Future of Furnaces Event Guide

EVENT GUIDE

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CONTENTS

EVENT GUIDE Editor: Nadine Bloxsome nadinebloxsome@quartzltd.com Tel: +44 (0) 1737 855115

Editorial Assistant: Zahra Awan Tel: +44 (0) 1737 855038 zahraawan@quartltd.com

Production Editor: Annie Baker

Sales & Directory Co-ordinator: Esme Horn esmehorn@quartzltd.com Tel: +44 (0) 1737 855136

International Sales Manager: Nathan Jupp nathanjupp@quartzltd.com Tel: +44 (0) 1737 8555027

Subscriptions: Elizabeth Barford subscriptions@quartzltd.com

Managing Director: Tony Crinnion CEO: Steve Diprose

Published by: Quartz Business Media Ltd,

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Welcome by Nadine Bloxsome, Editor

4 News

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Conference Agenda Speaker Profiles Exhibitors and Supporter Profiles Industry 4.0: Use of in-furnace thermal imaging for industry 4.0 and decarbonisation in steel, non-ferrous and glass BIFCA Column: BIFCA Seminar to highlight standards

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Association update:

A resilient UK foundry industry remains optimistic

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Furnace for the future:

The ‘Furnace for the Future’ project gathers momentum

Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000.

Email: furnaces@quartzltd.com www.furnaces-international.com Furnaces International is published quarterly and distributed worldwide digitally.

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Smart furnaces: GHI Smart Furnaces works in the supply of the key equipment of the new casthouse to Almexa in Varacruz (Mexico)

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FUTURE OF FURNACES

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VISIT US!

HTK High Temperature Chamber Furnaces GPCMA Modified Atmosphere Chamber Furnace

DEBINDING, SINTERING & HEAT TREATMENT

LABORATORY & INDUSTRIAL FURNACES UP TO 3000 °C CARBOLITE GERO manufactures laboratory and industrial furnaces and ovens from 30 °C to 3000 °C. The company has considerable experience in the heat treatment of MIM parts and is a well-known furnace supplier for additive manufacturing (AM) in the field of powder metallurgy.

www.carbolite-gero.com

Carbolite-Gero-TCT-GB-210x297.indd 1

26.08.2021 08:43:20

WELCOME

What does the future look like for furnaces?

Welcome to the first ever Future of Furnaces virtual event, in association with Furnaces International, the BIFCA Standards Seminar and supported by FEVE. Manufacturing industries are already seeing the results of the ‘Furnace of the Future’ in reducing CO2 emissions and producing cleaner, more sustainable materials.

But how can energy-intensive manufacturers work towards making this future a reality? Are we already seeing the benefits of adopting smarter and more sustainable technologies within furnaces? Or, could we be doing more?

This online event will unite the glass, aluminium and steel sectors to discuss overcoming heat treatment challenges and present a collaborative approach to bring the Furnace of the Future to life. Offering a special focus on what the ‘Furnace for the Future’ will look like, is our Keynote Speaker, Fabrice Rivet, Environment, Health and Safety Director at FEVE. Fabrice will open the event with a look at the Furnace for the Future (F4F) project and explain how it will develop a break-through technology to dramatically reduce CO2 emissions from container glass furnaces.

We have a host of other great speakers joining us from across the glass, steel and aluminium sectors and the second day will host the BIFCA Standards Seminar, which all delegates are invited to attend.

We hope you enjoy the event and look forward to interesting discussions and the online networking opportunities.

Nadine Bloxsome, Editor, Furnaces International, nadinebloxsome@quartzltd.com Furnaces International

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NEWS IN GENERAL

MoU with the Spanish Government will see a €1 billion investment in decarbonisation technologies at ArcelorMittal ArcelorMittal signed a memorandum of understanding (MoU) with the Spanish Government of a €1 billion investment in decarbonisation technologies at ArcelorMittal Asturias’ plant in Gijón, including the addition of a New DRI and EAF. The investments aim to reduce CO2 emissions at ArcelorMittal’s Spanish operations by up to 4.8 million tonnes, which represents approximately 50% of emissions, within the next five years. The key changes to the plant include the addition of a 2.3 million-tonne green hydrogen direct reduced iron (DRI) unit which will be complemented by a 1.1 milliontonne hybrid electric arc furnace (EAF).

ArcelorMittal will introduce new manufacturing processes that contribute to a considerable reduction of CO2 emissions.

This starts the transition of the Gijón plant away from the blast furnace to the DRI-EAF production route, which carries a significantly lower carbon footprint. The production of the new DRI and EAF will be in before the end of 2025.

To maximise the emissions reduction potential, ultimately green hydrogen will be used to reduce the iron ore in the DRI, with the EAF powered by renewable electricity.

The initiative involves the construction of multiple large-scale solar farms, with hydrogen

produced in situ and with the corresponding impact in terms of employment.

Speaking at the signing of the MoU in Gijón, Aditya Mittal, CEO ArcelorMittal, said: “It is widely understood that for the world to achieve net-zero by 2050, faster progress over the next decade is essential. The MoU we have signed today will play an important role in doing exactly that. “ Expressing their support for the plan, Spain’s Minister of Industry María Reyes Maroto said: “The Government of Spain and the ArcelorMittal Group fully agree that the transition towards a decarbonised economy is an essential objective for Spain”.

For more information, Visit: https://corporate.arcelormittal.com/media/press-releases/arcelormittal-signs-mou-with-the-spanish-government-supporting-1billion-investment-in-decarbonisation-technologies

Carbolite Gero launches a new tube furnace Carbolite Gero’s announced a new range of tube furnaces, developed over 18 months by specialists, industrial designers and skilled engineers.

The new design of new tube furnaces claims to boast the high-quality heating elements and an innovative thermal insulation design in comparison to a classic furnace. With rapid

heating & cooling as well as temperature uniformity, the company has also focused on the sustainability of the new furnace, significantly reducing power consumption over previous models.

Optional work tube packages are also available to enable users to equip their tube furnace for operation under vacuum or with a

modified gas atmosphere, providing a furnace for individual costumers. The gas packages available optimise the inert atmosphere inside the work tube. Gasses available are: nitrogen, argon or carbon dioxide.

Carbolite Gero will also be featuring at the Future of Furnaces event - 14 -15 September 2021. Visit the booth today!

For more information, visit: https://www.carbolite-gero.com/news/new-tube-furnace-range

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Furnaces International

ALUMINIUM NEWS

Gillespie & Powers Inc. supplies new Batch Homogenizing furnace to Ellwood Aluminium

Gillespie & Powers Inc. has announced an agreement with Ellwood Aluminum for the supply of one 200,000 Lb. Batch Homogenizing Furnace, which will assists with Ellwood Aluminium’s phase 2 expansion in

Hubbard OH. The new furnace, which the company claims will be operational in 2022, marks Gillespie & Powers Inc. fourth addition to Ellwood Aluminium’s expansion. Gillespie & Powers

Inc. has previously supplied a Tilting Melter, Tilting Holder and SOW Drying Oven during their initial plant construction and is excited to be partnering with Ellwood Aluminum in their continued development of their business.

For more information visit: http://www.gillespiepowers.com

Glass experts Furnace support Process optimization Training and R&D Celsian’s aim is to minimize the cost of making glass for end users and the environment. We have an agile team of glass experts using proven methods like furnace modelling, laboratory measurements and practical furnace health checks to optimize glass melting processes. We also train operators and glass technologists through our standard course, dedicated programs and various e-learning modules. We strive to be the best partner for optimization of glass production worldwide.

www.celsian.nl Furnaces International

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GLASS NEWS

Encirc to use hydrogen in its glass manufacturing furnaces

Encirc announces its new commitment to use hydrogen in its manufacturing furnaces to create ultra-low-carbon glass bottles. The glass bottle manufacturer and filler, states hydrogen will enable the expansion of Encirc’s Elton facility, which is said to create at least 200 jobs, whilst also protecting existing roles.

Encirc’s Elton facility has over 1,000 employees and will use the proposed HyNet North West (a hydrogen and carbon capture and storage project that aims to unlock a low carbon economy) project in its furnaces, moving towards the decarbonisation of glass

packaging by 2025.

Adrian Curry, Managing Director at Encirc, commented, “It is vital that glass packaging decarbonises to meet our zero-emission future.”

He added,“Glass already has so many incredible environmental and health benefits over other materials, but the carbon intensity of our furnaces is a key challenge we need to address.”

One in amongst many, the HyNet North West scheme is in competition to be one of two chosen by Government to produce, store

and distribute hydrogen as well as capture and store carbon in the North West of England and North Wales by 2025.

The project has the potential to reduce CO2 emissions by 10 million tonnes every year by 2030 – the equivalent of taking four million cars off the road, as well as create and maintain thousands of local jobs and form long-term sustainability for businesses and financial security for communities across the region.

For more information, visit: https://www.encirc360.com/2021/07/08/beis-minister-visits-encirc-as-company-announces-plans-to-boost-jobs-and-decarboniseusing-hydrogen/

Gerresheimer invests furnace expansions for glass maufacturing Gerresheimer has invested €50.1 million in furnace expansions at two of its production facilities.

The group has invested the €50.1 million in six months (December 2020 and May 2021) into its Primary Packaging Glass division, which were related to the investments at its Kosamba, India and Lohr, and German facilities.

Gerresheimer has also invested in its production capacity for injection vials and plans to expand its production in its plants in North America and Europe.

In half year, the financial results of the company reported revenue increase of 3.6% to €320.1 million in its glass division.

It reported that the demand of its cosmetics

business recovered in the second quarter of the financial year of 2021 and was higher overallyear on year. The company did experience a sharp drop as a result of the Covid-19 pandemic.

It also reported ‘significant revenue increases for high-value solutions in particular, such as Elite Glass products’.

For more information, visit: https://www.glass-international.com/news/gerresheimer-invests-in-glass-manufacturing-furnace-expansions

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FUTURE OF FURNACES Furnaces International

NEWS

Glass manufacturing furnace to be constructed

by Horn for Bastürk Cam Horn has announced the build of a 560 t/d end fired furnace for Bastürk Cam at its Malatya plant, Turkey.

The new furnace is designed to focus in the production of container glass with the feature of six forehearths. The furnace’s production will to contribute to a sustainable and healthy life and to respond to the diverse product

demands in glass sector.

