16 minute read
Editor’s Comment International news
GREG MORRIS, EDITOR
Facing up to some huge challenges
The last two years has seen some colossal news stories impact the glass industry.
Starting with the Covid-19 pandemic, the past 24 months has been a rollercoaster journey for those involved in the sector.
From the apocalyptical start of the pandemic and the closure of the hospitality sector, to glass’s status as an essential industry and the gradual recovery in demand for glass from end consumers, there has never been a dull moment.
Its latest headwind lies in the challenge of rising energy costs, exacerbated by the conflict in Ukraine. Not only has this increased energy costs but added to the shortfall in raw materials for the sector.
All the while, the industry has also faced up to the ongoing challenge of sustainability and innnovation in order to decarbonise.
The twin pillars of decarbonisation and the energy crisis are linked: why depend on overseas energy from an unpredictable source when it is possible to channel ‘green’ energy from closer to home? Thanks to innovation and inspiration, more glass manufacturers are moving forward. A glimpse of our news pages this month reveals agreements between a number of companies intensifying their efforts to go green.
While energy prices will continue to rise across the supply chain in the short term, the effort to decarbonise must remain a long-standing priority. FRONT COVER IMAGE: www.pennine.org
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AGC and E.ON sign first green PPA in France
AGC and E.ON signed the first green Power Purchase Agreement (PPA) in France to improve energy efficiency and decarbonisation.
The joint project will tackle waste heat recovery and production of green power at AGC‘s float glass plant in Seingbouse, France.
The project will be developed, implemented, financed and operated by E.ON and supported by the French Government as part of the ‘France Relance’ plan set up by ADEME (French Environment and Energy Management Agency).
Both parties have agreed to structure the project as PPA where E.ON will produce and sell electricity to AGC on a long-term basis at fixed price. This will allow AGC’s site to become largely independent of volatile energy markets.
At AGC’s Seingbouse site, heat will be recovered to generate CO2-neutral electricity by implementing an innovative Organic Rankine Cycle (ORC) plant with a capacity of 1.3 megawatts (MW).
To further decarbonise, E.ON is also installing a photovoltaic power plant with a capacity of 2.7 MW on the factory’s premises. It will generate renewable electricity on a total of 27 000 m2.
By combining the photovoltaic panels with the ORC power plant, E.ON will annually provide AGC with around 10 gigawatt hours (GWh) of decarbonised electricity from 2023 onwards.
This electricity is fully produced and consumed on AGC’s site and covers a large part of the electricity needs. On this basis, around 595 tons of CO2 are annually avoided.
Marc Bartheld, Plant Manager AGC Seingbouse, said: “Our plant is one of AGC’s larger production lines for the building sector with a yearly production of 240,000 tons of float glass. Our goal is to reduce our greenhouse gas emissions by 30% and our energy consumption by 20% by 2030.
“To achieve this, we are constantly working to improve the environmental performance of our production sites.
“The project in Seingbouse here in France is a perfect example of how E.ON can help us to not only achieve our sustainability goals, but also to secure the site’s long-term competitiveness.”
Nippon Electric Glass melts Nippon Electric Glass melts glass with hydrogen glass with hydrogen
Nippon Electric Glass (NEG) has succeeded in melting glass with combustion technology using a hydrogen-oxygen burner.
The company has demonstrated the melting of glass using hydrogen fuel from a hydrogen-oxygen combustion burner, developed in collaboration with Taiyo Nippon Sanso Corporation.
The newly developed hydrogen-oxygen combustion burner can change the mixing ratio of natural gas and hydrogen as appropriate.
In the demonstration, it was confirmed that in either combustion method used, only hydrogen or a mixture of hydrogen and natural gas, a melting capacity equivalent to that from natural gas combustion could be obtained by adjusting the flow rate of fuel according to the mixing ratio.
This enabled oxygen combustion technology and hydrogen combustion technology to be combined, thereby resulting in zero CO2 emissions from combustion.
Oxygen combustion technology removes more excess nitrogen than air combustion, thereby reducing the amount of exhaust gas/ heat. It has been introduced in almost all melting furnaces of the company.
For glass melting, NEG promoted the switching of fuel from heavy oil to LPG and natural gas, which generate less CO2, and completed the conversion to natural gas in 2010.
The company has set the “promotion of carbon neutrality” as a priority measure and is working on the technological development of CO2-free fuels, such as hydrogen, to achieve carbon neutrality by 2050.
