Flexible furnaces: a new opportunity for lower-carbon glass production

How can glass manufacturers cut emissions while remaining competitive in a changing energy market? GIFFT’s latest market assessment explores the potential of fuel-flexible furnaces and highlights what will matter most for industrial uptake.

The GIFFT project combines biomass-derived synthetic gas, plasma-assisted heating and the reuse of biomass ash in glass production. Its approach allows manufacturers to adjust their energy mix according to the availability and cost of biomass, renewable electricity and green hydrogen.

Energy flexibility could offer a competitive advantage. The assessment identifies opportunities to increase electrical heating when electricity prices are favourable, while retaining fuel-based heat production at other times. For manufacturers, this could help manage exposure to fluctuating energy prices. Actual savings will depend on each plant’s operating conditions, energy costs and investment requirements.

Environmental performance depends on the complete system. An initial life cycle assessment covering 15 technical configurations shows substantial potential to reduce environmental impacts. It also finds that switching fuels alone does not necessarily improve overall performance: biomass processing and hydrogen production can introduce additional impacts. Combining alternative fuels with plasma heating and suitable ash reuse can strengthen the environmental benefits.

Local conditions will shape market uptake. Input from partners in Germany, Sweden, Lithuania and the United Kingdom highlights differences in energy infrastructure and biomass availability. Reliable fuel supplies, competitive electricity prices and compatibility with existing furnaces will influence which solutions work best at each location.

Across the participating regions, high investment costs and technological uncertainty remain major barriers. Manufacturers need evidence of reliable operation, consistent glass quality and manageable maintenance costs before committing to new systems.

GIFFT’s next steps therefore focus on further validation and scale-up. For the glass industry, the assessment points to a promising opportunity: combining emissions reduction with greater operational flexibility, supported by careful evaluation at plant level.