How can we reduce our carbon emissions with new furnace concepts and ideas. New ideas only can be safely developed and tested by using validated Computational Fluid Dynamics (CFD) such as GS Glass Furnace Model (GS GFM). It is quite logical that no glass producer will build a new furnace concept melting 100+ tons per day without thorough analysis, calculations and extensive CFD modeling. Lately most glass producers are asking how to reduce carbon emissions with either increasing the amount of electric melting or hydrogen. We have seen in the past such intensive use of CFD modeling when the Oxy-fuel applications emerged. Now with the next generation of large Hybrid (with more than 50% electric boosting) or all Electric melters we can see an increase in demand once again.

“La Maison Française du Verre » (LMFV) is producing borosilicate glass for cookware in its factory of Châteauroux (France). 

Its hybrid furnace is melting around 160 tons per day and its design is improved during each rebuilt, every 5 years, focusing on glass quality and energy efficiency. Currently, the combustion space using oxygen and natural gas, combined with electric boosting within the bath of glass. This configuration has been successful in increasing the electrical energy to a high degree, resulting in significantly reduced CO₂ emissions.

To address the rebuilt needed in 2022, to face the realities of global warming and to tackle once gain CO₂ emissions, “La Maison Française du Verre”, Glass Service a.s and F.I.C worked together during three years to determine what could be the next step for this furnace and its forehearths.

The presentation will be divided into three parts:

• First, we will present an overview of the initial data analysis and all the benefits obtained for the understanding of the furnace and its potential evolutions.  
• Secondly, we will describe a synthesis of the modeling and design work, for the furnace and one of its forehearth, to obtain a final recommendation. There was a redesign discussed in implementing new design features and to convert the entire design into a FIC-HVP-system that potentially can go all Electric with 80% Energy savings.
• To conclude, we will show final results after the rebuilt led during summer 2022  

The final furnace emits only 157 kg of CO₂ per ton molten glass.