Hydrogen-oxygen combustion technology is expected to contribute significantly to carbon neutrality through its combination with the power ratio of melting energy, which the company has been working on for some time.
The company will continue to develop the technology toward application as a mass production process.
Nosotros releases 100% recycled glass bottles
Nosotros Tequila & Mezcal will produce 100% recycled glass bottles for all products.
The shift to 100% recycled glass bottles aids Nosotros’s sustainability goals by removing millions of pounds of glass waste from landfills, emitting lower CO2 levels, and reducing production resources.
Crafted in Jalisco and Oaxaca, Mexico, Nosotros Tequila and Mezcal products are sustainable, small-batch, 100% agave, gluten-free and Kosher.
NEWS IN BRIEF
Monofrax acquisition
Saint-Gobain Performance Ceramics has acquired the US refractory producer Monofrax, from the German fund Callista.
Saint-Gobain said the acquisition would help accelerate its growth in the refractory industry. SaintGobain Ceramics Business Unit is led by Nicolas Miegeville. Both SEFPRO and PCR (Performance Ceramic Materials) belong to this BU.
Vidrala’s CO2 success
Vidrala’s CO2 reduction targets have been validated by the Science-Based Targets initiative (SBTi)*.
The manufacturer aims to reduce its Scope 1 and 2 greenhouse gas emissions by 47%, and its Scope 3 emissions by 28% by 2030.
The Science-Based Targets (SBTs) will aid in the prevention of rising the planet’s temperature more than 1.5°C compared to preindustrial levels.
Glaston receives €4 million order
Glaston has received an order for an advanced flat tempering line from a North American glass manufacturer.
A North American glass manufacturer required additional capacity with a quality end product.
The tailored line, with automation and flexibility for high capacity thin and thick glass production, met the customer’s needs.
Gerresheimer growth
Pharmaceutical and cosmetics glass manufacturer Gerresheimer has reported record revenue growth. In its latest financial note, the German headquartered group reported revenue of €1,497 million last year, an increase of 7.6%.
Dietmar Siemssen, CEO, said: “The results show our strategy is paying off: We are turning Gerresheimer into the leading provider of solutions and systems for the healthcare and beauty industry.”
NEWS IN BRIEF
Sisecam launches GlassTool
Sisecam has renewed its Performance Calculator under the name of Sisecam GlassTool.
The Performance Calculator, in which performances such as light transmittance, solar factor, and U value of the combinations created by changing the thickness and properties of Sisecam’s flat glass products can be achieved, has been renewed under the name of Sisecam GlassTool.
Schott plots Turkish factory opening
Schott has been present in Turkey since 1988 and currently has around 700 employees at its two sites in Çerkezköy and Bolu.
A new factory will be starting operations in Bolu in spring 2022, which will increase the manufacturing volume at the site by 50%.
Sibelco has announced offered a tender offer for 100% of Polish glass recycler Krynicki Recykling’s shares Krynicki Recykling is the largest glass recycler in Poland, and Sibelco has offered PLN23 per share.
O-I receives $3.5 million funding boost
O-I Canada will receive $3.5 million in government funding to modernise its Montréal plant.
The Canada Economic Development for Quebec Regions (CED) will provide the repayable contribution as part of a nearly $40M investment from the Government of Canada for green projects.
The company plans to acquire digital production equipment to increase the amount of recycled glass introduced into the production line at its Montréal plant. The expansion project will enable up to 75,000 tonnes a year of cullet and glass to be diverted from landfill sites.
Pilkington UK has become the world’s first flat glass manufacturer to fire its furnace on 100% biofuel, as part of an industry trial to find sustainable alternatives to natural gas.
A sustainable biofuel made from organic waste materials powered the St Helens furnace entirely for four days, creating 165,000ft2 of the lowest carbon float glass ever made.
The fuel emits circa 80% less CO2 than traditional natural gas used in the sector.
The trial forms part of a £7.1 million project led by industry research and technology organisation Glass Futures, working under the Department for Business, Energy and Industrial Strategy’s Energy Innovation Programme.
It aims to demonstrate that the furnace could run safely at full production on the lowcarbon fuel without impacting product quality.
Neil Syder, managing director at Pilkington UK, said: “Our world-first trial with Glass Futures proves how biofuel presents a realistic low-carbon alternative to natural gas, which will allow manufacturers to cut thousands of tonnes of CO2 from their production years ahead of alternative zerocarbon options becoming more readily available.