The furnace has been designed to have a melting area of 185.4 m², which will have the ability to produce flint glass. The fuel for the furnace will be by means of Natural Gas or Back-up Diesel oil burners.

Horn’s furnace has a scope of supply encompassing the engineering of the

refractory and steel structure, the Combustion System, Boosting System, Measuring and Control equipment, a new Horn HVR 600F batch charger, supervision of erection, heat-up and commissioning.

Installation of he furnace is planned to start in the second quarter of 2022.

For more information, visit: https://www.hornglass.com/company/news/detail/horn-to-construct-560-t-d-furnace-for-bastuerk-cam

Noelle + von Campe secures €1.8 million glass furnace grant German container glass manufacturer Noelle + von Campe has received a €1.8 million grant to help the development of a new furnace.

The glass manufacturer plans to build a new melting furnace at Plant II in Boffzen, Germany.

The background to this is that the previous melting tanks 1 and 3 at plant location I are to be gradually shut down.

A new, separate building is to be built for

the planned melting tank and the subsequent process units. In addition, a new workshop and social building is to be built and the long halls are to be renovated.

This should create 20 new permanent jobs and secure 160 existing jobs.

Lower Saxony’s Minister of Economic Affairs, Dr. Bernd Althusmann handed over a cheque to the company last week.

Minister Althusmann when handing over the decision in Boffzen: “I am delighted that we can support Noelle + von Campe in their commitment with the individual investment subsidies.

“This example shows that entrepreneurial courage pays off even in the current difficult economic times and that the regional economy can be boosted and jobs can be secured.”

For more information: https://www.glass-international.com/news/noelle-von-campe-secures-eur1-8-million-glass-furnace-grant

STEEL NEWS

ArcelorMittal Sestao claims it will be the world’s first zero emissions steel plant ArcelorMittal has announced that with the instillation of its new Direct Reduced Iron (DRI) and Electric Arc Furnace (EAF) installations in Gijón, the company will reduce carbon emissions by roughly 50%.

The company has gone on to claim that the installation will result in the ArcelorMittal Sestao steel plant being the world’s first fullscale zero carbon emissions plant.

The established company signed a memorandum of understanding (MoU) with the Spanish Government last week to confirm their commitments towards a decarbonised industry. The MoU underlined the commitment of both the Government of Spain and ArcelorMittal to invest around €1 billion in decarbonisation technologies. They company aims to reduce emissions at the site by up to 4.8Mt – or by 50% – within the next five years.

Lakshmi Mittal, CEO, ArcelorMittal Group,

commented on the claims of the Zero carbon plant, “It is widely understood that for the world to achieve net-zero by 2050, faster progress over the next decade is essential. The MoU we have signed today will play an important role in doing exactly that. The construction of

the new green hydrogen DRI plant in Gijón will not only enable us to reduce emissions from our Spanish operations by half but will also result in the world’s first full-scale zero carbonemissions steel plant in Sestao.”

At the centre of the plan is a 2.3Mt green hydrogen DRI unit, complemented by a 1.1Mt hybrid EAF. This begins the transition away from blast furnace-basic oxygen furnace steelmaking to DRI-EAF production, which has a far lower carbon footprint. The initiative involves the construction of multiple large-scale solar farms, with hydrogen produced in situ and with the corresponding impact in terms of employment.

The Gijón DRI will also feed the company’s Sestao plant, situated approximately 250km from Gijón, where production is already entirely from the electric arc furnace route.

For more information, visit: https://flateurope.arcelormittal.com/flatnews/news_july_2021/sestao-zero-carbon-emissions

Can-Eng has been awarded with Two New Car Bottom Furnaces Contracts Can-Eng Furnaces International has been awarded with a contract to design and manufacture two new (2) 50,000 lb/hr Car Bottom Furnaces for one of the leading Metals and Mining companies in the World.

The custom engineered furnaces designed

by Can-Eng claim to support the manufacturing critical metal hot rolling machine components used in the production rolling of high value-

added automotive steel sheets and plates.

During the bidding process, Can-Eng was able to identify areas of improvement within the customers existing heat treatment system, this then allowed Can-Eng to develop a concept that better suited the customers needs while providing faster, more efficient, enhanced quality, and reduce operating costs for the customer.

The two systems, although located side by side, will feature independent control systems allowing for flexibility in schedules and maintenance. The furnaces will be interconnected to the larger plant wide system for data acquisition and trending capabilities with Can-Eng’s Support to further enhance the machine.

For more information, visit: https://www.can-eng.com/News/News-Press-Releases/two-new-car-bottom-furnaces-contracts-awarded-to-can-eng

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FUTURE OF FURNACES Furnaces International

STEEL NEWS

SECO/WARWICK cooperate with another fortune global 500 company One of the leading Chinese aviation companies has announced a cooperation with SECO/WARWICK and placed an order for a Vector® vacuum furnace for carburizing (LPC) and gas quenching. The furnace will be used for the manufacture of hydraulic pump components and other machinery.

The vacuum furnace ordered by the aviation company will be used mostly for gas quenching parts sensitive to hardening deformations made from such types of steel as tool steel, stainless steel, structural steel, bearing steel or high-speed steel. The device designed by SECO/WARWICK plans to

feature the LPC option, which will be used for vacuum carburizing.

FineCarb and PreNitLPC are modern and economical methods for low pressure carburizing (LPC). By dosing a nitrogen medium during the controlled heating stage, the carburizing process can be performed under higher temperatures (1000°C and more) while ensuring the small-grain structure of the processed layer. This technology enables savings of process costs by shortening the carburizing cycle and reducing the consumption of process gases. aciej Korecki, VP, Vacuum Business Segment

at the SECO/WARWICK Group commented on this development, “We are pleased that a Fortune Global 500 company has placed trust in us and commissioned the manufacturing of this technology,… Our furnace is a guarantee of the perfect quality of workpieces and of a highly repeatable and uniform carburizing process. We understand that the aviation industry is certainly very demanding. Meeting the strictest standards allows us to successfully cooperate with the largest companies in the aviation and automotive industries”

For more information, visit: https://www.secowarwick.com/en/news/another-fortune-global-500-company-becomes-a-seco-warwick-customer/

Tenova announces successful start up of two New Walking Beam Furnaces at its plant located in Ternium Pesqueria Tenova announce the successful start up of its two new state-of-the-art technology Walking Beam Furnaces (WBFs), designed to reduced emissions and save energy, at the new Ternium hot strip mill facility.

The new WBF’s furnaces are designed to heat steel slabs (up to 39 t) at 1,250°C, with a specific consumption of 1.16 MJ/Kg, while keeping NOx emissions lower than 60 ppm – lower than the required limit.

The furnaces feature a Smart Burner Motoring System (SBMS), which enables the monitoring and optimisation of the burners performance, operation and maintenance. The

SBMS works with embedded sensors that are connected to Tenova’s digital infrastructure.

The data is then collected and processed to provide the company with a unique approach to the inspection, maintenance and tuning, as well as reducing safety risks of the plant.

Paulo Lopez, Pesquería Plant Director at Ternium, commented on the investments and developments of Tenova, “The Ternium Industrial Center started its first phase in 2013…, we have started up the main production line of the 2nd phase, a new hot rolling mill with a capacity of 4.4 million tons. The two new WBFs are part of the plant’s

new lines and will produce coils to be used in the automotive market in the USMCA area, granting Ternium an increased access in this sector”.

Nicola Cavero, Senior Vice President Tenova Italimpianti added, “This new Tenova equipment joins the previous walking beam furnaces built for Ternium … confirming the fruitful collaboration between the two companies of the Techint Group for this type of application. This represents an important new reference for Tenova in the reheating furnaces market”

For more information, visit: https://www.tenova.com/news/detail/walking-beam-furnaces-for-ternium-at-pesqueria/

Furnaces International

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STEEL NEWS Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, events, and regular columns from the British Industrial Furnace Constructors Association (BIFCA).

Published quarterly in a digital format, Furnaces International magazine is sent straight to the inbox of over 25,000 professionals from across the aluminium, steel, and glass industries.

Contact us now: Yaoyi Stainless Steel has

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YAOYI invests in the Bright Annealing Furnace line to improve steel production

announced the precision stainless steel strips for over two elongation, surface and mechanical properties Nadineinvestment Bloxsome Jupp Esme Hornof Yaoyi has of cold-rolled Manuel Martinquereda stainless steel coils. manager of over $150,000 Nathan to renovate the decades, the general announced the investment of over $150,000 Bright Annealing Furnace Line.

Editor Sales Manager Glass & Primary Metals International Sales Executive to renovate the Bright Annealing Furnace in the research and 855027 Department Co-ordinator +44 1737 Specialists 855115 +44 (0) 1737 +44 (0) 1737 855023 will 1737 greatly855136 improve the development, production and sales of high- line, which claims it+44 nadinebloxsome@ nathanjupp@ ManuelM@ quartzltd.com quartzltd.com esmehorn@quartzltd.com quartzltd.com For more information, visit: https://www.prnewswire.com/news-releases/yaoyi-technology-has-transformed-the-bright-annealing-furnace-line-and-improvedthe-quality-of-cold-rolled-stainless-steel-coils-301350677.html

BUSINESS MEDIA

Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, events, and regular columns from the British Industrial Furnace Constructors Association (BIFCA).

Published quarterly in a digital format, Furnaces International magazine is sent straight to the inbox of over 25,000 professionals from across the aluminium, steel, and glass industries.

Contact us now:

SIGN UP TO RECEIVE YOUR FREE COPY

Nadine Bloxsome

Nathan Jupp

Esme Horn

Manuel Martinquereda

Editor

Sales Manager

International Sales Executive

+44 1737 855115

+44 (0) 1737 855027

Glass & Primary Metals Department Co-ordinator

nadinebloxsome@ quartzltd.com

nathanjupp@ quartzltd.com

+44 1737 855136 esmehorn@quartzltd.com

ManuelM@ quartzltd.com

+44 (0) 1737 855023

BUSINESS MEDIA

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GLASS SERVICE

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CONFERENCE AGENDA

DAY ONE –14TH SEPTEMBER 09.00 KEYNOTE: Securing our Industry’s Future: Towards Climate-Neutral Container Glass Fabrice Rivet - Environment, Health and Safety Director, FEVE

09.30 Use of In-Furnace Thermal Imaging for 4.0 and Decarbonisation in Steel, Non-Ferrous and Glass Neil Simpson - BEng(Hons) CEng MEI FSGT MIRefEng, Independent Consultant - Simpson Combustion and Energy Ltd

10.00 Tools that Reduce Energy Demanded by Furnaces While Keeping Quality and Furnace Lifetime in Tact René Meuleman - Director of Business Development, CelSian

10.30 What if a Furnace was Intelligent Enough to Improve its Own Performance?

Mark Allen - Sales Director, Mechatherm NETWORKING BREAK

11.30 Net Zero – Future Challenges for Furnace Operators Dan Hulme - Business Development Manager, Inspired Energy

12 noon The Aluminium Recycling Plant of the Future Iñigo Guinea - CEO, GHI Hornos Industriales LUNCH & NETWORKING BREAK

14.00 Plasma Torches: Electric / Zero CO2 Conversion for Fossil Fuel Burners David D’Aoust - Sales Manager – Drosrite™, PyroGenesis Canada Inc.

