The most discussed energy carriers\nof the future are electricity and hydrogen. But which is likely to win, or do\nthey both have a future in glass manufacturing asks Rene Meuleman*?<\/p>\n\n\n\n
The entire glass manufacturing\nindustry will need to undergo the biggest technological change since its\ninception in order to comply with the Paris Agreement on climate change, and to\nmeet the demand for carbon free manufactured products coming from its customers.\n<\/p>\n\n\n\n
Being forced to move away from\nfossil fuel towards alternative energy sources will have a huge impact on\ntechnologies, operations and finances. <\/p>\n\n\n\n
All stakeholders involved in the\nindustry have a responsibility to make sure the industry survives, and in that\nrespect, all options need to be investigated. Bearing in mind, that the\nultimate objective is to find the most cost-effective and cost-efficient way of\nmelting glass without emitting CO2. <\/p>\n\n\n\n
Today, the most discussed energy\ncarriers of the future are electricity and hydrogen. <\/p>\n\n\n\n
But which is likely to win, or do they both have a future in glass manufacturing? <\/p>\n\n\n\n
Hydrogen<\/strong> The electrolysis process obviously\nneeds green electricity to split water into hydrogen and oxygen. And even\nthough large-scale hydrogen production based on electrolysis is feasible, it\nloses at least 20% of energy in the conversion. <\/p>\n\n\n\n Therefore, the question arises; why\nnot use the electrical energy in the melting process in the first place? <\/p>\n\n\n\n Thermochemical water splitting\nmethods can use heat powered by solar or nuclear energy without electricity as\nan intermediary. These thermochemical cycle processes are considered to be\npromising, but only for long-term, large-scale hydrogen production. <\/p>\n\n\n\n Be aware: hydrogen is an excellent\nand clean reductant that can be used in steel manufacturing. <\/p>\n\n\n\n However, in glass manufacturing it\nwill only be used as a very inefficient (45% of energy at the most ends up in\nthe glass) heat source, representing a huge waste of energy. In locations where\nhydrogen availability remains insufficient to fully supply the transportation,\nsteel, cement and glass manufacturing industries, those who need it the most\nwill pay for it. In this situation, automotive, steel and cement industries\nwill be the main consumers, leaving little available for glass manufacturing.<\/p>\n\n\n\n As previously mentioned, at least\nanother 20% of energy is lost in the conversion from electrical energy into\nhydrogen; therefore, only around 36% of the initial energy will end up in the\nglass melting process by using hydrogen combustion, compared to around 85% of\nelectrical energy ending up in the process if an all-electric melting system is\nused.<\/p>\n\n\n\n Electricity<\/strong> Also, most container glass furnaces\nare equipped with electrical furnace boosting, either to increase furnace pull,\nmanage darker glass output or a combination of both. It is a common\nmisunderstanding that large all-electric furnaces have never existed, when\nreally, they have! <\/p>\n\n\n\n All-electric furnaces have been\naround for decades, the largest having mostly been decommissioned only due to\ncommercial reasons. <\/p>\n\n\n\n Smaller versions remain in\noperation, new ones have been put into operation and there are perfectly viable\narguments for that. <\/p>\n\n\n\n Smaller all-electric furnaces are\nmore energy efficient by far, in comparison to smaller fossil fuel fired\nfurnaces. <\/p>\n\n\n\n Furthermore, all-electric furnaces\ncan consistently produce a much higher glass quality compared to fossil fuel\nfired furnaces. Emissions are much lower, and all-electric furnaces are easier\nto control. <\/p>\n\n\n\n Natural gas or other alternative\nfossil fuels might be cheaper than kWh\u2019s, but considering the huge energy\nefficiency difference between fossil fuel fired and electric furnaces, together\nwith what needs to be paid for CO2 and other fossil fuel related emission taxes\nand penalties, the break-even point is close. <\/p>\n\n\n\n Recently, the Netherlands\nEnvironmental Assessment Agency, focusing mainly on the established Dutch\ncommodity glass manufacturing industry, rated electric melting with a\ntechnology readiness level (TRL) of 7, against hydrogen rated with a TRL of\njust 4. <\/p>\n\n\n\n Considering the high number of\nall-electric melters in operation, against the number of hydrogen fired melters\nof which there are very few, this seems to put electrical energy far in front\nof hydrogen.<\/p>\n\n\n\n Conclusion<\/strong> It is already understood, with some\nlimitations, that electric glass melting works either in an all-electric or\nhybrid design. It is an established technology and is very energy efficient\neven in larger furnaces. <\/p>\n\n\n\n More research needs to be done to\novercome some specific concerns, like high cullet content, possible issues with\nreducing glasses and refractory wear in all-electric melting. <\/p>\n\n\n\n Perhaps multiple smaller\nall-electric furnaces running in parallel or each supplying only one IS-machine\nneed to be considered, specifically in greenfield initiatives? Testing,\nprototyping, proof of concept and scaling up or scaling down can be done in\nmost existing facilities. <\/p>\n\n\n\n Hydrogen fired furnaces will need\nmuch more R&D and testing, as there is obviously not much experience\navailable to kick start such an initiative. <\/p>\n\n\n\n However, hydrogen can be considered\nin a hybrid furnace design in place of fossil fuel, where it is typically used\nfor only 20% of the energy supply. <\/p>\n\n\n\n This will at least help to move\ntowards the goal of 0% CO2 emissions from the heating system by 2050. Safety\nalso needs to be considered. <\/p>\n\n\n\n What are the implications of having\nhydrogen, possibly in combination with oxygen in manufacturing facilities? <\/p>\n\n\n\n Perhaps the most important remaining\nquestions are: Direct electrical heating is by far\nthe most energy efficient method, but will the local electrical grid be able to\nsupport the amount of energy needed in the future? <\/p>\n\n\n\n Hydrogen can be stored, but only at\nthe cost of losing another big portion of energy efficiency by cooling down\nclose to 0\u00b0K or compressing it up to 600 bar. Will it still be cost efficient? <\/p>\n\n\n\n If opting for hydrogen combustion,\nwould it be advantageous to have both hydrogen and oxygen available to prevent\nNOx emissions? Will the NG grid be able to support that?<\/p>\n\n\n\n What will it truly cost and can glass manufacturing survive? Author: Rene Meuleman,\nBusiness Leader Global Glass at Eurotherm by Schneider Electric<\/p>\n\n\n\n Source: Glass International<\/p>\n","protected":false},"excerpt":{"rendered":" The most discussed energy carriers of the future are electricity and hydrogen. 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\nHydrogen in its pure form doesn\u2019t exist and needs to be produced. There are\nseveral production methods available, but only water splitting by electrolysis\nor thermochemical cycles can produce so called \u2018green hydrogen\u2019. <\/p>\n\n\n\n
\nSince 1902, electric melting has developed into an established, efficient, high\nenergy technology used by many glass manufacturers all over the world,\nspecifically for tableware, borosilicate and insulation glass fibre\nmanufacturing. <\/p>\n\n\n\n
\nNobody should dismiss any possible future technology that might be able to\ncontribute to CO2 free glass manufacturing, without having valid, objective and\nsolid arguments. <\/p>\n\n\n\n
\n
\nWhere will the green energy come from and how can it be supplied to glass\nfacilities? <\/p>\n\n\n\n
It makes sense to figure out the answers to these types of questions first. As part of Schneider Electric, a globally recognized industry partner for energy and sustainability solutions, Eurotherm is able to help find answers and ways for glass manufacturers to move the industry into a green, prosperous future. <\/p>\n\n\n\n