Hybrid Furnace Project

Introduction

Saint-Gobain's Hybrid Furnace Project (HFP) implements and validates the first hybrid glass wool furnace that receives 50% of its heating power from electricity (Boosting). HFP is the result of multiple years of research and development within Saint-Gobain. It provides a more environmentally friendly alternative to flame furnaces that are used to produce molten glass. HFP has been initially implemented at the Saint-Gobain Isover plant in Etten-Leur, the Netherlands. Here, it will lead to a relative greenhouse gas emission avoidance of 22% compared to the reference scenario and an annual reduction in natural gas consumption of around 50 gigawatt hours (GWh).

Environmental Benefits

Saint-Gobain has developed a more environmentally friendly alternative to full flame furnaces for the production of molten glass for its glass wool products. The HFP will implement and validate a glass wool furnace at an industrial scale.

Hybrid Technology

The furnace consists of hybrid technology that electrically heats the glass wool furnace to an unprecedented level of 50% of the required temperature. For the remaining heat requirement, the furnace's combustion process is improved through the injection of pure oxygen, which is supplied by a separately implemented oxygen plant.

Expected Results

The expected results from HFP include:

1. A reduction of greenhouse gas (GHG) emissions.
2. A reduction of natural gas consumption of around 55%.
3. An overall decrease in energy consumption by around 26%.

The absolute greenhouse gas emission avoidance is about 100,000 tonnes CO2 equivalent over the first ten years of operation.

Importance of Glass Wool Insulation

Glass wool insulation is extensively used in buildings all over the world. As well as creating more comfortable homes, effective insulation is also important to create more sustainable homes.

Energy Efficiency

Effectively insulated buildings require less energy for heating, thereby reducing greenhouse gas emissions. However, the production of glass wool insulation is also an energy-intensive production process that emits considerable amounts of greenhouse gases if fossil fuels are used.

Saint-Gobain's Commitment

Saint-Gobain acknowledges this problem and with the HFP, it takes yet another measure to reduce its carbon footprint. The HFP meets both EU climate targets to reduce carbon emissions by 55% in 2030 (compared to 1990) as well as Saint-Gobain's roadmap to its net-zero carbon emission target in 2050.

Replication and Impact

After its first implementation and validation at Saint-Gobain Isover's plant in Etten-Leur, the Netherlands, the HFP can easily be replicated within Saint-Gobain's network of glass wool plants that run flame furnaces.

Potential Impact

The potential impact of implementing the HFP at all of Saint-Gobain's plants in Europe would lead to an additional GHG emissions avoidance of circa 100,000 tonnes CO2 equivalent per year.

Broader Application

In addition, the HFP's technology could also be deployed by other glass wool manufacturers, which would lead to a further decarbonisation of the sector, having a global impact.