14.30 Looking Forward Through Glass Stuart Hakes - Chief Executive, F.I.C. (UK) Limited

15.00 Glass Melting Furnaces Dirk Schnurpfeil - Research and Development, Nikolaus Sorg GmBh & Co. KG

15.30 Reducing Emissions and Increasing Output in a Continuous Thermal Process using AI Claudio Goldbach - Chief Executive Officer, Perfil Group

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CONFERENCE AGENDA

DAY TWO –15TH SEPTEMBER IN ASSOCIATION WITH THE BRITISH INDUSTRIAL FURNACE CONSTRUCTORS ASSOCIATION STANDARDS SEMINAR

10.25 Chairman’s Introduction Arthur Watson, BIFCA Chairman

10.30 DSEAR from a Gas Engineers Perspective Danny Brennan – Director, DB Gas Associates Danny Brennan will give his views on DSEAR/ATEX from a practical gas engineering perspective and discuss DSEAR Risk Assessments from a hands-on viewpoint.

11.00 European and International Furnace Standards Rene Branders, President of CECOF and Andrea Baio, Vice President of CECOF Rene Branders and Andrea Baio have vast collective experience in the development and practical application of industrial furnace standards. This presentation will uncover the current status of the evolving EN746 series of European safety standards and the progression of some of them to international ISO versions.

11.30 The Importance of Safety Standards Adrian Goodbrand, Director of Sales, Vacuum Furnace Engineering Ltd Adrian will outline the key principles of standards and why they are necessary. He will address this from the perspective of the furnace designer/ manufacturer with the production of vacuum furnaces in mind and, of course, the benefits to the end user.

12.00 An Overview of Gas Standards in the UK Jonathan Farmer, Sales Director, Duomo The Institute of Gas Engineers have produced a set of gas standards for application in the UK. Jonathan will outline the scope of these standards as available to the industrial furnace industry and attempt to position them alongside other established European and worldwide furnace standards.

12.30 Furnace Operations Safety – A User’s Perspective Richard Heath, Health, Safety and Environment Specialist, the Cast Metals Federation This presentation will cover the safety and technical issues with the operation and maintenance of a furnaces in a foundry environment. It will consider the application of relevant standards (where available!) and Richard will highlight some interesting statistics relating to situations commonly encountered.

13.00 UK Gas Regulations and the Gas Quality Debate Danny Brennan – Director, DB Gas Associates Danny will be looking at the controversial plans to fluctuate the quality of gas throughout Europe and what the impact this will have on the UK and what it could mean for the UK Gas supply.

13.30 Market Access for the UK Mark Lindsay, Director, Product Approvals UK The dominant furnace standards in Europe and the UK since the late 1980’s have been the EN746 series. Brexit has now happened and infrastructure changes are taking place. CE marking still exists and will continue to exist but the UK has introduced the UKCA mark. What will this mean? Mark will illustrate and clarify some of the issues surrounding ‘Notified Bodies’, ‘Approved Bodies’ and the options facing not just UK players but international ones as well.

14.00 DISCUSSION FORUM (ONLINE) Furnaces International

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FABRICE RIVET

FABRICE RIVET ENVIRONMENT, HEALTH AND SAFETY DIRECTOR EUROPEAN CONTAINER GLASS FEDERATION (FEVE) SECURING OUR INDUSTRY’S FUTURE: TOWARDS CLIMATE-NEUTRAL CONTAINER GLASS The Furnace for the Future (F4F) project will develop a break-through technology to dramatically reduce CO2 emissions from container glass furnaces. Container glass production is an energy intensive industry, largely dependent on fossil fuels to provide energy for the chemical glass forming reactions and to melt the glass. Over the past decades a lot of improvements have been implemented to make the conventional

technologies more energy efficient and less polluting. However, the conventional furnace technology is approaching the thermodynamic efficiency limits of the glass melting process.

F4F proposes a breakthrough allowing the industry to become significantly more energy efficient and drastically reduce the GHG emissions. A large-scale industrial hybrid oxyfuel furnace will be demonstrated,

running on 80% renewable electricity, thereby reducing the currently used fossil fuel energy sources. The F4F project is technically and financially supported by 19 container glass companies who all signed a binding agreement and who together represent about 98% of the production covered by FEVE (the European Container Glass Federation).

BIOGRAPHY Since January 2009, Fabrice is Environment, Health and Safety Director at the European Container Glass Federation (FEVE).

FEVE is the Federation of European manufacturers of glass containers and machine-made glass tableware. Its members produce over 20 million tonnes of glass per year. It is an international not-for-profit association, which currently numbers over 60 company members and 22 corporate groups across the European Union, Switzerland and Turkey.

Fabrice has launched and has been involved since the beginning in the FEVE Innovation WG, which has been looking for decarbonization solutions for the container glass industry and has identified the hybrid “Furnace for the Future” technology as the most promising one. He also manages the legal working group working on the different contracts between the participants.

He is very active on climate policy, and represents the whole glass industry in the Commission Expert Group on Climate Change and also chairs the Environment Committee of Glass Alliance Europe, the European Alliance of Glass Industries which regroup all the glass industries to work on common issues. It is composed of 19 national glass associations and of the main sectors of the glass industries: container glass, flat glass, special glass, domestic glass and continuous filament glass fibres.

He worked previously at the Vrije Universiteit Brussels, then for the Belgian Glass Association.

He has 22 years experience in environmental sciences, support to industry, European Affairs and lobbying. He holds a masters degree in physics from the ULB, and is a qualified civil engineer. He also holds a masters degree in environmental sciences and training in management from Mercer University in the USA.

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NEIL SIMPSON

NEIL SIMPSON INDEPENDENT CONSULTANT SIMPSON COMBUSTION AND ENERGY LTD USE OF IN-FURNACE THERMAL IMAGING FOR 4.0 AND DECARBONISATION IN STEEL, NON-FERROUS AND GLASS For over 100 years, optical pyrometers have been the temperature measurement instrument of choice for high-temperature combustion processes. In many of these processes temperatures are taken using an optical pyrometer at least once per shift and sometimes every 20 minutes. Whenever there is a process related problem, an AMETEK Land Cyclops L or equivalent pyrometer is used to check temperatures at critical points in the furnace or kiln. Thirty years ago, during the commissioning of a 2D model-based steel reheat control system, there was only one fixed location pyrometer on a furnace.

Ten years ago, AMETEK Land developed

the Near Infrared Borescope [NIR-B], which initially measured 324,000 optical temperatures continuously in the furnace. For ease of display, the temperatures generate a visual, thermal image of the furnace, often confused as simply a CCTV image. It now displays up to 3 million fully radiometric calibrated camera pixels in the temperature range from 600 to 1800 °C / 1112 to 3272 °F – a development of technical significance for energy-intensive heavy industries like steel, non-ferrous and glass production.

When analysing the massive amounts of furnace temperature data captured by the NIR-B, it is worth looking to other professions

such as accountants who use variance and models. In-furnace thermal imaging enables the validation of CFD models and supports predictive control. The use of alarms for variance to design, set point, and previous minute/hour/day/week/month improves quality and yield and reduces waste as the first step to decarbonisation. The second is the optimisation and reduction of specific energy.

The third is the optimisation of alternative, bio and renewable fuels and the final element is the support for developing new technologies and control.

BIOGRAPHY Neil Simpson holds a Bachelor (Hons) of Engineering in Energy from Edinburgh Napier University. Initially, he worked for Laidlaw Drew to develop oxy burners, including oxy oil, then BOC’s CGM development team in Ohio, US. He was a BOC GMIC representative and chair of the Energy Efficiency Committee. He moved back to the UK and joined Eclipse as Glass Industry Manager and then re-joined BOC in the UK with responsibility for Glass, Metals and Cement.

Seven years ago, Neil established Simpson Combustion and Energy Ltd as an independent consultancy to work with the glass industry worldwide. He is a registered trainer for CelSian and organises 5-day training courses, plus supports the delivery of specialist combustion modules.

With over 20 published patent applications, he is a Chartered Engineer, a member of the Energy Institute, and the Institute Refractory. He is also a Fellow of the Society of Glass Technology, and previously a Chairman of the Board of Fellows and chaired the Melting Technical Committee, which organises Furnace Solutions.

In 2016, he became a consultant to AMETEK Land and, in June 2017, was part of the team, including AMETEK Land and Encirc, that won a British Glass - Glass Focus Innovation Award. Supporting AMETEK Land in the optimisation of glass furnaces, he has supported joint papers presented at the last four Glass Problems Conferences, plus the most recent AFGM, AIGM, Sise Cam and INFUB 12 conferences.

The COVID lockdown has now led to him delivering remote consulting and online training courses with attendees from around the globe.

His courses include Basics of Combustion, In Furnace Thermal Optimisation, Oxy Fuel Combustion, and the most recent addition, Industrial Combustion Decarbonization 101.4.

Furnaces International

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RENÉ MEULEMAN

RENÉ MEULEMAN DIRECTOR OF BUSINESS DEVELOPMENT CELSIAN

TOOLS THAT REDUCES ENERGY DEMANDED BY FURNACES WHILE KEEPING QUALITY AND FURNACE LIFETIME IN TACT René Meuleman’s talk will show multiple tools to reduce energy while keeping quality and furnace lifetime in tact.

