Hybrid mid-sized pilot furnace for flat glass

Introduction

The objective of the project is to design and build a novel hybrid glass furnace combining electric melting and oxy-gas combustion. The integrated design provides an alternative to the mostly natural gas-fired flat glass industry. The highly electrified furnace offers a more cost-efficient and scalable solution to abate the CO2 emissions of the flat glass industry compared to other clean alternatives, such as a full clean hydrogen combustion option.

Pilot Implementation

The new design will be piloted through a partnership with Saint-Gobain in AGC’s existing patterned glass furnace in Barevka (Czech Republic). The hybrid furnace is expected to reduce the pilot site’s scope 1 and 3 emissions by 75% compared to the reference scenario.

Technology Overview

This first-of-a-kind technology consists of an all-electric melting technology and oxy-gas combustion that are combined in an integrated furnace. This enables a 50% electrification rate while ensuring the high-quality standards necessary for float glass.

Sustainability Model

Furthermore, the sustainability model of the project will be strengthened by substituting virgin raw materials with up to 100% recycled glass. The flat glass sector accounts for approximately 4.6 million tonnes of CO2 equivalent of direct emissions annually in Europe, with around 75% from natural gas combustion and 25% from raw materials. The novel furnace is therefore expected to reduce the energy-related emissions, resulting in a planned emission reduction of over 193,000 tonnes CO2 equivalent over the first ten years of operation.

Contribution to European Goals

The project will contribute to the European goals set out in the REPowerEU communication by reducing fossil fuel consumption in industry and transport through innovative technologies and electrification.

Socio-Economic Impact

The project is also expected to have a positive socio-economic impact at the regional level. While the Barevka site currently produces approximately 90 tonnes of glass a day, the project has great potential for scalability through technology uptake at bigger production sites (600-800 tonnes daily).

Replication Potential

Furthermore, there is significant replication potential throughout Europe, as the industry currently produces around 9 million tonnes of glass annually and is a critical supplier to the construction, automotive, and consumer goods industries. Therefore, the technology could promote the upstream decarbonization efforts of critical sectors (construction and automotive) while safeguarding the competitiveness of the EU flat glass industry.