Non Melting energy project

In 2018, Verallia initiated a process to identify and activate levers for reducing the energy consumption of the industrial processes implemented at its sites (excluding melting).

Main project's drivers for reducing the greenhouse gas (GHG) emissions

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Energy sobriety and resources

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Energy decarbonization

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Improved energy efficiency

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Improved efficiency in the use of non-energy resources

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Emission removal

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Financing low-carbon issuers or disinvestment from carbon assets

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Reduction of other greenhouse gases emission

Project objectives

Identify and activate levers for reducing energy consumption in industrial processes (excluding melting) for glass production. production processes (excluding melting).

The approach initiated by Verallia consists of analyzing the energy consumption of the main non-melting equipment: air compressors, fans and annealing arches. This analysis makes it possible to compare current consumption with theoretical consumption calculated using digital models. The difference is then analysed in detail to identify the origin of the losses; for each identified loss, technical solutions for improvement are proposed and an efficiency calculation is made for each proposed action. A methodology is applied to enable a systematic and detailed analysis of all aspects of consumption. The maximum value of unidentified losses is set at 5% of the theoretical consumption value. An efficiency calculation incorporating the cost of CO2 is used to prioritise investments.
This approach then makes it possible to optimise energy consumption, electricity and natural gas, on compressors, fans and annealing arches. The reduction in emissions remains modest for each project but the number of projects is significant:

  • Dozens of projects concerning annealing arches
  • More than 100 projects concerning compressed air production

For example:

  • The reduction of heat loss from the arches and the improvement of their operating conditions has 150 tCO2/year by limiting gas consumption.
  • Optimisation of electricity consumption for the production of compressed air and ventilated air, but also, more simply, of the consumption of electricity.

Emission scope(s)

on which the project has a significant impact

  • Emission scopes
  • Description and quantification of associated GHG emissions
  • Clarification on the calculation

Scope 1

Direct emissions generated by the company's activity.

Scope 2

Indirect emissions associated with the company's electricity and heat consumption.

Scope 3

Emissions induced (upstream or downstream) by the company's activities, products and/or services in its value chain.

Emission Removal

Carbon sinks creation, (BECCS, CCU/S, …)

Avoided Emissions

Emissions avoided by the activities, products and/or services in charge of the project, or by the financing of emission reduction projects.

Scope 1 - Reduction of fossil fuel of fossil fuels from heat loss arches and improvements in their conditions of use

  • Example for an arch : -150 tCO2/year

Scope 2 - Optimisation of the power consumption of compressed production of compressed air and air production.

  • Example for a compressor : - 527 tCO2/year
  • Example for a compressor fleet in a factory : -1104 tCO2/year

The reduction in emissions is modest for each project but the number of projects is significant:

  • Several dozen projects concerning annealing arches
  • More than 100 projects concerning compressed air production

Key points

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Invested amount

Between 400 and 500 k€ per site

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Starting date of the project

2018

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Project localisation

Worldwide

Project maturity level

Prototype laboratory test (TRL 7)

Real life testing (TRL 7-8)

Pre-commercial prototype (TRL 9)

Small-scale implementation

Medium to large scale implementation

Economic profitability of the project (ROI)

Short term (0-3years)

Middle term (4-10 years)

Long term (> 10 years)

Illustrations of the project

This project contributes to SDG 9: Innovation, industry, infrastructure.

The deployment of the methodology is replicable to all VERALLIA sites. 

The success of these projects depends on the impetus given by the general management and the availability of limited CAPEX. 

No partnerships are involved in this project.

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Contact the company carrying the project :

corporate.communication@verallia.com

Verallia’s other projects :

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