BIOGRAPHY René studied electrical engineering and started his career in the glass industry in 1969 as an employee of Vereenigde Glasfabrieken in The Netherlands. During his early years, he built his broad knowledge and experience in design and development of electronic quality equipment for container glass manufacturing and was involved in the implementation of their first-generation PLC and DCS systems, as well as electronic timing systems for IS-machines. The company became part of BSN and later part of O-I. After O-I René joined the Eurotherm by Schneider Electric group where he is responsible for the technical and commercial glass business development. Based on the Eurotherm and Schneider-Electric portfolio and together with his global glass business team he worked on the development of innovative, pragmatic and competitive glass manufacturing process and power control systems.

Now during his last years before retirement, René works as Director Business Development for the Dutch Glass Engineering company CelSian, focusing on supporting glass manufacturers and suppliers with the upcoming energy transition.

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Furnaces International

MARK ALLEN

MARK ALLEN SALES DIRECTOR MECHATHERM

WHAT IF A FURNACE WAS INTELLIGENT ENOUGH TO IMPROVE ITS OWN PERFORMANCE? What if a furnace was intelligent enough to improve its own performance? It was the simple question that inspired a Research project introducing artificial intelligence into a standard Mechatherm Melting furnace.

With one trial underway, and successful early results, Mechatherm have discovered a way to leverage cloud-server technology and artificial intelligence capabilities at plant level, allowing a furnace to learn from its own

performance and adapt over time, becoming more efficient with each passing day. With the core of this technology established, where else could this be applied, and to what gain?

The possibilities are endless.

BIOGRAPHY Mark Allen began his Mechatherm career as a software engineer in 1998. Working on all of the company’s major software projects until around 2006, when Mark set up the company’s Industrial IT division, focusing on the application of more complex client-server architectures into largescale casthouse projects. In 2015 Mark, in collaboration with one other person, founded Mechatherm’s service division, growing from an office of two with zero revenue, to a multi-million-pound turnover and team of ten in just three years. Now Mark has brought the concept of service-led sales to the core of Mechatherm’s sales team, maintaining a keen focus on the application of technology into traditional casthouse projects.

Furnaces International

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DAN HULME

DAN HULME BUSINESS DEVELOPMENT MANAGER INSPIRED ENERGY

NET ZERO – FUTURE CHALLENGES FOR FURNACE OPERATORS ‘Net Zero’ has become a common part of language in the energy and sustainability world since the UK government legislated to hit net zero carbon emissions by 2050.

But how is this going to affect manufacturing businesses that are operating typically fossil fuel heavy furnaces?

This session will provide insight as to what net

zero really means, how this is going to prove challenging for businesses operating furnaces and what possible steps they can take to understand their future options.

BIOGRAPHY Experience, skills, qualifications and expertise Dan qualified as a surveyor out of college before pursuing a career in the energy consultancy sector. Having worked with the energy intensive sector for over seven years, he brings a wealth of experience and knowledge of manufacturing processes and their impact on the operating costs and environmental impact. His specific areas of expertise are around compliance, levy exemption, and energy and carbon reduction strategies.

Dan supports clients by understanding their challenges, drivers and opportunities to help develop a solution to better manage energy costs, improve efficiency and reduce impact on the environment.

Part of Dan’s role at Inspired is to support the UK Manufacturing sector through a relationship with Make UK. He regularly presents on workshops and seminars for their members to improve awareness and share best practice.

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Furnaces International

~ INIGO GUINEA

ÍÑIGO GUINEA CEO OF SMART FURNACES GHI HORNOS

RECYCLING ALUMINIUM IN THE PLANT OF THE FUTURE To face the climate change, the developed world needs to lead the reduction of greenhouse emissions cutting them 50% by 2030.

Governments are progressively increasing green taxes to force companies to use

cleaner technologies and launching grant schemes to mitigate the burden of these new investments and achieve climate neutrality.

This new paradigm requires new green technologies. The plant of the future feeds on green energy. The plant of the future is Digital

and profitable. The plant of the future is Zero Waste.

When can we expect this future to be a reality?

Sooner, much sooner than you think.

BIOGRAPHY Íñigo Guinea prides himself as a family businessman; CEO of Smart Furnaces, a national leader in the industrial furnaces and digitalisation market, and GECSA, a company dedicated to the design and manufacture of special electrical conductors and industry 4.0.

Outside the family business, he has previously held positions as general manager, financial director, consultant and senior software systems auditor.

He holds a degree in Business Administration from the University of Deusto and an MBA from IESE and The Wharton School”.

Furnaces International

FUTURE OF FURNACES

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DAVID D’AOUST

DAVID D’AOUST SALES MANAGER – DROSRITE™

PLASMA TORCHES: ELECTRIC / ZERO CO2 CONVERSION FOR FOSSIL FUEL BURNERS For over 20 years, PyroGenesis has been commercially operating plasma torches day in and day out aboard US navy aircraft

carriers. Today, the technology is the clear front runner in the manufacturing sectors race to decarbonize by replacing dirty fossil fuel

burners with clean, high temperature electric fired plasma torches.

BIOGRAPHY David D’Aoust is a business development manager specializing in PyroGenesis’ Aluminium Environmental Services business segment. He is passionate about driving increased adoption of environmental technologies that help to preserve nature, while improving operating economics and achieving cost reductions for aluminium smelters.

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Furnaces International

ARTHUR WATSON

ARTHUR WATSON BIFCA CHAIRMAN

CHAIRMAN’S INTRODUCTION

BIOGRAPHY Arthur has been working at the Almor Group for over 20 years. He is responsible for sales, engineering and project management of Wild Barfield equipment and major site service projects. He previously worked for British Furnaces, Wellman Furnaces and Marathon Monitors in a number of engineering roles. He is a qualified Mechanical Engineer and has been involved in the furnace and process industry for almost 50 years.

Arthur is currently Chairman of BIFCA, the trade association for the British Industrial Furnace Industry. In his spare time he enjoys most sports (watching only these days), gardening and travel.

Furnaces International

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DANNY BRENNAN

DANNY BRENNAN PRINCIPAL CONSULTANT DB GAS ASSOCIATES

THE GAS QUALITY DEBATE AND GAS FIRED PROCESS HEATING EQUIPMENT At present the gas quality in the UK is governed by the Gas Safety (Management) Regulations 1996 which specifies the maximum and minimum energy content of the natural gas in the UK system. The EU are looking at extending the range of the gas quality and as we have two interconnectors with Europe and two interconnectors to the Republic of Ireland it is thought, despite

BREXIT, we will still be part of the proposed extended gas quality range.

The UK have carried out limited trials in Oban, in Scotland, on possible increasing the range of the gas quality but there is very limited knowledge on how this increased range will affect natural gas fired industrial process heating equipment. It would appear that the consultants involve in the trials also have

limited knowledge or experience of gas fired industrial process heating. The presentation will examine some of the trial work and then look at how the proposed increase in gas quality range is likely to affect industrial gas fired process heating equipment based on the knowledge and experiences of a practical gas engineer.

BIOGRAPHY Danny Brennan was initially employed by British Gas designing gas fired process heating equipment, including furnaces, kilns, ovens, driers etc. Having moved into industrial natural gas consultancy Danny ultimately left British Gas to set up DB Gas Associates, where he is Principal Consultant.

DB Gas Associates, which were established 24 years ago, are involved in consultancy on all aspects of gas fired process heating equipment as well as preparing/running site specific and bespoke industrial gas awareness and gas safety courses. Over the years Danny has been involved in incident investigation as well as being engaged in ‘Expert Witness’ work, he is acknowledged as an expert in all aspects of gas fired process heating equipment, including Gas Regulations and Gas Standards, by Courts throughout the UK. Danny Brennan has also been invited to give lectures, talks and presentations to many learned bodies and institutions on all aspects of natural gas fired process heating equipment including gas safety.

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Furnaces International

RENÉ BRANDERS

RENÉ BRANDERS PRESIDENT OF CECOF EUROPEAN AND INTERNATIONAL FURNACE STANDARDS

EUROPEAN AND INTERNATIONAL FURNACE STANDARDS René Branders has experience in the development and practical application of industrial furnace standards.

This presentation will uncover the current status of the evolving EN746 series of European safety standards and the progression of some

of them to international ISO versions.

BIOGRAPHY René Branders graduated from the University of Brussels in chemical engineering in 1986, René Branders is involved in the wire industry since 1988.

He is presently the CEO of FIB Belgium, a private family company designing heat treatment lines for the steel wire industry and that was awarded “Industry of the year” by Ernst & Young in 2008 for the south part of Belgium.

Since September 2012 he holds the Chair of the European Association CECOF - The European Committee of Industrial Furnace, Heating and Metallurgical Equipment Associations- where BIFCA represents the UK interests of the branch.

He is also the President of many other organizations such as AGORIA the Federation of the technology industry in Belgium, the Federation of the Belgian Chambers of Commerce and the Belgian collective research center SIRRIS focusing on the transposition of new technologies to industrial scale solutions.

Furnaces International

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ADRIAN GOODBRAND FEATURE

ADRIAN GOODBRAND DIRECTOR OF SALES VACUUM FURNACE ENGINEERING LTD

THE IMPORTANCE OF SAFETY STANDARDS Adrian will outline the key principles of standards and why they are necessary. He

will address this from the perspective of the furnace designer/manufacturer with the

production of vacuum furnaces in mind and, of course, the benefits to the end user.

BIOGRAPHY Adrian Goodbrand is a technical and sales professional with over 15 years experience in the vacuum furnace industry and has worked with VFE for 7 Years. Adrian holds an MEng qualification in Chemical Engineering and is a Chartered Engineer through the Institute of Materials Minerals and Mining.

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Furnaces International

JONATHAN FARMER

JONATHAN FARMER SALES DIRECTOR DUOMO (UK)

AN OVERVIEW OF GAS STANDARD IN THE UK The Institute of Gas Engineers have produced a set of gas standards for application in the UK.

Jonathan will outline the scope of these standards as available to the industrial furnace industry and attempt to position them

alongside other established European and worldwide furnace standards.

BIOGRAPHY Jonathan Farmer has 25 years working within the combustion/furnace industry.

Previous roles at Stordy Combustion, Fives North American, Hasco Thermic, Solios Thermal, Nu-way and Hotwork Combustion Technology.

Application experience of both high and low temperature combustion.

Currently on the IGEM update/revision panel as an industry expert forUP12 Application of industrial burners.

As a business we are also assisting the CBM with energy efficiency support and direct involvement with Hydeploy looking at hydrogen deployment into the UK gas network for industry.