“Last Summer, we became the first glass manufacturer in the world to fire a furnace with hydrogen, which represented a major step forward towards our future as a net-zero industry. But a significant body of work remains before hydrogen and electrification become feasible alternatives to natural gas for glassmakers, making biofuels an important transitionary fuel.
“The success of this trial is also important for the many sectors that rely on glass as an integral supply chain material. We’re now far closer to glass with less embodied carbon being accessible, which will help developers to create a more sustainable built environment.”
Aston Fuller, General Manager at Glass Futures, said: “It is great to see a technology demonstrated on a container furnace one year ago be adopted onto a float line just one year later.
“Biofuel represents a real short-term opportunity for the UK glass sector to lead the way in sustainability among energy intensive industries, and this trial is another great example of what can be achieved when industry, academia and public partners work together to tackle the major challenges and opportunities of the future.”
In a glass furnace, burning gas is pumped into a 20-metrelong chamber to heat it to 1,600 degrees celsius, causing raw materials including sand and recycled glass to melt to the consistency of treacle. This is then floated on top of a bath of molten tin, making the glass perfectly flat before being cooled.
Pilkington UK fired hydrogen on its glass furnace in August 2021 in a worldfirst trial as part of the HyNet Industrial Fuel Switching project to decarbonise industrial processes across the North West of England.
Ciner submits plans for UK plant
Ciner Glass has submitted its planning proposal for a glass plant in Wales, UK.
Ciner Glass has lodged plans with the local council to build a glass bottle factory at the Rassau Industrial Estate on the outskirts of Ebbw Vale, Wales for its UK market.
Ciner is one of the largest producers of natural soda ash, a key material in the production of glass bottles.
The site’s location will help reduce the company’s carbon footprint in association with its transportation.
Arup, the agent for the project, said: “The proposed development seeks to construct the glass manufacturing facility within Rassau Industrial Estate, utilising two vacant employment land allocations and an undeveloped land parcel within the site, making effective use of the A465 strategic road network to facilitate distribution.”
There could be as many as 670 jobs associated with the running of the facility and at the peak of the construction period 450 jobs.
Arup also said the factory would provide apprenticeship and training opportunities for the local labour market.
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NEWS IN BRIEF
Wiegand-Glas starts furnace heat up
Wiegand-Glas has started the second amber glass furnace at its Schleusingen plant in Thuringia, Germany.
Wiegand-Glas said it was “happy and proud” of its colleagues who made the successful start of production possible.
The furnace start-up was postponed in January due to Covid sickness among staff as well as the risings costs of energy and raw materials.
Knauf Insulation opens recycling facility
Knauf Insulation has opened a €15 million Glass Mineral Wool recycling facility in Visé, Belgium.
It said the facility will pave the way for an exciting new recycling service for the construction and deconstruction industry.
Allied Glass in hydroelectricity plan
Drax Energy Solutions has signed an agreement with Allied Glass to provide 66 gigawatt hours (GWh) of electricity annually from a river hydroelectric scheme in Scotland. With a bespoke Corporate Power Purchase Agreement (CPPA), 100% of the electricity used by Allied Glass is certifi ed with Renewable Energy Guarantees of Origin (REGOs) from the Drax Group Galloway Hydro Scheme.
This allows Allied Glass to match its energy use with the renewable electricity generated to support its carbon reduction goals.
Alan Henderson, CEO at Allied Glass, said “We chose to source our renewable power from Drax’s Galloway Hydro Scheme, as knowing exactly where our electricity comes from helps us continue towards our 2025 sustainability targets. “We work closely with our suppliers to ensure that the materials and resources we use are sustainable. Renewable electricity is very much part of that process.”
Top 10 stories in the news
Our most popular news over the past month, as determined by our website traffi c. All full stories can be found on our website.
� 1. Ambev invests in Brazilian glass bottle production plant � 2. Allied Glass to source hydroelectricity from Drax � 3. Pilkington fi res fl oat glass furnace on 100% biofuels � 4. NEG successfully melts glass with hydrogen � 5. Decarbonisation & Public Funding: What’s in it for the Glass Industry? � 6. Vidrala CO2 reduction targets validated by SBTi � 7. Ciner submits plans for UK glass plant � 8. Crisa Libbey to host tour of Monterrey Plant for Glassman attendees � 9. Wiegand-Glas starts furnace heat up � 10. Forglass prepares for GLA 2022
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BDF tallest ISmachine installation
BDF has installed one of its tallest IS glass manufacturing machines in the world at a production facility in Western Europe.
The 12-section machine has been raised 3” because the customer needed to produce tall products. The delivery constant angle increases the height of the machine in relation to the delivery and ease of alignment.
