Glass production is an energy-intensive process and is one of the most difficult industrial sectors to decarbonise. Worldwide, 75% of container glass is produced in so-called “end-fired regenerative furnaces” which rely heavily on fossil fuels. Less polluting technologies, such as electric furnaces, are available but have a shorter lifespan. Now, thanks to a €2.2 million grant from the Innovation Fund, the BEAR project is set to revolutionise this landscape by creating a new type of furnace that combines the best of both technologies. 

This state-of-the-art furnace will replace the traditional design with a more energy-efficient and semi-electric functionality. The result will be a hybrid, end-fired regenerative furnace that sources electricity for 40% of its heat supply, surpassing the maximum 10% limit in a traditional furnace. The electricity will be produced from renewable sources and marks a substantial step forward in sustainable glass manufacturing.

The furnace started its baseline operations in January 2024, already producing up to 170 tonnes of container glass per day and sourcing 15% of its heat supply from electricity.  The hybrid furnace is expected to be fully operational by early 2025, reaching its targeted electric share of 40%. This will allow the production site to reduce its natural gas consumption by over 50% and avoid almost 100,000 tonnes of carbon dioxide (CO2) equivalent over the first ten years of operations. This reduction is enough to offset the total yearly greenhouse gas emissions of 20,000 households in the Zasavje region.

With the BEAR project, the parent company Steklarna Hrastnik aims to replace its existing regenerative furnace for extra-white flint glass production at one of its two sites. Both production sites are in Zasavje, a transitioning coal region in Slovenia with a high unemployment rate. Steklarna Hrastnik accounts for roughly 5% of jobs in the region and represents over 10% of the region’s GDP. By investing in sustainable production technologies, the BEAR project is expected to have a great impact on the local economy by not only maintaining current jobs, but also creating new ones.

By coupling innovative technologies with local renewable energy sources, the project will also serve as a decarbonisation model for other energy intensive industries in the EU. In addition to the use of renewable electricity, hybrid furnaces could also use biogas and hydrogen from renewable electricity as sustainable energy sources to transition the glass sector towards a climate neutral future.

Overall, the BEAR project demonstrates how innovative technology can drive significant environmental and economic benefits. By integrating traditional and electric furnace technologies, this project is setting a new standard for sustainable glass production.

About the Innovation Fund

Funded by the EU Emissions Trading System, the Innovation Fund focuses on groundbreaking projects that significantly reduce greenhouse gas emissions​. It is one of the world’s largest support programmes for the deployment of net-zero and innovative technologies. The support from the Innovation Fund has been instrumental in helping the project reach financial maturity earlier, ensuring that its benefits extend beyond Steklarna Hrastnik to the broader European community and the environment.