Furnaces International

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RICHARD HEATH

RICHARD HEATH GROUP HEALTH, SAFETY AND ENVIRONMENT MANAGER THE CAST METAL FEDERATION

FURNACE OPERATIONS SAFETY – A USER’S PERSPECTIVE This presentation will cover the safety and technical issues with the operation and maintenance of a furnaces in a foundry

environment. It will consider the application of relevant standards (where available!) and Richard will highlight some interesting statistics

relating to situations commonly encountered.

BIOGRAPHY Richard has worked in the foundry industry since leaving school, with 25 years in a high pressure diecasting foundry where, from starting as a trainee toolmaker, he ultimately became the Group Health, Safety and Environment Manager. In 2012, he joined the Cast Metals Federation, which is the trade association for the UK foundry industry, as the Health, Safety and Environment Officer. Amongst other activities, he is the administrator of the SHIFT Initiative, the only dedicated foundry industry safety initiative in the Western Hemisphere. Richard is a member of the Health & Safety Executive’s oversight committee for foundry safety (CHASAC) and represents the industry on a number of other HSE groups and committees. He also represents the UK on the European Foundry Association’s Committee for Energy, Environment, Safety and Health, and is the national NEPSI representative for the UK foundries.

In 2018 Richard was awarded the Institute of Cast Metals Engineers’ (ICME) Oliver Stubbs Medal for his work in training and improving health & safety in the UK’s metal casting industry. He is also a Professional Member of the ICME.

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Furnaces International

MARK LINDSAY

MARK LINDSAY CO-DIRECTOR AND CO-OWNER OF PRODUCT APPROVALS LTD

MARKET ACCESS FOR THE UK The dominant furnace standards in Europe and the UK since the late 1980’s have been the EN746 series. Brexit has now happened and infrastructure changes are taking place.

CE marking still exists and will continue to exist but the UK has introduced the UKCA mark.

What will this mean? Mark will illustrate and clarify some of the issues surrounding

‘Notified Bodies’, ‘Approved Bodies’ and the options facing not just UK players but international ones as well.

BIOGRAPHY Mark Lindsay BSc CEng MIET joined as a co-director and co-owner of Product Approvals Ltd in January 2014.

Mark has over 20 years’ experience in the compliance engineering.

Having previously worked as a senior compliance engineer specialising in product safety for a global electronics manufacturer, and since joining product approvals has worked on many projects from machinery to appliances to control equipment across many global certification including CE, North America and Australia.

Mark sits on the Underwriters Laboratories UL 50 / 50E (Enclosures for electrical equipment environmental / non-environmental) and UL 840 (Insulation co-ordination) Standards Technical Panels and will contributes to the further development of these standards. He is well versed in many others standards across several compliance fields.

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STUART HAKES

STUART HAKES CHIEF EXECUTIVE

LOOKING FORWARD THROUGH GLASS

This presentation will consist of the options available for the future of glass furnaces

in order to reduce the impact on climate change. The presentation will look at existing

technologies and future developments in the pipeline or mooted

BIOGRAPHY Stuart has been in the glass industry for 55 years . He started as a cadet at Key Glass, Harlow (now O-I Harlow) and on qualifying took the role of Furnace Supervisor. He was then Batch & Furnaces Superintendent before going to the New Cross Plant, London as Production Manager. He then returned to his native New Zealand as Manufacturing Manager at Crown Crystal Glass, part of the ACI Group in Australasia.

He joined FIC (UK) Limited as C.E.O. in 1999 and has been there ever since.

He is currently President of the Society of Glass Technology, starting his 3 year term in 2019.

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Furnaces International

CLAUDIO GOLDBACH

CLAUDIO GOLDBACH CHEMICAL ENGINEER

REDUCING EMISSIONS AND INCREASING OUTPUT IN A CONTINUOUS THERMAL PROCESS USING AI This case will show how TERMICA Solutions is helping Arcelor Mittal Tubarao to reduce

emissions and increase output using data science and machine learning as tools but

business, people and environment as main favored.

BIOGRAPHY Chemical Engineer, Claudio Goldbach has 25 years of experience in thermal processes, and extensive knowledge of industrial equipment such as furnaces, ovens and heaters.

He has guided his career in the relentless pursuit of innovation and efficiency of industrial thermal processes.

CEO of PERFIL Group, holding company in the thermal industry, established in Brazil and USA. He is also Director of ABII (IIoT&Industry 4.0 Brazilian Association), Advisor and Board Member.

Furnaces International

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DIRK SCHNURPFEIL

DIRK SCHNURPFEIL RESEARCH AND DEVELOPMENT MANAGER GLASS MELTING FURNACES GLASS MELTING FURNACES

This presentation will explore the general aspects of glass melting furnaces and factors influencing the furnace design.

BIOGRAPHY Dirk Schnurpfeil studied chemical technology of high-temp. “melting silicate materials“ at Mendeleev University of Chemical Technology of Russia in Moscow. He now has a Diploma as an Engineer of chemical technology of glass. First beginning his career in hollow glass / lighting industry at Glashuette Limburg Gantenbrink & Co KG. He went onto work on replacement of lead-containing coatings with sol-gel-based ones. Dirk Schnurpfeil then moved to float glass industry, Guardian Flachglas GmbH Thalheim (Germany) and worked as a process engineer in all possible positions along the line (Batch house, Furnace, TinBath, AnnealingLehr, ColdEnd, QualityControl & QM). For the last couple years he has worked in the regional OpEx-group, supporting all european plants of the group.

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Furnaces International

ANDREA BAIO

ANDREA BAIO VICE PRESIDENT, CECOF

EUROPEAN AND INTERNATIONAL FURNACE STANDARDS

René Branders and Andrea Baio have vast collective experience in the development and practical application of industrial furnace

standards. This presentation will uncover the current status of the evolving EN746 series of European safety standards and the

progression of some of them to international ISO versions.

BIOGRAPHY Andrea Baio has a Degree in Aerospace Engineering at Milan Polytechnic. He was employed at ESA S.p.A. from December 2003 and became the R&D Manager from October 2005 transferring to a technical Manager from September 2009.

H was also the project management of combustion processes at national and international level with development of new burner system, according to fuel saving and low emissions. Andrea Baio also has a technical background in Mechanical and Fluid Dynamics.

Now working for CECOF, his employment timeline is as follows: Technical Delegate for CECOF – The Italian Furnace Manufacturers Association from December 2016 President of CICOF – The Italian Furnace Manufacturers Association from April 2019 Vice President of CECOF - The European Committee of Industrial Furnace, Heating and Metallurgical Equipment Associations CEN/TC186 expert from February 2018 ISO/TC244 expert from October 2019 Convenor of the “GET – Hydrogen” for ANIMA - Confindustria (the Italian mechanical engineering industry Association) from July 2021

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EXHIBITOR & SUPPORTER PROFILES

AMETEK LAND

CAST METALS FEDERATION (THE)

https://www.ametek.com/

https://www.castmetalsfederation.com

AMETEK Land is the world’s leading manufacturer of monitors and analysers for industrial infrared non-contact temperature measurement, combustion efficiency and environmental pollutant emissions.

The Cast Metals Federation works to foster development, collaboration and innovation in the UK casting industry, in partnership with businesses and stakeholders, to promote good practice and represent the Best of British casting across the globe.

As the single voice for the UK foundry industry, CMF promotes the UK castings industry as a whole, influencing discussions with government bodies, negotiating and consulting on UK and European legislation that affects us all.

CMF Members come from every part of the industry and produce around 85% of all castings produced in the UK. From global foundry groups to small jobbing foundries, our Members supply precision finished parts and assemblies in a range of sizes, metals and processes to global markets, valued at over £2.2B.

Through its trusted range of leading-edge technologies, it is chosen the world over to deliver the highly accurate measurement solutions that precisely meet every customer’s process needs. With unrivalled applications knowledge, choosing AMETEK Land ensures the highest standards of process safety, process control and product quality are reached.

BIFCA BRITISH INDUSTRIAL FURNACE CONSTRUCTORS ASSOCIATION

CECOF

https://www.cecof.org http://www.bifca.org.uk The aims and objectives of BIFCA: � To provide a means of co-operation between the members in the mutual interests of themselves and their customers. � To develop the growth of trade relevant to the industry and to take action in regard to any matters of general interest to that trade. � To co-operate by affiliation or otherwise with bodies having kindred interests. � To be a channel through which the views of the industry on economic and trade problems can be made known. � To represent the interests of members in negotiations with Government Departments, Trade Organisations and other relevant bodies. � To be a full and active member of CECOF, the European Committee of Industrial Furnace and Heating Equipment Associations. � To provide facilities for personnel in the industry to continue their education and training. � To take whatever actions are necessary to fully implement the Association’s Constitution.

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CECOF was founded in 1972 as a European association platform for the thermo processing industry. Since then, CECOF has developed into the respected voice and lobby organisation of the the industry in Europe. Against the background of common interests, it was decided at the 2019 General Assembly to open up to companies of the metallurgical plant construction sector. The full name is now CECOF - The European Committee of Industrial Furnace, Heating and Metallurgical Equipment Associations.

CECOF represents the industry’s interest vis-à-vis national and European institutions, sets and harmonises national rules, regulations and standards and elaborates technical guidelines. Attractive platforms are provided by organising events and supporting exhibition activities.

Furnaces International

EXHIBITOR & SUPPORTER PROFILES

CELSIAN

FEVE THE EUROPEAN CONTAINER GLASS FEDERATION

https://www.celsian.nl https://feve.org/ Glass Experts CelSian’s aim is to minimize the cost of making glass for end users and the environment. We have an agile team of glass experts using proven methods like furnace modelling, laboratory measurements and practical furnace health checks to optimize glass melting processes. We also train operators and glass technologists through our standard course, dedicated programs and various e-learning modules. We strive to be the best partner for optimization of glass production worldwide.

FEVE is the Federation of European manufacturers of glass containers for food and beverage and flacons for perfumery, cosmetics and pharmacy markets. Its members produce over 80 billion glass containers per year. The association has some 60 corporate members belonging to approximately 20 independent corporate groups. Their 160 manufacturing plants manufacturing plants are located across 23 European States and maintain 125.000 direct and indirect jobs along the total supply chain.

