Glass Lyon 2026

Abstract 1: Advanced Modelling for Regenerator Design Optimization: Driving Energy Efficiency in Glassmaking.

Reducing the carbon footprint of the inherently energy-intensive glassmaking process is a major challenge. Achieving this goal will require a gradual technological transition, starting with incremental improvements to existing solutions and progressing toward groundbreaking innovations in the long term.

When it comes to mature technologies, regenerative furnaces have already delivered substantial energy savings in the glass industry over the last decades. Despite this progress, ongoing efforts by SEFPRO and Glass Service indicate that further optimization of regenerators is still possible. An optimal regenerator design should strike the best balance between energy efficiency (and thus CO₂ reduction), maintenance requirements, lifetime, and, of course, CAPEX.

Recent enhancements to Darcy porous wall models for standard checker bricks and Cruciforms® geometries now enable more accurate numerical simulations to address regenerator optimization. This advanced modeling approach can simultaneously define the most efficient and durable packing configuration and determine the most appropriate regenerator chamber size, while respecting typical space and CAPEX constraints. It also allows seamless integration of regenerators with the furnace in a comprehensive and reliable simulation.

The first part of the presentation will cover the methodology used to build an extended library of Darcy porous wall models. Then, we will present a concrete regenerator optimization case study for a cross-fired furnace. Specifically, we will show how chamber dimensions can be reduced without compromising regenerator efficiency, thanks to careful engineering of packing configurations tailored to the specific requirements and conditions at each furnace port.

Abstract 2: Optimizing High Boosting Furnaces: A Modeling Approach towards Innovative Solutions 

In the context of the glass industry's transition to decarbonized glass production, the adaptation of melting technologies is critical. 

This study emphasizes the role of advanced modeling techniques in understanding and optimizing electric melting processes in highly boosted furnaces.We begin by modeling the effects of high electrical power on fused cast refractories, identifying key challenges that glass producers face in this transition. Our modeling closely replicates a series of test campaigns, allowing for a detailed analysis of critical parameters of glass as well as refractory materials. Operating parameters, such as the amount of electrical power and the impact of the electrode heights are also investigated.

Through our expertise in numerical simulation and experimental testing, we aim to provide valuable insights that will guide our customers in selecting the most suitable solutions for their high boosting furnaces. This research not only addresses immediate operational challenges, but also anticipates future demands and complexities associated with sustainable glass manufacturing.

Abstract 3: Decarbonization Pathway of the Glass Industry, Challenges, Opportunities for Different Segments and Possible Solutions Regarding Different Energy Inputs

The European Union has established stringent targets for CO₂ emissions over the next 30 years. By 2030, emissions must be reduced by 55% compared to 1990 levels, with the ultimate goal of achieving climate neutrality by 2050. It is evident that these ambitious targets cannot be achieved using current furnace designs. 

The International Commission on Glass (ICG) has a pivotal role in fostering collaboration and knowledge exchange across regions by organizing conferences focused on sustainability.

To achieve meaningful reductions in carbon emissions, innovative furnace designs and new technologies must be developed. Such advancements require the use of validated Computational Fluid Dynamics (CFD) tools like the GS Glass Furnace Model (GS GFM). No glass producer would risk building a new furnace concept capable of melting over 100 tons per day without rigorous analysis, calculations, and CFD modeling. Recent trends show increasing interest in reducing carbon emissions through greater reliance on electric melting or hydrogen, similar to the widespread adoption of CFD modeling during the rise of oxy-fuel technologies. Now, with the next generation of large hybrid furnaces (with over 50% electric boosting) or fully electric melters.

These complex furnaces, with multiple heat inputs, also require advanced control systems, such as Model-Based Predictive Control, to optimize the balance between electricity and natural gas usage. This approach considers fluctuating costs and aims to maximize carbon reduction.

Abstract 4: How Numerical Simulation Can Reveal the Underestimated Criticality of Refractory Block Thermo-Mechanical Behavior on Glass Furnace Lifetime

The thermo-mechanical behavior of refractory materials has often been underestimated regarding corrosion evolution and glass tank expected duration.
The lifetime of soldier blocks is partially driven by their mechanical behavior during the heating-up phase—a critical period for the formation of stresses and cracks at early stages of furnace operation—and by the evolution of these stress patterns during block wear. Indeed, crack formation can significantly accelerate localized corrosion processes, such as upward-drilling corrosion.

SEFPRO has developed an original approach, thanks to FEM modeling, to assess strain and stress fields inside refractory blocks during these different periods using numerical simulation. We developed a 3D model that integrates SEFPRO in-depth knowledge of refractory materials' thermal and mechanical properties as a function of temperature. This allows us to take into account the complex thermal expansion behavior linked to the zirconia crystallographic phase transformation in fused-cast AZS, as well as stress relaxation by visco-plastic behavior.

The impact of different parameters, such as heating-up conditions and block cooling methods used to limit corrosion, will be discussed in the presentation. Based on these results, SEFPRO can support glassmakers in their refractory lining design, cooling processes, and heating-up strategies to optimize glass furnace lifetime.

This new numerical tool opens very interesting perspectives for understanding and improving refractory material corrosion resistance in glass furnaces.

Abstract 5: Refractory corrosion - A problem that could be predicted?

The corrosion of refractory materials is a critical aspect for the lifetime of a furnace operation. Whilst some parts of the furnace are almost untouched after stopping the production, others are almost completely dissolved. It is therefore of the highest importance knowing the critical areas, using appropriate methods for protecting them and monitoring them during the production.

As Glass service (GS) is a part of the SEFPRO now, the cooperation on the corrosion modelling became much easier -> GFM (software internally developed in GS for glass melting processes simulations) provides the necessary boundary conditions for SEFPRO’s corrosion model. The result of such cooperation is a corrosion profile in examined area. After fining the critical part in the furnace, different ways can be used to enhance the lifetime of the critical structure.

An example of such approach will be demonstrated.

Target of this cooperation is to prolong the lifetime of the glass furnace and thus help decreasing the costs and increase the sustainability of the production.

Abstract 6: The Glass Crisis: Are Glass Containers Obsolete Before Net-Zero?

Glass has many faces, and it has allowed human mankind to explore the universe and understand nature, it connects people around the world and brings brightness and warmth to homes. The glass industry played a crucial role in the fight against Covid as it provided vials to safely store billions of vaccine doses, but the industry is facing a crisis due to economic, environmental and technological pressures.

In the race towards net-zero the lack of renewable energy, unfair regulations, and misleading advertisements the pressure from alternative materials rises. Glass as beverage packaging material in particular must compete with alternative materials like aluminum, PET, and different material composites. Each material claiming to be more environmentally friendly as less greenhouse gas emissions are related to the production process, or the transportation is environmentally friendly due to lightweight packaging, while hiding the end-of-life emissions.

Amongst other reasons the increased competition with alternative materials lead to a decrease of the global container glass manufacturing capacity by 5%. This paper aims to raise awareness of the ongoing market transition and to shed light on the environmental impact of materials.