Ecology / Sustainable Development

As one of the representatives of the energy-intensive industry, we are fully aware of the responsibility that rests upon us. The production of nearly 80 million glass products annually requires high energy input, which is successively being reduced. For years, we have been implementing a series of cost-saving investments that have a huge impact on reducing CO2 emissions into the atmosphere.

For each pro-ecological investment made, we monitor the ecological and energy effects achieved, thanks to which employees' awareness of environmental protection is constantly increasing.

W5 and W8 bathtubs

In order to keep the unit energy consumption at a low level, we modernized glass furnace W5 in 2021. The performed Energy Efficiency Audit confirmed a saving in gas energy consumption of 8,000 MWh/year and a reduction in CO2 emissions of 1,600 tons.

Furnace W8 was modernized in 2019. Thanks to this, we achieved annual savings in gas energy consumption of 14,000 MWh and a reduction in CO2 emissions of 2,800 tons.

Thermal economy

We replaced the central gas boiler room, which was over 20 years old, with two boiler rooms: one serving the needs of the Manual Production building and the other supplying heat to the remaining buildings. We built the central boiler room as a new facility, with a steel frame structure and warm sandwich panel cladding.

Along with high-efficiency boilers, we installed a heat distribution system, automation, and water treatment. The power of the boiler units adjusts smoothly to external conditions, significantly reducing natural gas consumption.

In the Manual Production building, a local boiler room with condensing boilers featuring vertically arranged burners was separated, which eliminated heat losses and produces heat 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. The replacement of old compressors with turbocompressors with an IGV regulating valve, a screw compressor with an inverter, and the installation of a new stainless steel compressed air main allowed us to reduce specific energy consumption. Additionally, to eliminate water consumption, we decided to adapt a fan-driven cooling tower, which operates in a closed loop. The result of these actions was a reduction in CO2 emissions by 2,650 tons annually.

Vacuum – vacuum pumps

We use vacuum to produce glass on our production lines. The vacuum is generated in high-efficiency dry claw vacuum pumps controlled by inverters. The use of new-type vacuum pumps has allowed us to reduce CO2 emissions by 850 tons annually.

Moreover, due to a change in the pump design, we have completely eliminated the need for water cooling.

Tunnel washer

To ensure high quality, the glass component undergoes many cycles during the entire production process: grinding, cutting, and notching, which cause contamination. The adaptation of a tunnel washer in the Manual Production building allowed for closing the water loop, thanks to which water is only periodically used to replenish the charge.

The component after washing is clean, and the glass dust itself is selectively deposited on the filters.

Economiser W8

This device allows for the utilization of waste heat contained in exhaust gases. It was installed between the recuperator and the chimney on the W8 tank, which allows for raising the water temperature for technological and domestic purposes, and thanks to this, we can save 550 kW. This heat is used to support the building heating process and provide domestic hot water to our employees.

LED

We replaced fluorescent, mercury, and halogen luminaires with new, energy-efficient LED luminaires in the Mechanical and Manual Production building. The new luminaires, 3500 units, ensure compliance with lighting standards and contribute to an annual energy saving of approximately 1250 MWh, which translates into a reduction in CO2 emissions – 952 tons of CO2 annually. The investment costs are estimated at PLN 1.7 million.

Thermal modernization

In order to reduce the heat demand of the Manual Production building, we replaced two external facades of the building and partially the southern facade from single reinforced glazing with a sandwich panel facade with mineral wool insulation and double glazing with a 7-chamber frame. The actions taken significantly improved the comfort of work for users and contributed to the reduction of heat consumption and CO2 emissions.

Media Monitoring

Media at Krosno Glass S.A. are continuously monitored using a monitoring system, and any anomalies are quickly detected and analyzed. Regular meetings regarding media consumption allow for better process control, and awareness among both energy and production staff is constantly being raised.