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Carbon Reduction by Auxiliary Firing TEchniques for glass Melter (CRAFTEM)
Start date: May 1, 2012, End date: Apr 30, 2015 PROJECT  FINISHED 

Each year, the EU’s Primary glass melters producing container and flat glass consume some 150 PJ of energy and emit some 10 Gigatonnes of fuel related CO2. Most of the EU’s large glass melting furnaces already employ reversing regenerators to achieve a thermal efficiency of 50% or more, a very good figure for a process operating at about 1600˚C. The industry is facing conflicting challenges to reduce its carbon emissions while respecting ever tighter limits on nitrogen oxide emissions since increasing heat recovery from the exhaust gases through the use of more regeneration would result in an increase in NOx emissions. Responding to this challenge, three of the partners in the present proposal have developed and patented a new combustion strategy for glass melters (Auxiliary Firing). Auxiliary Firing has been shown on a glass furnace simulator to offer up to 5% direct energy savings. It also reduces NOx emissions to meet the 2009 EU limits offering further indirect energy savings by avoiding the energy currently consumed by some exhaust gas NOx clean-up processes (a further 5 to 10% of furnace fuel in some NOx reduction processes).The CRAFTEM proposal brings together the Auxiliary Firing developers and two major Glass Makers with the objective of demonstrating the new combustion process on two full scale glass melters. The demonstration furnaces will represent the two major firing configurations (cross-fired and end-fired) currently used on the majority of the EU’s glass melters. The aim of the demonstrations will be to show that Auxiliary Firing will yield the expected Carbon Savings while maintaining glass output and quality, and reducing NOx emissions to the 2009 EU limits. A successful demonstration will allow immediate replication of the new firing technique within the operation of the two glass making partners, and subsequently throughout the EU Glass Sector.

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