MAnufacturing of Glass through iNnovative hybridisation Up-Scaling

Introduction

The MAGNUS project aims to decarbonise the domestic glass industry through partial electrification of the furnace. This main intervention is coupled by forehearth conditioning insulation, gas exhaust control, and thermal imaging monitoring inside the furnace. This combination of insulation and control will contribute to optimising combustion and therefore lower energy consumption.

Energy Sources

As part of the project, photovoltaic (PV) panels are installed nearby to provide part of the required electricity. Natural gas is partially replaced by a volume of 100 Standard Cubic Metres per hour (Sm3/h) of biomethane, meaning that 18% of natural gas needs are replaced by certified biomethane. The combination of these technologies will allow a relative greenhouse gas (GHG) emission avoidance of 25% compared to the reference scenario.

Technological Innovation

The MAGNUS project is innovative both with respect to the commercial and the technological state-of-the-art because of the high share of electrification (35%) of the glass melting process. The current share in the European glass industry is 10-20%, and increasing this amount to 35% would significantly reduce emissions.

This project involves changes to traditional furnace management with the electric booster covering the energy baseline needs and gas providing the remainder of the required energy. The MAGNUS project will lead to a new glass furnace management, further reducing GHG emissions. Additional savings are expected through:

1. Forehearth conditioning insulation
2. Digital combustion controls (laser gas sensors and thermal imaging cameras)

Policy Impact

The MAGNUS project will provide relevant policy feedback for the glass industry and will help achieve the EU Green Deal and REPowerEU targets. The substantial increase in electricity use as melting support also requires a diversification of energy sourcing to the industry.

The use of locally installed PV panels supports the transition to independent, secure, and sustainable energy. The furnace will still be partly heated by gas but will transition to using biomethane to reduce overall emissions and strengthen the biomethane supply chain in Italy and, more broadly, Europe.

Environmental Benefits

Sustainable production will reduce GHG emissions of the industry and help sustainable glass to replace single-use plastics, further supporting the reduction of emissions in our society. These actions are in line with the strategy to reduce single-use plastics and the EU Circular Economy action plan.

Economic Impact

This project can positively impact the local economy, especially in terms of added value and supply chain sustainability. The glass industry represents a strong asset in the economy of the region of Emilia Romagna in Italy. Therefore, the sustainable transition of such an important sector will be beneficial for the economy and the environment.

In addition, the supply chain of biomethane from local agricultural sources is strengthened.