses and Prices is as a rule cullet originating from the plant s own furnaces Edit Glass Recipe amp Calculate Batch Recipe Define raw materials and types of cullet iE i Evaluate Batch Recipe Recalculate Batch Recipe You complete at least the ID and Name fields for every raw material and for every Calculate Raw Material Usage type of cullet An entry is identified uniquely by the ID Provided no localized name Calculate Glass Properties has been defined the name is used for displaying the entry in other areas of Create Report BatchMaker e g when entering the raw materials and cullet used in the Glass Options Recipe Note As soon as you use raw material or a type of cullet in other area
48. te the associated batch recipe in the following step BATCHMAKER SUITE Example of Application 29 4 3 Calculating Batch Recipe To calculate the batch recipe from the sample glass recipe gt Select the Calculate command from the Edit menu or click the icon with the same name in the toolbar or the Calculate button in the glass recipe window The calculated batch recipe is displayed in the Batch Recipe window At the same time there is a warning that the tolerance value for Fe203 was exceeded in the calculation dh Batch Recipe Flint glass modified Batch Ingredients Glass Components Glass Properties Component Synthesis Nominal Tolerance Deviation Molar X synthesis E 4 203 15000 31 5000 00100 00000 0 8788 x Fe203 0 1149 0 1000 0 1149 0 0430 11 8691 Glass sand lo 20 9879 29 12 10 08 3 11 1 95 0 37 0 26 0 08 0 05 0 03 0 00 Ingredient Absolute Relative gt Acknowledge the warning with OK The row with the Fe203 entry is highlighted in red Thus you see directly the components for which tolerances were exceeded gt You activate one after the other the individual tab cards of the batch recipe you obtain detailed information about each tab card in the Online Help BATCHMAKER SUITE 4 3 1 General Example of Application The master data of the batch recipe are summarized on the General tab card Batch Recipe Flint glass modified
49. the individual components were entered if available on the Glass Components tab card Here the nominal values are only used for checking the tolerances and are not considered for the batch calculation it New Batch Recipe ace Glass ents Glass Components Component Nominal olerance Component 71 2828 Na20 p 2 0000 B 10 5000 2 5000 K20 Cr203 MnO TiO2 PbO 13 0000 2 Click the Calculate button to calculate the batch recipe from the input BATCHMAKER SUITE Example of Application The calculated batch recipe is displayed in the Batch Recipe window Component Synthesis Nominal Tolerance Deviation Molar Ri CQ CQ synthesis 1128 A203 2 0000 2 0000 0 0100 0 0000 1 1760 Fe203 0 3171 0 1131 12 2357 11 8357 0 7643 0 4865 10 5000 10 5000 0 0500 0 0000 11 2257 2 5000 2 5000 0 0100 0 0000 3 7188 0 0343 0 0138 0 0343 0 0230 0 0669 0 0502 0 0800 0 0599 0 0082 0 0022 0 0720 0 0203 0 0046 0 0036 0 0075 0 0037 0017 noma SS BATCHMAKER SUITE Example of Application 4 6 Comparing Batch Recipes BATCHMAKER SUITE contains a function which makes it possible to display and compare data from multiple batch recipes gt Select the Batch Recipe Comparison command from the Tools menu or click the corresponding icon in the toolbar The Batch Recipe Comparison window opens Copy to Clipboard Click the Load button
50. tion of all windows and functions in the Online Help 4 1 Opening and Editing Configuration A configuration or a master data and analyses file must always be loaded to enable work to be done with BATCHMAKER SUITE At the first start of BATCHMAKER SUITE after the installation the supplied sample configuration Demonstration config is loaded automatically The file name of the loaded configuration without file extension is displayed in the title bar of the main window To open the master data of the configuration for display and or editing gt Select the Edit gt Master Data menu command or click the Edit Master Data icon in the toolbar The Master Data window is opened Master Data Dernonstration 14 xm Plants Fumaces amp Glass Types Raw Materials amp Cullet Chemical Components Energy Sources Options Plants Types Name Hoat Glass Soda Lime Glass Tableware Furnaces of Plant Container Glass Name Furnace 2 Furnace 3 Repot Check Save Clase BATCHMAKER SUITE Example of Application 18 The Master Data window is divided into the following tab cards O the Plants Furnaces amp Glass Types tab card you define the plants and the furnaces for which you want to produce glass recipes and batch recipes as well as the produced glass types e g amber glass green glass lead crystal or opal glass
51. to display the data as a report Save As Print Print Preview Page Setup Glass Property Thermal expansion Density Refractive index Dispersion Abbe number Chemical resistance Hydrolytic class Young s modulus Shear modulus Bulk modulus Poisson s ratio Specific heat 20 C Specific heat 800 C Surface tension 1300 C Viscosity log n dPas T NERONE ee NOTE If you want to save the report including the viscosity curve select Web Archive single file mht as file type 700 co en UN ole A ele waj Glass Properties Amber glass 236 0 0023 38 00 1 22 74 42 1 67 1 92 0 92 1000 Temperature T C Glas2 Unit 493 0 008 5181 0 0018 2 87 80 0 96 84 ugNa2O g 70 52 21 88 28 99 0 95 4143 2 817 44 K 1370 107 308 4 47 1300 1600 BATCHMAKER SUITE Example of Application 47 4 8 Calculating Raw Material Usage BATCHMAKER SUITE contains a usage calculator with which you can calculate from arbitrary batch recipes over selectable periods and tonnages the total consumption and the costs of raw materials and cullet gt Select the Raw Material Usage command from the Tools menu or click the icon of the same name in the toolbar The Raw Material Usage window opens Prices As defined batch recipes gt Click the Load button gt
52. y dialog file extension GlassProps dll and click the Open button The new library appears in the Registered glass property libraries list gt Activate the required glass properties in the Available glass properties list NOTE You can adapt the display sequence of the glass properties to your requirements with the Move Up and Move Down buttons In this case you can also mark and shift several glass properties simultaneously with SHIFT or CTRL BATCHMAKER SUITE Commissioning 11 2 6 3 Defining Fixed Points The fixed points for parameter dependent glass properties such as viscosity as function of temperature are defined on the Fixed Points tab card You see in the Glass property dropdown list box all functional glass properties that have been activated on the Glass Properties tab card Gis oops amp Use default fixed points Enter custom fixed points Name T log n dPas C Working point Flow point Littleton paint Annealing point Strain point gt Select the required glass property from the Glass property dropdown list box The fixed points of the selected glass property are displayed in the table As a rule the predefined Default fixed points are sufficient for the calculation However if you want to define your own fixed points gt Activate the Enter custom fixed points option gt Enter the wanted fixed points in the table BATCHMAKER SUITE Basic Operating Principles 12 3 Basic Operating Principle
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