Out of concern for the environment
As one of the representatives of an energy-intensive industry, we are fully aware of the responsibility that lies with us. The production of almost 80 million glass products annually requires high energy inputs, which are successively reduced. For years, we have been introducing a number of saving investments that have a huge impact on reducing CO2 emissions into the atmosphere.
For each of the pro-environmental investments, we monitor the achieved ecological and energy effect, so the employees’ awareness regarding caring for the environment is constantly increasing.
W5 tank furnace
In order to keep the specific energy consumption at a low level, we modernised the tank furnace in 2021. The completed Energy Efficiency Audit confirmed the saving of energy contained in gas by o 8 000 MWh/year and the reduction of CO2 emissions by 1,600 tons.
W8 tank furnace
The tank furnace was modernised in 2019. This enabled us to save 14 000 MWh of energy contained in gas per year and reduce CO2 emissions by 2,800 tons.
We replaced the over 20-year-old central gas boiler house with two boiler rooms, one working for the needs of the Manual Production building and the other supplying heat to the other buildings. We built the central boiler house as a new facility, in a steel frame structure covered with a sandwich panel.
Together with high-efficiency boilerswe installed heat distribution, automation and water treatment systems. The power of the boiler units smoothly adapts to external conditions, thanks to which the consumption of natural gas has been significantly reduced.
In the Manual Production building,a local boiler room together with condensing boilers with vertical arrangement of burners has been separated, which allowed us to eliminate heat losses, and the heat itself is produced with much greater efficiency compared to the old system.
Compressed air – Compressor room
Compressed air is one of the most energy-intensive utilities, which is why at Krosno Glass we focus on using it as efficiently as possible. Replacing the old compressors with turbine compressors with an IGV control valve, a screw compressor with an inverter, and installing a new compressed air line made of stainless tube allowed us to reduce the specific energy consumption. In addition, in order to reduce water consumption, we decided to adapt the cooling tower, which works in a closed system. The effect of these actions was the reduction of CO2 emissions by 2,650 tons per year.
Vacuum – vacuum pumps
We use vacuum to produce glass on production lines. The vacuum is created in high-efficiency dry claw vacuum pumps controlled by inverters. The use of new type vacuum pumps allowed us to reduce 850 tons of CO2 per year.
In addition, due to the change in the design of the pumps, we have completely eliminated the need to cool them with water.
To maintain high quality, during the entire production process, the glass workpiece goes through many work cycles (grinding, cutting, notching), which cause contamination. Adaptation of the tunnel washer in the Manual Production building made it possible to close the water circuit, thanks to which water is used only periodically to replenish the load.
The washer makes the workpiece completely clean, and the glass dust itself is selectively deposited on the filters.
It is a device that allows the use of waste heat contained in exhaust gases. It was installed between the recuperator and the chimney on the W8 tank furnace to raise the water temperature for technological and living purposes, thus allowing us to save 550 kW. This heat is used to support the process of heating the buildings and provide our employees with hot water.
In the Mechanical and Manual Production building, we replaced fluorescent, mercury and halogen luminaires with new, energy-saving LED luminaires. New luminaires (3,500 pieces) ensure compliance with lighting standards and contribute to the generation of annual energy yield of approx. 1,250 MWh, which translates into a reduction of CO2 emissions (952 tons of CO2 per year). The investment costs are estimated at PLN 1.7 million.
In order to reduce the heat demand of the Manual Production building, we replaced two external façades of the building and partly the southern façade made of a single reinforced glass pane with a façade made of sandwich panels with mineral wool insulation and double glazing with a 7-chamber frame. The actions taken have significantly improved the comfort of work and contributed to the reduction of heat consumption and CO2 emissions.
Monitoring of utilities
Utilities in Krosno Glass S.A. are monitored on an ongoing basis by means of a monitoring system, and any anomalies are quickly detected and analysed. Cyclical meetings regarding utility consumption result in increasingly more effective control of the process, and the awareness of both the energy and production staff is constantly raised.