World’s first large-scale hybrid electric furnace set to be built for flat glass production

Saint-Gobain and AGC Group, the two biggest names in worldwide flat glass production, have come together to build the large-scale hybrid electric furnace. Known as the FurHy project, the massive installation will replace a traditional gas furnace at Saint-Gobain’s facility in Avilés, Spain. The facility expects to begin construction in January 2027 and return to active production by the second half of 2027. “This type of furnace is the largest electric furnace ever built for flat glass, making it a world first,” the company stated. The goal is to cut direct carbon emissions in half by transitioning 75% of its melting process to low-carbon electricity supplied through local Spanish renewable energy contracts. Emissions reduction A glass furnace is a high-temperature industrial kiln designed to melt raw materials such as silica sand, soda ash, limestone, and recycled glass. These materials are turned into homogeneous molten glass at temperatures exceeding 1,500°C (2,700°F). As glass furnaces operate around the clock for up to almost 20 years before requiring a rebuild, the technology deployed today directly locks in carbon footprints for decades to come. The FurHy furnace aims to change this equation. Replacing standard gas operations with high-efficiency hybrid technology will slash the project’s environmental footprint. Notably, the new furnace is expected to save approximately 265 GWh of natural gas each year, which represents an 80% reduction compared to conventional models. This shift will halve the plant’s overall carbon footprint, preventing roughly 80,000 metric tons of CO₂ emissions annually. The decision to team up didn’t happen overnight. It builds on the success of the duo’s smaller VOLTA project in Barevka, Czech Republic, where they proved that electrifying glass production was not just a theoretical concept, but an operational reality Supported by the EU Innovation Fund, the duo are pooling capital and sharing technology risks to accelerate heavy industry’s transition toward net-zero carbon operations by 2050. Meeting the market demand The initiative directly addresses a surging demand across housing, commercial, and infrastructure markets for sustainable building materials. While modern windows reduce a building’s operational energy use, manufacturing standard glass leaves behind substantial embodied carbon. Glass produced from the Avilés hybrid furnace will directly supply Saint-Gobain’s ORAÉ® low-carbon glass line and AGC’s sustainable product portfolio. “Following the successful adoption of our very low-carbon glass ORAÉ®, this project marks a major step in the decarbonization of flat glass manufacturing, supporting Saint-Gobain’s commitment to reach net zero carbon emission by 2050,” said Nicolas Miègeville, Chief Technology Officer, Saint-Gobain. Both companies are giving architects and developers the vital tools needed to secure top-tier green building certifications like LEED and BREEAM as they slash the upfront environmental footprint of facade materials. To reduce its carbon footprint, the glass industry is pursuing various decarbonization strategies centered on circular material use and technological innovation. For instance, increasing the proportion of recycled glass scrap, known as cullet, significantly lowers furnace energy demands. At the same time, it eliminates the chemical process emissions associated with melting virgin raw materials like limestone and soda ash. At the same time, manufacturers are shifting away from fossil fuels by testing alternative energy sources such as hydrogen blends. For residual emissions that electrification cannot resolve, carbon-capture systems are being deployed to intercept greenhouse gases before they reach the atmosphere. Recommended ArticlesGet the latest in engineering, tech, space & science - delivered daily to your inbox.Mrigakshi is a science journalist who enjoys writing about space exploration, biology, and technological innovations. Her work has been featured in well-known publications including Nature India, Supercluster, The Weather Channel and Astronomy magazine. If you have pitches in mind, please do not hesitate to email her.