Periodic Reporting for period 1 - GIFFT (Sustainable Glass Industry with Fuel-Flexible Technology)
Berichtszeitraum: 2023-10-01 bis 2025-03-31
Throughout the last century, the glass industry has reduced energy consumption and CO2 emissions by more than 75% by adopting low-carbon technologies like waste heat recovery, ORC systems, insulation, and automation. However, traditional approaches are now approaching thermodynamic limits, so further advances depend on a transformation in fundamental energy and rising circularity. The "Flexible Hybrid Furnace of the Future" conceptualizes combining renewable electricity, recycled raw materials, and hybrid fuel systems. In this context, the GIFFT project aims to implement a low-CAPEX, green heat production technology based on plasma-assisted combustion and biomass e-gasification. The process enables a 75% reduction of CO2 emissions per tonne of glass, syn-gas production from biogenic residues, and the utilization of residual ash as a raw material substitute in glass production. Thermal plasma facilitates flexible operation and cleaner combustion in the event of a green electricity supply. This approach enables deep decarbonization, circularity, and energy source flexibility. The project will draw on economics, environmental and social impact assessment, and market analysis capabilities. Life-cycle analysis will evaluate sustainability, and business research will guide market potential and commercialization strategy.
Activities Performed and Main Achievements According to Specific Objectives
Specific Objective 1:
Develop an integrated heat production technology and process for glass manufacturing utilizing biomass/waste and excess or cheap renewable electricity for syngas production.
During the first reporting period, work mainly focused on WP2 and WP3. In WP2, the GIFFT process was assessed through detailed energy and mass flow evaluations (D2.3). Two application cases were developed for different furnace types in glass manufacturing: SCHOTT’s oxy/fuel furnace and PS’s air/fuel regenerative furnace. These cases established target concepts for further analysis in WP7. A review of biomass availability in Lithuania, Sweden, and Germany (D2.1) confirmed that logging residues, agro-waste, and lignin are available in sufficient quantities and at cost levels aligned with project KPIs. A technology review (D2.2) identified plasma-assisted entrained flow gasification as a promising method due to its efficiency and low tar output. Additionally, its vitrified ash may be used in glass manufacturing if residual carbon is low. WP3 focused on preparing for gasification testing. This included modifying the reactor to include a plasma-assisted burner (D3.1) preparing feedstock (D3.2) and completing construction and maintenance work. Initial testing is expected by May 2025. Most experimental validation for this objective will take place in the next project phase.
Specific Objective 2:
Develop and validate at TRL5 the key enabling technologies required for realizing the GIFFT process.
This objective was addressed mainly in WP4 and WP5. The design basis and process evaluation for the hybrid plasma combustion system were completed by M12 (D4.1) combining theoretical and practical insights. Two plasma burners were developed: a hot cathode burner (LEI) and a cold cathode burner (PlasmaAir) (D4.2). Testing is planned for M20, with further design improvements anticipated. In WP5, early work focused on the use of biomass ash in glass manufacturing. Tasks included characterization of raw and gasified ashes (T5.1) analysis of treatment techniques (T5.2) and trials on incorporating ash into glass batch compositions (T5.3). These activities are ongoing and will provide more definitive results in the second half of the project.
Specific Objective 3:
Verify the techno-economic feasibility and environmental impact of the innovative GIFFT technology and process applications in the European glass manufacturing process.
WP7 is evaluating the feasibility and profitability of the GIFFT concept compared to current decarbonization solutions. LEI modeled integration scenarios for the hybrid flexible-fuel process (D2.3) identifying the most energy-efficient pathways. TUM developed a methodology using detailed Aspen Plus simulations (D7.1) which will inform upcoming techno-economic and life cycle assessments (T7.2). VMU has started work on these assessments, developing an evaluation methodology aligned with the simulation framework.
Specific Objective 1:
Develop an integrated heat production technology and process for glass manufacturing utilizing biomass/waste and excess or cheap renewable electricity for syngas production.
During the first reporting period, work mainly focused on WP2 and WP3. In WP2, the GIFFT process was assessed through detailed energy and mass flow evaluations (D2.3). Two application cases were developed for different furnace types in glass manufacturing: SCHOTT’s oxy/fuel furnace and PS’s air/fuel regenerative furnace. These cases established target concepts for further analysis in WP7. A review of biomass availability in Lithuania, Sweden, and Germany (D2.1) confirmed that logging residues, agro-waste, and lignin are available in sufficient quantities and at cost levels aligned with project KPIs. A technology review (D2.2) identified plasma-assisted entrained flow gasification as a promising method due to its efficiency and low tar output. Additionally, its vitrified ash may be used in glass manufacturing if residual carbon is low. WP3 focused on preparing for gasification testing. This included modifying the reactor to include a plasma-assisted burner (D3.1) preparing feedstock (D3.2) and completing construction and maintenance work. Initial testing is expected by May 2025. Most experimental validation for this objective will take place in the next project phase.
Specific Objective 2:
Develop and validate at TRL5 the key enabling technologies required for realizing the GIFFT process.
This objective was addressed mainly in WP4 and WP5. The design basis and process evaluation for the hybrid plasma combustion system were completed by M12 (D4.1) combining theoretical and practical insights. Two plasma burners were developed: a hot cathode burner (LEI) and a cold cathode burner (PlasmaAir) (D4.2). Testing is planned for M20, with further design improvements anticipated. In WP5, early work focused on the use of biomass ash in glass manufacturing. Tasks included characterization of raw and gasified ashes (T5.1) analysis of treatment techniques (T5.2) and trials on incorporating ash into glass batch compositions (T5.3). These activities are ongoing and will provide more definitive results in the second half of the project.
Specific Objective 3:
Verify the techno-economic feasibility and environmental impact of the innovative GIFFT technology and process applications in the European glass manufacturing process.
WP7 is evaluating the feasibility and profitability of the GIFFT concept compared to current decarbonization solutions. LEI modeled integration scenarios for the hybrid flexible-fuel process (D2.3) identifying the most energy-efficient pathways. TUM developed a methodology using detailed Aspen Plus simulations (D7.1) which will inform upcoming techno-economic and life cycle assessments (T7.2). VMU has started work on these assessments, developing an evaluation methodology aligned with the simulation framework.
Although the project is ongoing, preliminary results already indicate significant advancements beyond the state of the art. The integration of plasma-assisted gasification and hybrid combustion systems for glass manufacturing presents novel pathways for reducing CO2 emissions and improving energy flexibility. Initial design, modelling, and material characterization activities have validated the technical feasibility of key components. To ensure future uptake, further research, validation tests, and alignment with regulatory and standardization frameworks will be essential. Final techno-economic and environmental assessments will guide potential commercialization, market integration, and support needs for investment, policy alignment, and industrial adoption.