DUOMO

F.I.C

https://www.fic-uk.com https://duomo.co.uk Duomo (UK) Ltd was set up in 1994 to meet the requirement for enhanced gas safety in boiler plant rooms and commercial kitchens.

Duomo secured large contracts with major local authorities and this led into the more commercial market.

The word spread; the gas safety equipment led to different product sectors too. the company started to sell carbon dioxide sensors and process burner controls, the latter as a result of our prior experience in industrial combustion and its control.

Duomo grew , doubling its capacity within six years and then redoubling that again in 2014. The Duomo design, manufacturing and testing facility in Droitwich, Worcestershire has been conceived to bring new products onto the market as quickly as trends and standards change.

Furnaces International

Industrial Furnaces for Melting Metals Starting at Penzance in corneal, the company is now recognised across the world.

F.I.C design and supply electrical boosting systems for all glass types and manufacturing processes including TFT, LCD, float, fibre, holloware and borosilicate. Additionally, they supply all-electric furnaces and forehearths, offering advanced glass conditioning options with the Isothermal unit to improve side to middle and top to bottom temperature gradients.

The company also offer systems to extract heat out of the glass to aid glass conditioning and reduce gas consumption through the use of removable water-cooled tubes. These tubes can be placed anywhere from the throat to the back of the forehearth. These cooling tubes can also be inserted adjacent to severely eroded refractories to delay or even prevent premature replacement of these areas.

Within the range of electrode holders manufactured by FIC is the High ‘Q’ holder, in which the cooling circuit is replaceable in less than 10 minutes. More than 10,000 of these holders have been supplied since their introduction about 20 years ago. Recently they have introduced the Maxi ‘Q’ holder which is constructed such that no welded portion is located within the refractory and it has the largest cross-sectional area of waterway when compared to all other holder designs.

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EXHIBITOR & SUPPORTER PROFILES

GHI

MECHATHERM

https://www.ghihornos.com/en/

https://www.mechatherm.com/

Industrial Furnaces for Melting Metals GHI have an extensive catalogue of products and services for ensuring the highest quality standards.

Established in 1973, Mechatherm International Ltd. is a world leading provider of bespoke casthouse equipment to the global Aluminium industry. Specialising in solutions tailored to each of our client’s specific requirements, Mechatherm can take on various sized projects ranging from small existing plant upgrades right through to multi-million-pound turnkey projects.

Since 1937, GHI have been designing and manufacturing industrial furnaces for melting, heat treating and heating any type of metal.

The equipment uses cutting-edge technology, which enables the company to identify anomalies, provide support for in-use improvement, and plan predictive maintenance activities. The aim is to minimise unexpected downtime and to maximise the potential of installations.

INSPIRED ENERGY

https://inspiredenergy.co.uk Established in 2000, Inspired Energy has grown to become one of the largest energy consultancies in the UK, and is now part of a group of companies within Inspired plc.

The current climate change challenges facing UK businesses are vast and there has never been a substantive independent solutions provider to support them.

Inspired PLC is changing that.

We operate three divisions. The core Energy Solutions division and the emerging Software Solutions and ESG Solutions divisions.

We provide expert energy advisory and sustainability services to over 3,000 UK businesses, which represent c.6.5% of the UK’s expenditure on electricity, and over 400 businesses in the Republic of Ireland (ROI). containers per year. The association has some 60 corporate members belonging to approximately 20 independent corporate groups. Their 160 manufacturing plants manufacturing plants are located across 23 European States and maintain 125.000 direct and indirect jobs along the total supply chain.

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Supplying to both primary and secondary Aluminium markets, Mechatherm’s core products include all types of melting furnaces, contaminated scrap recycling furnaces, interconnecting launder systems, VDC casting machines alongside the integration of third party supply equipment such as stirring and filtration systems into our designs.

With integrated spares and service divisions, lasting partnerships are embedded into Mechatherm’s core values. Strategically focused on the future, developing the design process with innovative technologies that reduce not only operational costs but also their impact on the environment.

PERFIL GROUP

https://perfil.group/ PERFIL Group, founded in 1982, develops integrated solutions for thermal processes, from design to maintenance, in various segments.

With a highly qualified technical team that analyses and defines the most appropriate applications for the needs and structure of each client, acting through its three operational units: Thermal Profile, TERMICA Solutions and TERMIA Technology.

Currently, the operating companies serve various economic sectors, including the production and processing of ferrous and nonferrous metals, foundry, metallurgy, steel, petrochemical, chemical, agribusiness, food, OEM, wood, pulp, paper, ceramics, glass, among others. With units in Brazil (Joinville and Curitiba) and in the United States (Florida), the PERFIL Group has an experienced

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EXHIBITOR & SUPPORTER PROFILES

and dedicated technical-commercial team supported by a multidisciplinary engineering team.

VFE VACUUM FURNACE ENGINEERING (VFE)

It achieved a prominent position in terms of commitment, quality and innovation in the market. As part of the Clean Company project, the group works for integrity and against corruption. As signatories of this project, our mission is to promote a more honest and ethical market.

PRODUCT APPROVALS LTD

https://www.productapprovals.co.uk Product Approvals Ltd works on product certification requirements.

Product Approvals Ltd offers comprehensive fully independent consultancy, project management and testing services. Including obtaining UL listing and UL approvals for the USA, CE marking for the EU, design safety reviews, checking & testing of imported products, managing approvals on your behalf and training on compliance subjects.

https://www.vfe.co.uk Vacuum Furnace Engineering (VFE) is a market-leading provider of maintenance servicing for heat treatment industry equipment including vacuum furnaces, melting and casting furnaces, electron beam welders, pumps, spark plasma sintering and autoclaves.

VFE is also is a specialist in the design, supply and overhaul of vacuum furnaces including control system upgrades and modifications, and hotzone design, replacement, and overhaul.

VFE has a world-wide portfolio of high profile customers in all sectors of manufacturing industry including aerospace, land based power generation, automotive, medical, general engineering and sub-contract heat treatment industries.

SORG

PYROGENESIS

http://www.sorg.de https://www.pyrogenesis.com PyroGenesis Canada Inc., a high-tech company, is a leader in the design, development, manufacture and commercialization of advanced plasma processes and sustainable solutions which reduce greenhouse gases (GHG), and are economically attractive alternatives to conventional “dirty” processes. PyroGenesis has created proprietary, patented and advanced plasma technologies that are being vetted and adopted by multiple multibillion dollar industry leaders in four massive markets: iron ore pelletization, aluminum, waste management, and additive manufacturing.

With a team of experienced engineers, scientists and technicians working out of its Montreal office, and its 3,800 m2 and 2,940 m2 manufacturing facilities, PyroGenesis maintains its competitive advantage by remaining at the forefront of technology development and commercialization. The operations are ISO 9001:2015 and AS9100D certified, having been ISO certified since 1997.

Furnaces International

SORG was founded in 1872 in the Thüringen Forest area of Germany. Following World War II, SORG relocated to Lohr am Main where we continue to grow and develop. Today SORG is the leader in glass melting and conditioning technologies. We solve customers’ problems, keeping their investments safe and sustainable.

FUTURE OF FURNACES

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INDUSTRY 4.0

Use of in-furnace thermal im for industry 4.0 and decarbo in steel, non-ferrous and gla

By Philippe Kerbois* and Neil Simpson**

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Furnaces International

INDUSTRY 4.0

maging onisation ass

Ensuring consistent temperatures within furnaces is essential to maintaining highquality production of metal or glass, and for extending the campaign life of the furnace.

There are a variety of furnace locations where the temperature must be closely monitored to achieve these objectives. For best results, the ability to trend temperature measurements throughout the whole furnace is essential.

For more than a century, optical pyrometers were the temperature measurement instrument of choice for high-temperature combustion processes.

Temperatures were taken within the process at least once per shift, and sometimes every 20 minutes.

A portable pyrometer – such as the AMETEK Land Cyclops L or equivalent – is often used to check temperatures at critical points in the furnace whenever there is a process problem.

Ten years ago, AMETEK Land developed remote, infrared imaging technology, allowing hundreds of thousands of temperature measurement points to be recorded every second.

The company’s innovative Near Infrared Borescope (NIR-B) initially measured 324,000 optical temperatures continuously in the furnace, enabling accurate temperature measurement from any point.

This provides much greater accuracy and control of temperatures in the furnace, ensuring optimum product quality, efficiency and asset longevity.

Benefits of thermal imaging Near Infrared thermal imagers generate a visual, thermal image of the furnace – not to be confused with a simple CCTV image.

Modern devices display up to 3 million fully radiometric calibrated camera pixels in the temperature range from 600 to 1800 °C (1112 to 3272 °F) – a development of technical significance for energy-intensive heavy industries like steel, non-ferrous, cement and glass production.

*Glass Sector Lead at AMETEK Land **Consultant of Simpson Combustion & Energy Furnaces International

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INDUSTRY 4.0

IMAGEPro advanced

Thermal imaging offers many advantages over visual imaging and point temperature measurements. A permanently installed thermal imaging camera that actively records all necessary and useful data allows the video to be stopped at any frame. Accurate measurements can be taken at the exact same point in the process, allowing processes to be tuned more accurately.

Glass furnace monitoring AMETEK Land’s NIR-B thermal imaging cameras have been operating continuously since 2014, with more than 50 reference installations in glass melting furnaces globally.

More recently, transportable instruments are being used to perform dedicated in-furnace thermal surveys.

For decades, in-furnace endoscopy and external furnace thermal imaging have been used to monitor and record visual changes in refractory. With the NIR-B there is the potential for an additional “visual endoscopy” with previously unmeasured thermal data.

Wherever there is an existing peep-site, there is the potential to obtain a 95° field of view image. While a visual image will look similar, the thermal data can identify a difference of

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only a few degrees.

An NIR-B survey is often recommended, as it offers all of the benefits of a permanent and continuous temperature measurement installation, which provides significant benefits over the traditional “snapshot” method.

In all cases, the key benefit of continuous measurement during a furnace reversal is that it gives better visibility of maximum and minimum temperatures. That is important because in glass, if the temperature goes below 1388 °C (2440 °F), there is a risk of sodium hydroxide (NaOH) condensation.

The potential scope of a survey is significant, and the challenge is to decide the priority of what to look at – with now nearly 3 million thermal data points in one image, the analysis and interpretation of the data can take longer than making the actual measurements.

The in-furnace thermal survey is not an alternative to a conventional traditional refractory inspection, but a supplementary service.

