SGT - 19th Furnace Solutions

Abstract 1: High-performing bottom paving solutions for efficient and long-lasting hybrid furnaces

The reduction of carbon emission and environmental footprint of glassmaking is a major challenge for glassmakers. Even though some measures can still be taken to increase the energy efficiency of glass furnaces, reaching carbon-neutrality will require technological changes.

Seems to be unavoidable and should grow for all kind of glass furnaces, including for container and float markets.

From increased electrical boosting to hybrid furnaces, electrification brings great opportunities for carbon-emission reduction and new challenges for the refractory lining of the furnaces. Increased electrification often leads to higher glass temperature, and increased convection and velocity inside the melt. Both factors have a significant effect on the corrosion behavior of refractories.

This presentation will describe the modification of the corrosion behavior of glass melting tanks, focusing on the sidewalls and bottom paving through the analysis of industrial feedback and numerical simulation.

Then, we will discuss solutions to help maximizing the lifespan of furnaces while maintaining energy efficiency. The selection of refractory materials with higher corrosion resistance and higher electrical resistivity to minimize the wear and new numerical simulation tools can help finding the desired balance between thermal losses and corrosion rate. 

Abstract 2: Let It Be: Stop Iterating, Start Revolutionizing Glass Furnace Designs 

Over the past century, the glass industry has significantly reduced the specific energy demand for producing one metric ton of glass, from 20 GJ to just 3 GJ. However, further advancements are constrained by thermodynamic limits, as the energy required to transform raw materials into glass through high-temperature processes sets a lower boundary. For instance, melting a container glass batch with 50% cullet requires approximately 2.2 GJ/t, even under ideal conditions without energy losses. Presuming it would be possible to melt a glass without losses, direct carbon emissions from combustion processes and indirect emissions from the electricity generation still cause major carbon emissions. Notably, glass containers have a higher carbon footprint compared to alternative beverage packaging materials like aluminum and PET, underscoring the need for innovation to maintain competitiveness.

As renewable energy sources such as wind, solar, and tidal power become increasingly cost-effective, they present a promising path forward for decarbonizing glass production. However, the variability in renewable energy availability poses a significant challenge for the glass industry, as glass melting demands a continuous and stable energy supply. To achieve net-zero emissions and remain competitive with alternative materials, the industry must embrace innovative furnace designs capable of accommodating variable energy inputs.

In this context, Glass Service is advancing its state-of-the-art Glass Furnace Model—a computational fluid dynamics software designed to pave the way for next-generation furnaces that can adapt to fluctuating renewable energy inputs and drive the future of sustainable glass production.