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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This innovative approach to product visualization aims to provide customers with a clear and engaging understanding of the advanced technology behind these high-performance machines.

Customers can now experience a virtual tour of the TK Lamijet ovens, gaining valuable insights into their inner workings and key features. This commitment to customer support reflects TK’s dedication to empowering clients with the knowledge they need to make informed decisions.

The TK Lamijet product range represents a significant advancement in glass lamination technology. These ovens are engineered to meet the demanding requirements of the industry, offering a combination of robust construction, advanced heating systems, and user-friendly controls. Key features highlighted in the 3D video include:

• Durable construction: built with high-quality European materials and components, ensuring long-lasting performance
• Uniform heating: advanced radiation technology and a multi-zone system provide precise temperature control and even heat distribution across the glass surface
• Hybrid heating technology: an air mixer combines radiation and convection, resulting in faster heating cycles and improved uniformity
• Rapid cooling: a forced cooling system reduces lamination cycle times, allowing for quicker turnaround and increased productivity
• Versatile compatibility: the ovens accommodate a wide range of interlayers, making them suitable for diverse lamination projects
• Intuitive interface: the user-friendly control panel simplifies operation, even for those with limited technical expertise

Explore the new 3D TK Lamijet video and dive into the future of 3D videos technology.

Source: TK Srl with additional information added by GlassBalkan

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This scheduled halt in operations marks the beginning of a transformative revamping process aimed at integrating a state-of-the-art furnace design that promises significant advancements in sustainability by slashing direct CO2 emissions by an impressive 75 percent.

In 2023, Saint-Gobain Glass joined forces with AGCin a collaborative development project designed to revolutionize flat glass manufacturing. By leveraging their respective complementary technologies, the two companies are working towards the creation of a technologically advanced hybrid furnace. This innovative system will serve as a benchmark for the future of glass production, being powered 50 percent by electricity and the remaining 50 percent using a sophisticated mixture of oxygen and gas.

Currently, the Barevka facility is undergoing extensive modifications to accommodate this cutting-edge technology. Most preliminary studies and procurement processes have reached completion, and the project team is diligently orchestrating the efforts of various professionals on-site to facilitate the construction of the new furnace. This collaborative approach aims to ensure that the transition to the new system is as seamless as possible.

As the revamping progresses, preparations for the production start-up are already underway. The commissioning phase includes a comprehensive plan for testing all equipment and process components to guarantee a successful launch of the new furnace. Furthermore, the production team is receiving thorough training to equip them with the necessary skills to operate this groundbreaking industrial tool effectively.

Anticipated to begin operations in early 2025, this endeavor is part of the “Volta” project, which is generously supported by the Innovation Fund of the European Union. Through such initiatives, Saint-Gobain is not only aiming to enhance its production capabilities but also contributing significantly toward a more sustainable future in the glass manufacturing industry. The commitment to reducing environmental impact while maintaining high-performance standards exemplifies the forward-thinking approach that defines modern industrial practices.

Source: Saint-Gobain Glass 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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Steklarna Hrastnik, a leading glass manufacturer, is approaching the final stages of construction for its cutting-edge hybrid glass furnace in Hrastnik, Slovenia. This state-of-the-art facility marks a significant milestone in the company’s commitment to sustainable and efficient glass production.

Introducing the BEAR Project: Pioneering Hybrid Glass Furnace

Through its pioneering project, the BEAR (Hybrid Regenerative Glass Furnace), Steklarna Hrastnik is set to unveil a one-of-a-kind hybrid end-fired regenerative furnace. The construction of this ground-breaking furnace commenced in September 2022, with a projected operational launch in the first quarter of 2025.

A Leap Towards Sustainability: Achieving Unparalleled Efficiency

The new hybrid furnace will replace the existing end-fired regenerative furnace specifically designed for extra-white flint glass production. This upgrade is expected to yield exceptional results, with a remarkable reduction of over 50% in natural gas consumption and a significant 33% decrease in greenhouse gas emissions over the furnace’s initial decade of operation.

Exceptional Features and Capacity

Featuring an impressive electrical melting share surpassing 40%, the hybrid furnace boasts a substantial throughput capacity of 170 tons per day (tpd). These advanced capabilities will empower Steklarna Hrastnik to elevate its glass production efficiency to unprecedented levels.

Driving Economic Growth and Inspiring Industry Transformation

Beyond its environmental benefits, this substantial investment in sustainable production technologies will have a profound impact on the local economy. By preserving existing jobs and creating new employment opportunities, Steklarna Hrastnik aims to foster growth and prosperity within the region.

A Beacon of Decarbonization: Leading the Way for Energy-Intensive Industries

Steklarna Hrastnik’s hybrid glass furnace is not only an industry game-changer but also serves as a guiding light for decarbonization efforts in energy-intensive sectors. By integrating innovative technologies with locally sourced renewable energy, this pioneering project paves the way for the sustainable transformation of other industries in the region.

Source: Steklarna Hrastnik with additional information added by GlassBalkan

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