It can provide data to show when there is either too much or insufficient cooling at the metal line and, in extreme cases, where there is a hole. By utilising a negative image,

the lighter points show where there may be too much cooling, which leads to increased energy and resulting emissions, but also increased wear of the refractory as the batch piles drag along the refractory.

This information allows corrective action to be taken before it results in a more costly or disruptive outcome.

The furnace thermal profile will define the hot spot and the location of the thermal up-well. If the furnace is flat bottomed, with no “mechanical” influencers, then the hot spot can move. However, if there is a mechanical device such as weir wall, bubblers, or electrodes, then the hot spot of the thermal profile needs to be at the same location. If it is not, then there is a conflict between the mechanical and thermal systems, with quality/ yield being the only loser.

With the fixed system NIR-B, the thermal profile may be continuously viewed, with the survey offering the opportunity to see the profile along the entire length of the furnace.

Using a single CCTV camera – traditionally in the bridge wall or throat end of the furnace – 60-80% of the furnace is typically visible. However, this means the wall where the camera is located is never seen.

Furnaces International

INDUSTRY 4.0

Auto-Retract System to protect the thermal imager from damage by overheating in the event of loss of water flow, air pressure, electricity supply or high borescope tip tem

Near Infrared Borescope (NIR-B-2K-Glass) thermal imaging solution for glass furnace applications

When an NIR-B thermal survey is performed on a float glass furnace, it is typical to view from all four corners. This establishes the hot spot and, specifically, if it has moved or is different from one side to the other. In the majority of float furnaces, the view from the dog-house towards the waist highlights areas where the temperature is below 1388 °C (2530 °F). In some cases, it highlights the corrosion which has already occurred to the silica refractories due to NaOH formation.

If one exhaust port is hotter than before, with another colder, it may suggest that the colder port is becoming blocked, and the exhaust flow is being restricted. If time permits and support is available, there is the option to view each port either through the target wall peep-site or through an under-port burner block.

This will help determine if there is an imbalance from the right to the left side target wall temperatures. The view shows which flame is hotter, suggesting which burner needs adjustment – typically, it is then necessary to make another set of measurements to confirm that the issues have been resolved.

Structural damage caused by abnormally Furnaces International

high or low operating temperatures can be identified early on and remedied before it develops into something far more serious, avoiding potentially dangerous situations, expensive repair costs and lost production time.

Thermal imaging technology makes it possible to accurately image the temperature of a large area of a furnace through only a small opening in the wall. It gives the operator access to data that would have previously been either time consuming or impossible to collect.

The latest infrared temperature measurement systems allow real-time data to be streamed in time-lapse modes, allowing process engineers to visualise the product flow. Alarms can be set in the control equipment to alert operators and ensure production achieves optimum quality.

Precise thermal imaging can extend the lifespan of the melt tank or furnace, providing greater asset protection through more accurate temperature measurement.

Thermal imaging cameras can also be positioned underneath the melt tank to detect hot spots early on, potentially preventing a break-out below the tank.

Conclusion Analysing the massive amounts of in-furnace temperature data captured by the NIR-B enables the validation of computational fluid dynamic (CFD) models and supports predictive control.

Using alarms for variance to design, set point, and previous times improves quality and yield, and reduces waste as the first step to decarbonisation.

Advances in measurement technology are helping plants to make significant improvements in the improved quality of output, and in reducing operating costs.

Thermal imaging technology that enables operators to maintain an accurate visual of the entire glass-melt tank, as well as take temperature measurements at any point in the process and in any location within the tank, can provide invaluable data for the operation of any modern plant. � FUTURE OF FURNACES

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BIFCA COLUMN

BIFCA Seminar to highlight standards BIFCA is pleased to announce that it is supporting the new Furnace Industry technology showcase event called Future of Furnaces.

This brand new online event will take place on 14-15 September 2021 and will attract an international audience of senior delegates from the furnace industry including manufacturers, end users and ancillary product and service providers.

The event will unite the glass, aluminium and steel sectors and is being promoted via this journal Furnaces International, and other key media including Aluminium International Today, Glass International and Steel Times International, whose collective reach is 50,000.

Industry 4.0; Furnace Maintenance; Heat Treatment; Energy Efficiency; Testing and Measurement; Operations and Productivity; Emerging Technologies and Retrofitting.

Alongside the two-day congress, participants will be able to join live discussions and will have the opportunity to network with new industry contacts, arrange video meetings and exchange resource information.

Subject areas will include: Adoption of

Additionally, BIFCA will be hosting its Standards and Regulations Seminar as part of the overall Future of Furnaces event on day two, 15th September (see separate panel).

Organisers, Quartz Business Media, have said “One way we have worked to keep our sectors connected is through virtual events, conferences and webinars”, in response to the continuation of business throughout the Covid-19 pandemic. “It gives people a platform to meet and discuss new projects and plan for the future.”

“One way we have worked to keep our sectors connected is through virtual events, conferences and webinars” Organisers, Quartz Business Media, in response to the continuation of business throughout the Covid-19 pandemic.

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BIFCA’s Annual Standards and Regulations Seminar will be held on 15 September 2021 alongside, and in support of, the Future of Furnaces two-day showcase.

This year’s seminar will be held on-line and once again we aim to update and inform the industry on the various safety standards and regulations affecting all aspects of our sector.

Central to the theme is the continuation of the evolving standards work within the suite of EN746 standards which will be presented by Lars Boehmer of CECOF. Even though Brexit has now happened, many UK industries are entrenched in safety standards developed in conjunction with our European partners over many years and it is likely that the work mandated within these reference texts will continue as European documents within a national framework.

The expert speakers have vast experience and will highlight key changes and updates occurring within the last twelve months in relation to safety, design and use of various types of furnace equipment. Legislation comes in the form of both standards and regulation effected by directives such as the machinery directive.

If you are interested in submitting a presentation for the BIFCA seminar please contact the Association: enquiry@bifca.org.uk.

We particularly welcome papers from end users on the impact of furnace standards in all types of applications.

IN-FURNACE THERMAL GLASS SURVEYS GAIN INSIGHTS INTO THE THERMAL PROCESSES IN A GLASS MELT TANK WITH ACCURATE REAL-TIME TEMPERATURE MEASUREMENTS. A unique service for the thermal optimisation of furnaces, the In-Furnace Thermal Glass Survey produces real-time and recorded images for analysis, supplementing traditional refractory inspections.

A SURVEY HELPS TO: Improve productivity with optimised pull rates Increase thermal and combustion efficiency Lower fuel costs Protect the refractory from damage Extend campaign life Optimise flame pattern to reduce energy consumption Ensure emissions compliance

MARKET-LEADING TECHNOLOGY

NIR-B Glass

Optimised for measuring high temperatures between 1000 to 1800°C (1832 to 3272°F), the NIR-B Glass thermal imager creates detailed and live highresolution images from within the furnace. Dedicated image processing software ensures accurate data analysis. The Lancom 4 portable multi-gas analyser measures up to eight flue gases for the optimisation of combustion and emissions processes.

Lancom 4

THE IN-FURNACE THERMAL GLASS SURVEY IS AMETEK LAND’S UNIQUE THERMAL OPTIMISATION SOLUTION FOR GLASS REFRACTORY APPLICATIONS L A N D. E N Q U I R Y @ A M E T E K . C O M

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W W W. A M E T E K - L A N D . C O M

ASSOCIATION UPDATE

A resilient UK foundry industry remains optimistic UK foundries report that there is hope for a return to pre-Covid capacity utilisation levels, despite the impact of the 2020 lockdown measures and the resulting decline in production activity. This is the finding of the Cast Metals Federation (CMF) Business Impact Survey – 2020 Summary Report.

Despite the negative impacts of the pandemic including a fall in demand, the need to pause business operations for a short period and make additional investments to make workplaces Covid-secure, and prolonged supply chain disruptions, the mood remains positive amongst CMF members, with most reporting optimism for 2021.

With 2019 resulting in a significantly better year than recent years for the UK foundry sector, a decline in order books was anticipated during the early part of 2020, with concerns surrounding the outcome of ongoing Brexit trade deal negotiations. By March, the industry was also faced with responding to the global coronavirus pandemic and has subsequently responded with agility and resilience. The rapid change in volumes for the automotive and aerospace sectors saw order books plummet, specifically in the diecasting and investment casting sectors. Two lockdowns and the practicalities of operating facilities under imposed government social distance restrictions – reduced workforce, additional health & safety measures in working and common areas, supply chain disruptions etc. – have taken their toll.

The impact on business has been significant. Throughout the summer order books remained short, but by the autumn business levels were picking up, with the foundry sector well placed to respond.

However, a resurgence in infection rates resulted in a second lockdown and a slowdown in demand as the year closed.

To counter the negative effects of the pandemic, CMF members have drawn on the assistance made available by various government schemes, such as CBIL loans for additional finance, deferred VAT payments and the coronavirus job retention scheme

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(CJRS), however this has not been without its own challenges.

CMF members report that by far the most significant support has been the CJRS, with a large number of members making use of the opportunity to furlough employees at different periods throughout the year for varying lengths of time. By the middle of 2020, the average percentage of employees on furlough was 30 per cent. This lifeline enabled Members to retain staff and meet customer demand, playing to the sector’s strength in terms of skills and responsiveness.

The scheme has allowed companies to maintain production levels when required, most notably in the latter half of the year particularly quarter 4 when orders increased.

There were however some redundancies, but the levels were low compared to other sectors.

As expected, business disruption has taken many forms and is not merely confined to a downturn in customer demand.

At the start of the crisis, many members significantly reduced or paused production to reorganise workplaces and implement social distancing measures, to enable operations to resume in a safe and efficient manner. In addition, procedures had to be adapted to accommodate operating with a reduced workforce to meet government guidelines and to support the shielding of vulnerable employees.

By the middle of the year, the industry had adapted to the new working procedures, but supply chain disruptions continued thanks in part to the lack of production capacity throughout the supply chain and logistical challenges. This was compounded by significant increases in costs for waste disposal, energy supplies (specifically in

quarters 3 and 4) and insurance. From midquarter 2 through to the middle of quarter 3, some members reported problems with sourcing the required PPE/RPE because of an increase in demand from the NHS and social care sectors, thus reducing availability and driving up the cost. However, this temporary problem was mostly resolved by the end of quarter 3.

