A super-boosted furnace for more sustainable production
Following the partial renovation of Furnace 3 in 2022, the complete renovation of furnace No. 1 at the Chalon-sur-Saône site is a key step in the modernization plan for this iconic plant in the Chalon basin. Specializing in the production of clear glass, furnace No. 1 produces iconic bottles from the Burgundy and Bordeaux regions, as well as specialty products for the spirits, still wine, and food markets, distributed locally, nationally, and internationally.

Thanks to this modernization, the furnace benefits from “super-boosted” technology, increasing the share of electricity in its energy mix. This now stands at 25 percent, thus reducing natural gas consumption to 75 percent. This development allows the Chalon-sur-Saône site to reduce its CO₂ emissions by 11 percent, while increasing its electrical melting power.

This is part of Verallia Group’s overall decarbonization strategy, which aims to reduce its CO₂ emissions by 46 percent by 2030 through the deployment of two new technologies: 100 percent electric furnaces, such as the one inaugurated in Cognac in September 2024, and hybrid furnaces planned for Spain in late 2025 and then in Saint-Romain-Le-Puy in 2026, reducing CO₂ emissions by 60 percent and 50 percent respectively.

Chalon-sur-Saône plant: 113 years of local anchorage and industrial expertise
Built in 1912, the Chalon-sur-Saône site is now the Verallia Group’s largest plant. With its 500 employees and three furnaces, the factory produces nearly a billion bottles each year. Recognized for its expertise in white glass, it notably produces the famous “dead leaf” colour, characteristic of Burgundy wines.

Source: Verallia France with additional information added by GlassBalkan

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In response to this challenge, HORN is taking significant strides forward, positioning itself at the forefront of the industry’s decarbonisation efforts. With a strong commitment to climate-neutral packaging, HORN has developed and evaluated hybrid furnace technology as a promising solution to reduce carbon dioxide emissions in glass production.

Understanding Hybrid Furnaces

Hybrid furnaces represent a groundbreaking innovation in glass manufacturing, aiming to replace a substantial portion of the natural gas traditionally used in the melting process with electricity. HORN defines a hybrid furnace as any system that combines electric power with fossil fuel, thus requiring both energy sources for optimal operation. Depending on the specific design of the furnace, the electric contribution can vary widely, ranging from 20% to as much as 80%.

This flexibility allows manufacturers to adapt their energy inputs to meet varying production needs while significantly curbing emissions. In particular, the combustion architecture of HORN’s hybrid furnaces, which features strategically placed oxygen burners along the side walls, enables precise control of temperature distribution. By dynamically adjusting gas distribution, operators can optimize the energy usage in different sections of the furnace. For example, when a higher electric share is utilized, the gas distribution can be redirected predominantly towards the refining area, with melting primarily powered by electrodes. This innovative configuration enhances energy flexibility well beyond that of traditional Hybrid End Fired Furnaces.

Environmental Impact and Efficiency

One of the most compelling advantages of HORN’s hybrid furnaces is their potential to drastically reduce CO2 emissions in the glass melting process. With configurations allowing for operation with up to 80% electric power, manufacturers can achieve a reduction of CO2 emissions by up to 50% compared to conventional fossil-based oxyfuel furnaces during the melting phase.

This technology not only addresses the environmental impact but also enhances operational efficiency. The hybrid furnaces are characterized by several key features:

– Low Carbon Footprint: Substantial reduction in greenhouse gas emissions compared to traditional methods.
– Electric Energy Input Up to 80%: Significant flexibility in energy sourcing allows for optimized operational efficiency and sustainability.
– Flexibility of Electric Boosting: Operators can adapt energy inputs to enhance performance based on production needs.
– High Glass Quality: Maintaining product integrity while utilizing diverse energy sources.
– Low Specific Energy Consumption (< 3 GJ): More efficient energy use translates to cost savings and reduced environmental impact.

Join HORN at Glasstec 2024

As the glass industry leans towards sustainable practices, HORN is proud to showcase the future of glass melting technology. At Glasstec 2024, HORN will present its latest innovations in the form of Hybrid Furnaces, Super Hybrid Furnaces, and All Electric Furnaces. We invite you to discover the transformative possibilities of using electrical energy in glass production by visiting our booth C32 in hall 13.

By embracing such innovative technologies, HORN is not only advancing its own capabilities but also contributing significantly to the glass industry’s collective goal of achieving climate neutrality. Together, we can pave the way towards a more sustainable and responsible future in glass manufacturing.

Source:Horn Glass Industries with additional information added by GlassBalkan

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In an extraordinary stride towards sustainable glass production, Ardagh Glass GmbH, a prominent division of Ardagh Glass Packaging (AGP) – Europe, has embarked on the construction of an innovative hybrid furnace at its glass manufacturing facility in Obernkirchen, Germany. This cutting-edge technology, aptly named the ‘NextGen’ furnace, promises to revolutionize the industry by facilitating a seamless transition to renewable electricity. The introduction of this hybrid furnace marks a momentous milestone in Ardagh’s ambitious decarbonization journey, contributing to the company’s 2030 Sustainability Strategy and significantly reducing CO2 emissions.

Setting a new standard with hybrid electric furnace technology

The NextGen furnace, a remarkable feat of engineering, will operate primarily on renewable electricity, with a small proportion of gas supplementation. This groundbreaking hybrid configuration will enable the furnace to capitalize on renewable energy sources while utilizing a substantial amount of recycled glass cullet. Anticipated to produce up to 350 tonnes of glass bottles per day, with a primary focus on amber glass and the ability to create various other colors, this state-of-the-art facility is poised to become a trailblazer in sustainable glass manufacturing.

A quantum leap towards decarbonization

Traditionally, glass production relies on a mix of approximately 90 percent gas and 10 percent electricity. However, the NextGen furnace seeks to revolutionize the energy landscape by inverting this ratio, favoring an impressive 80 percent renewable electricity and 20 percent gas. This shift in the energy mix will revolutionize the carbon footprint of glass packaging, substantially reducing its environmental impact.

Martin Petersson, CEO of AGP – Europe, affirmed, “Decarbonization is at the core of our business strategy, aligning with the aspirations of our valued customers. The NextGen Furnace represents a significant investment in fostering a sustainable future for glass packaging. We are committed to implementing this groundbreaking technology across other AGP facilities in the coming years, as we pursue our steadfast commitment to low-carbon solutions. We extend our heartfelt appreciation to BMWK* and KEI for their generous grant support, instrumental in making this technological breakthrough a reality.”

Pioneering sustainable initiatives for a greener future

Annelene Ikemann, Sustainability Director at AGP – Europe, emphasized, “As a leading supplier of sustainable, infinitely recyclable glass packaging, AGP takes great pride in unveiling the NextGen Furnace as an integral component of our Sustainability Roadmap. By combining this innovative furnace with our goal of achieving 100% renewable electricity supply to our facilities by 2030, we are taking a significant step forward in our commitment to a low-carbon future. In subsequent phases of this project, AGP aims to replace the remaining gas with green hydrogen, further reducing greenhouse gas emissions. Additionally, we will explore a wider range of alternative melting technologies as we advance our sustainability journey across our global facilities.”

Embracing a sustainable paradigm

Ardagh Glass is steadfast in its commitment to decarbonize glass production processes worldwide, with a resolute vision to replace conventional gas-powered furnaces with low-carbon alternatives across all Group manufacturing operations. By pushing boundaries, embracing innovation, and prioritizing sustainability, Ardagh Glass paves the way for a greener and more sustainable future in the glass packaging industry.

Source:  Ardagh Glass Packaging (AGP) – Europe with additional information added by GlassBalkan

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