Headquartered in the Czech Republic, the Glass Service (GS) group posits itself as an energy supply expert on melting glass in the most efficient way, depending on available energy sources and pricing. This know-how and service is supported by the company’s popular GS GFM simulation software.
GS’ Expert System III (ESIII) is rolled out worldwide to glass producers. ESIII dynamically controls furnace operation by means of a proven Model-based Predictive Control (MPC) system which utilises the energy source that is most cost-efficient to be used to melt glass.
ESIII not only brings down energy costs, it also reduces carbon. Typical energy cost reduction is around 3–4%, meaning ROI for most installations is just few months.
Burning hydrogen
Glass Service’s solutions do not stop at software and services. Together with its ‘daughter’ company FlammaTec, GS is prepared and ready as a primary combustion equipment supplier to supply its Carbon Free FT Hydrogen burner. The burner has already been used in demonstration tests to prove that the heat transfer will be similar to that from a natural gas burner.
Realistically, the market does not provide enough green hydrogen supply for all glass furnaces in operation. Most hydrogen currently available is either grey hydrogen – steam methane reforming of natural gas, or blue hydrogen with carbon capture.
For customers that have access to sufficient carbon-free hydrogen or biofuels, Glass Service can simulate an energy transition either with dilution/mixing of hydrogen until there is a 10 or 20% mixture into the natural gas stream, or a full 100% conversion to hydrogen for individual burners or total combustion.
However, the reality is that the short term agenda is not just carbon reduction, and now – especially in Europe – manufacturers must have a reliable heat source (back-up) available. Sufficient green hydrogen availability and pricing can only be expected after 2030 unless you have access to low-cost electricity and invest in an on-site electrolyser. These are not cheap and their efficiency in converting electrical energy into hydrogen energy is (currently) a maximum of 70%. However, in doing so, you will get oxygen as a bonus and this is may be of interest for oxy-gas furnaces.
FlammaTec
For several countries in Europe there may be a shortage of natural gas in the coming months or year(s). FlammaTec has received many urgent requests for oil, diesel or biodiesel backup burners. The good news here is that FlammaTec Germany is an experienced specialist in liquid fuel combustion and has developed the most efficient FlammaTec burner technology for this requirement.
Most FlammaTec gas injectors (burners) can easily be replaced with oil nozzles or even be changed to dual fuel burners, where the inner gas tube is replaced by an oil or diesel nozzle and the outer tube can still fire natural gas in any relative percentage from 0 to almost 100% fuel/gas. These fuels can also be biofuels, such as biodiesel, and therefore help to reduce carbon emissions.
F.I.C.
Specialising in electric boosting design and supply, another daughter company – F.I.C. – can assist with installing electric (super) boosting that can help to reduce carbon emissions and to maintain a furnace energy supply, just in case there is a shortage of natural gas in the near future. F.I.C. has a very experienced team available for hot drilling and installation, if required. Optimal boost position and amount can be simulated by Glass Service prior to installation.
Regrettably, carbon reduction may have to wait somewhat, but help is at hand if there is a drastic energy transition during the coming years.
Image: For customers that have access to carbon-free hydrogen or biofuels, Glass Service can simulate an energy transition.