In some instances, customers also sought notable price reductions with the foundry industry thus squeezed at both ends.

Despite all of this and as the economy mounted a tentative recovery during quarters 3 and 4, CMF members reported improvements in order books.

There are of course exceptions and those businesses considered to be in an ‘essential’ supply chain – 40 per cent of foundries and 15 per cent of foundry suppliers – had a busy year, often with increased demand and the specific challenges that poses.

Towards the end of the year and the end of the Brexit transition period, a large proportion (73 per cent) of members said they were prepared for a new way of working as the UK exited the European Union. There was concern over the late timing of the publishing of final detailed guidance, but there is also “hope” that there would be increased opportunities for local content in supply chains.

Notably, despite a very testing year, no member has reported the need to close or scale-down operations in the longer term.

Members also reported that on average they would return to 2019 capacity levels within ten to twelve months. � Contact: Dr Pam Murrell FICME, email: pammurrell@cmfed.co.uk Furnaces International

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FURNACE FOR THE FUTURE

The ‘Furnace for the Future’ project gathers momentum

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Furnaces International

FURNACE FOR THE FUTURE

FEVE’s ‘Furnace for the Future’ project has recently been elected to Stage 2 of EU funding.

Adeline Farrelly* explains what that means, what happens next and what it means for the future of the container glass industry.

If successful, Ardagh Group will build the first furnace in Germany in 2022 with the first bottles produced in 2023.

On 24th March 2021, the EU Commission published their short list of projects invited to enter the second-round application process for funding from the EU’s new ETS Innovation Fund. The container glass industry’s Furnace for the Future (F4F) was one of the selected projects.

“We are so proud to be on the list and to get to the next stage,” says Fabrice Rivet, FEVE’s Technical Director.

“The evaluators gave us very positive feedback, which is very encouraging, as we now prepare the full application for the 23rd June 2021 deadline”.

The Innovation Fund is one of the world’s largest funding programmes for the demonstration of innovative low-carbon technologies.

A total of 311 projects were submitted in the first round for grants totalling €21 billion making the ETS fund 21 times oversubscribed.

Furnace for the Future is one of the 70 projects selected to go forward to the final phse.

Industry ambition By 2050 the container glass industry aims to achieve a major revolution, starting now, in the way glass is produced making it fit for a circular and climate-neutral economy.

Companies are gearing up to secure the future of the sector and the jobs that depend on the industry within important value chains (food and beverage, pharma, cosmetics, and perfumery).

The F4F is a collective industry demonstration project, technically and financially supported by 19 container glass companies, which will develop a breakthrough technology to significantly reduce CO2 emissions from container glass furnaces by replacing 80% of the currently used natural gas by renewable electricity.

It will be the world’s first large-scale 350 tonnes/day hybrid electric furnace to overcome existing technological barriers, capable of melting all glass colours and incorporating high levels of recycled glass.

With this new hybrid technology, container glass will be able to cut 50% of current CO2 emissions from the factories.

Table 1.

Solving the carbon emissions will enable the sector to offer a fully climate-neutral packaging solution, in addition to being fully circular.

At present, 80% of container glass CO2 emissions come from the combustion of natural gas to melt glass and Furnace for the Future is addressing this head on. But there is also the 20% of CO2 emissions from the virgin raw materials used to make glass.

Circular economy – Closing the loop A different strategy is needed to eliminate this remaining 20%. Addressing these emissions involves replacing virgin raw materials with recycled glass (cullet). Closing the glass recycling loop is therefore a primary objective.

The industry will do this by increasing EU collection of recyclable glass from 76% to 90% and make the Circular Economy for glass work better.

To this end, the container glass sector launched ‘Close the Glass Loop’ in 2020 – a multi-stakeholder platform to unite the glass collection and recycling value chain, and to establish a material stewardship programme that will result in more bottle-to-bottle recycling.

This platform brings together all those involved in the collection schemes to achieve 90% collection of recyclable glass by 2030.

Close the Glass Loop action plans are being developed at EU level and in several countries.

Company decarbonisation strategies While these flagship sector decarbonisation initiatives are hugely significant, FEVE members are also testing out other strategies at company level.

A revolutionary project undertaken by glass container manufacturer, Encirc (a Vidrala company), and industry research and technology organisation, Glass Futures, is testing whether new bottles are able to be made from 100% recycled glass, using only the energy from burning ultra-low-carbon biofuels.

German glass makers are working with BV Glas to investigate hydrogen as a potential

*Secretary General, FEVE, Brussels, Belgium www.feve.org www.closetheglassloop.eu Furnaces International

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fuel source for melting glass and to see what extent it could work off the natural gas infrastructures already in place.

According to BV Glas, hydrogen is one of the most promising candidates in the switch from fossil fuels to renewable energy sources. It has been assessing the potential of hydrogen for a long time within the framework of its decarbonisation strategy.

“Every climate-neutral production project is an important step towards new approaches in glass manufacturing that will help us achieve the long-term aim of net-zero industrial emissions” says Dr Johann Overath BV Glas Director General.

If all energy-dependent processes were switched over to hydrogen, the glass industry could theoretically reduce its carbon footprint

in Germany by approximately 3.3 million tonnes per year.

The European glass industry is investing significantly every year in the decarbonisation of its manufacturing processes (e.g. R&D in hydrogen-firing, energy efficiency measures, use of biomass etc.) and will continue investing to manufacture glass products fit for a resource-efficient, low-carbon European society.

Every year, on average, the industry invests €610 million for plant upgrades, better energy efficiency and reduced CO2 emissions. This is a significant 10% of production costs each year.

What’s next?

In the near term, the container glass industry

is potentially one of the energy intensive industries to have a clear pathway to decarbonisation through direct electrification, but requires breakthrough technology in the Furnace for the Future project.

The Commission intends to evaluate the proposals and award the grants in October/ November 2021.

If F4F is successful, the commercial scale demonstration plant will be built by Ardagh Group in Germany in 2022 with the first low carbon commercial bottles being produced in 2023.

A Special Project Vehicle will be incorporated for this project where industry shareholders will co-finance this demonstration project in addition to the EU grant.

The Furnace for the Future project is bringing together 19 container glass companies to significantly reduce CO2 emissions by replacing 80% of natural gas to renewable electricity

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Furnaces International

FURNACE FOR THE FUTURE

Against this industry investment, all the learnings and know-how of running this furnace will be shared among the SPV partners so that this technology can be rolled out and scalable throughout the sector.

There are risks with any new technology and it is not certain that it will succeed. If it does, then this will be one of the most significant breakthrough technologies for glass and represents an iconic moment in the long history and tradition of glass making in Europe.

The 19 independent companies and FEVE operating in partnership to create, fund and demonstrate a technology to prove the concept are: See table 2. �

Existing electric furnaces in the container glass industry

Future hybrid furnace (F4F)

Size (tonne glass per day)

80 – 200

350

Technology

Vertical furnace

Horizontal furnace Reduced glass (amber

Type of glass produced

Oxidised glass: flint, emerald

(If successful, all colours will be possible)

) Cullet level (recycled glass)

0 - 30%

70%

% electricity

100%

Able to work from 20% to 80%

Table 1 - Benefits of the F4F project

Allied Glass Containers Ltd Ardagh Group BA Glass I – Serviços de Gestão e Investimentos, S.A. Beatson Clark Ltd FEVE - The European Container Glass Federation Gerresheimer Moulded Glass GmbH Gürok Turizm Ve Madencilik A.Ş. (Gca Gürallar Cam Ambalaj) O-I Europe Sàrl Pochet du Courval SAS Saverglass SGD Pharma Steklarna Hrastnik d.o.o Stoelzle Oberglas GmbH Verallia Packaging Verescence Vetreria Cooperativa Piegarese Soc. Coop.

Vetreria Etrusca Spa Vetropack Holding AG Vidrala SA Wiegand-Glashüttenwerke GmbH Table 2 - The companies involved with the F4F project

Furnaces International

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SMART FURNACES

GHI Smart Furnaces work key equipment of the new in Veracruz (Mexico) 48

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Furnaces International

SMART FURNACES

ks in the supply of the casthouse to Almexa Furnaces International

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SMART FURNACES

Almexa’s new casthouse will be the newest and most efficient in all America, it will be inaugurated in the second semester of 2021.

The key process equipment will be supplied

by GHI Smart Furnaces, a world leader in the furnaces industry. The plant will have the most advanced equipment for aluminium processing aimed to achieve a circular economy.

With a production capacity of more than 90.000 t/year, the plant will have the America’s largest tilting rotary furnace of 65 tons capacity, one of the for existing in the world and all supplied for GHI. It is specifically designed for aluminium recovery.

Additionally, a salt slag cooling system will be installed to achieve higher levels of metal recovery with low environmental impact.

Furthermore, a high efficiency melting and holding furnace of 50 tons capacity with regenerative burners will be installed.

The new casthouse will be a world reference for the production of canstock, it is carefully designed to obtain high quality

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aluminium with an environmentally friendly process with full automation and smartization.

The key equipment is completely sensorized, and the gathered data is analyzed with Big data and Artificial intelligence technological solutions leveraged in the Beyond Alea platform to improve the process productivity and control of the Smart Plant.

The tilting rotary furnace will work as the main melting equipment of the plant, the resulting aluminum will be transferred to a new melting and holding furnace where, additional melting capacity is installed and the alloy will be adjusted and then, it will be transferred to the vertical casting machine.

The 50-ton melting/ holding furnace has an open front which allows a fast and efficient loading of the raw material and enables the deslagging process to be carried out efficiently. The combustion equipment with regenerative burners reduces energy consumption and environmental impact, which is one of our customer’s main objectives. The furnace is equipped with porous plugs that

increase the temperature uniformity in the aluminium bath in order to achieve the optimal levels of homogeneity in the chemical alloy.

The supplied equipment has a high technological component as it is specifically designed for the recovery of aluminium, obtaining a high metallic yield. All the equipment will provide high energy efficiency and very low CO2 emissions per ton produced.

4.0 Technology In addition, GHI Smart Furnaces will incorporate 4.0 technology into the supplied equipment through the BeyondAlea 4.0 Platform. This platform includes advanced sensorization services, digitalization, technical assistance, process consulting and preventive maintenance. As a result, the customer will have better control over the production process and a greater reduction in the consumption of the plant and therefore in the production of CO2. �

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