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Factory for the production of float glass in the city of Zarafshan, Uzbekistan.

Functional Purpose Float Glass Production Plant in Zarafshan, Uzbekistan
Address Zarafshan, Uzbekistan
Plant Capacity 300 tons per day
Land Area 20.94 hectares
Total Facility Area 41,243 m²
Design Year 2018-2021
Design Stages Concept Design, Detailed Design, Author’s Supervision, Commissioning
Chief Architect Alexander Saratov
Technology German company “HORN”
Architects Alexander Saratov, Natalia Shabotinska, Maria Litvinenko, Sergey Lemekhov, Alexey Muras, Denis Bozhko, Svetlana Podkopay, Vladislava Shevchenko, Anastasia Pluzhnikova, Ruslan Sarana, Alexander Danchenko, Sergey Belitsky, Anna Yaroshok

For the construction of a float glass production plant, the crucial factor is the availability of raw materials – sands and energy sources. These conditions are met in the vicinity of the city of Zarafshan.

The planned area of the plant is part of the industrial zone of Zarafshan, situated in its western part. The entrance to the plant’s territory is from two sides: 1st from the side of the highway leading to Uchkuduk (A379), and 2nd from the side of the local road within the industrial zone of the city.

The territory is located 200 meters away from residential buildings, and the distance to the emission sources of the plant is more than 500 meters.

Around the planned plant, there are structures of various purposes, industrial, communal, and other objects of the Zarafshan industrial zone, in compliance with sanitary and environmental norms.

According to the technological requirements of this type of production, the following buildings and structures are envisaged:

Production building (No.1 according to the master plan) – located along the main axis, from south to north. The production line is situated inside the building, consisting of:

– Glass melting furnace section (1.1),
– Molten bath section (1.2),
– Lehr annealing section (1.3),
– Glass cutting line section (1.4),
– SО2 storage area.

Building of the finished product warehouse (No.3) – it includes an area for storing packaging material, charging, washing of loading equipment, and areas for truck loading. The warehouse occupies a significant part of the area and is positioned so that the loading area faces south. A turning platform for maneuvering trucks and entry for loading is arranged in front of the loading area.

Heat utilization installation with a smokestack (No.2) – located on the north side of the production workshop, where the scrubber (2.1) is also situated for purifying exhaust gases from nitrogen dioxide.

Raw material blending workshop (No. 4.1) – due to technological features, it is located near the main production and glass furnace (in the eastern part of the area). It produces the mixture used in glass production.

Raw material warehouse in “big bags” (initial raw material) (No.5) – located on the eastern side of the area.

Glass cullet warehouse (No.4.4, 4.5, 4.6) – consists of three sections and is located near the lehr building and the glass cutting and packaging section. It is connected by a transport gallery to the cutting section and the lehr section.

Shipment of charge transport gallery (No. 4.2) – above ground with a height of at least 5 meters above the roadway.

Administrative and residential building (No.11) – located in the southern part of the area in front of the loading area.

Power unit (No.7.1) – including a reverse water supply station, electrical substations, diesel generator room, and nitrogen workshop. The power unit is located on the west side of the molten bath section.

Diesel generators are installed in a separate room in the power unit (No.7.1).

Area for nitrogen and hydrogen storage, and a mixing station, consisting of areas for storing nitrogen and hydrogen containers, is located on the west side of the area.

SO2 storage area – an addition to the molten bath section is located on its west side.

Railway development area (No. 15) – is planned in the eastern part of the area.

Fuel storage warehouse (No.9) – underground, used for backup power for the furnace in case of gas supply failure and for diesel generators in case of power failure in the production network, located on a separate platform in the northwest part of the area.

GRP1 (No.20.1) (gas distribution point) is located at the gas inlet to the area from the side of the main gas pipeline from the northwest side of the area. The other two GRPs (No.2 and No.3) are located.

Stormwater treatment facilities – located in the northern part of the area, consist of two evaporative ponds.

Checkpoint 1 (checkpoint No.10) existing – located at the entrance and exit from the plant’s territory from the northwest side.

Truck scales (No.25.3) – located at the entrance, near Checkpoint 2.

On the west side of the area, tanks with fire and technological pumps (No.19) are designed.

In addition to the listed, the project includes the construction of parking lots separately for passenger and cargo vehicles in the transport areas near the plant’s entrance. The operating mode of the main production and technologically related auxiliary productions is continuous.