The machine is already in operation and the installation was completely managed by its mechanical and electrical team.
Glass Futures invites IS machine collaboration
Glass Futures has invited IS machine suppliers to partner with it in the development of technologies for the glass sector.
The UK research and development, and training hub said it was a great opportunity to support the industry, showcase machinery and demonstrate the latest glass container forming technology at its pilot facility in St Helens, UK.
If you are interested and would like to fi nd out more information please contact: peterjfi rth@gmail.com
NEWS IN BRIEF
FIC and SSRC enter refractory agreement
F.I.C. has entered into an agreement with SSRC to supply the refractories for a small all-electric furnace to melt a very special glass composition.
SSRC (Special Shapes Refractory Co.) is based in Bessemer, Alabama, USA and provides special solutions to the entire glass market. F.I.C. (UK) Ltd and its German based subsidiary F.I.C. Germany supply the global market with boosting systems up to 12MW for Superboost-Systems and also for both small and special AEM (All-Electric-Melter) and Hybrid-Melters. Hybrid-Melters are the final step in the decarbonisation process as the furnace should first be converted to an Oxy-fired-System with a large percentage of boosting initially.
Therefore, a part of the SSRC´s scope of supply includes a ceramic bonded AZS for the superstructure which is important for this application.
Burner equipment will be supplied by FlammaTec Germany, which is also a division of Glass Service Czech Republic.
Bastürk Cam orders Horn furnace
Horn is to build 560t/day end fired furnace for Turkish glass container manufacturer Bastürk Cam.
The furnace will have a melting surface of 185.4 m² in the Malatya, Turkey facility and designed for six forehearths for the production of container glass.
The contract also includes two new Horn batch chargers HVR 600F batch chargers.
The two batch chargers were recently subjected to a test with regard to conveyor capacity.
Each batch charger must have a conveyor capacity of 700 tonnes per day, so that each machine itself can handle the entire capacity of the furnace.
Stoelzle celebrates a year of US glass manufacturing
Stoelzle Glass Group has celebrated a year of container glass production in the USA.
It said since its acquisition of the Monaca plant in March 2021, continuous investment in Stoelzle USA has proven an impactful first year breaking into the North American market.
It serves diverse clientele ranging from North American Spirit partners such as Bulleit Bourbon to local distillers such as Middle West Spirits.
In the past year, Stoelzle has modernised the Monaca facility and said it will continue to enhance the plant production lines.
Nate Smith will become President of Stoelzle Glass USA. August Grupp will continue as a director of the board and will take over the role of chairman of the board from Georg Feith, the company’s CEO.
Smith brings more than two decades of experience to the appointed role of President, with previous positions in operations, manufacturing and most recently as Vice President of Operations.
In addition to Stoelzle, Smith has held roles with Anchor Hocking, Corning and Osram Sylvania.
In recognition of the refurbishments and plant success, CEO Georg Feith and President August Grupp, along with other local Stoelzle leaders commemorated the anniversary with a ribbon-cutting event last week, joined by the Beaver County Chamber of Commerce and local officials.
Since acquiring the Monaca, Pennsylvania plant, Stoelzle has found success with important customers such as Bulleit Burbon, while also focusing on the local market, with distilleries such as Middle West Spirits, taking the company to new heights in the local and prestige spirts niche markets.
Stoelzle has also modernised and refurbished plant facilities, while simultaneously improving employee safety measures and morale.
Within the upcoming year, Stoelzle will completely relaunch a new production line, in order to advance bottle manufacturing.
Verallia reports revenue growth
Global glass bottle packager Verallia has reported a revenue growth of 24% for the first quarter of 2022.
In the first quarter of the year, Verallia recorded revenue of €750 million, compared to €605 million in the first quarter of 2021. This represents a 24.0% increase in reported revenue and 23.9% organic growth.
Adjusted EBITDA also increased and stood at €183 million. However, the adjusted EBITDA margin decreased slightly (-72 bps) due to an increase in sales prices.
This amounted to 24.4% over the quarter.
Verallia continued to reduce its net debt during the quarter. Net debt stood at €1,222 million at the end of March 2022. This corresponds to a net debt ratio of 1.7x, down from 2.1x in March 2021.
Sales prices have also been increased to mitigate the impact of the cost inflation.
In Latin America, sales volumes in Brazil and Chile posted strong growth, while in Argentina production was limited due to a furnace repair. Moreover, a dynamic approach to managing sales prices has continued in order to offset local inflation.
