Glass decarbonization: Virtual trials could unlock lightweighting revolution, claims Exxergy CEO

19 Nov 2021 --- German consulting firm Exxergy is revealing details of promising new glass lightweighting technology following the close of the UN COP26 climate summit.

Exxergy has partnered with glass packaging giant Ardagh Group and software company Dassault Systèmes to scale the solution. The trio believe the upcoming technology – set to begin virtual trials next year – could be a major contributor to glass production decarbonization globally. 

Speaking to PackagingInsights, Exxergy’s CEO Thomas Sauer, explained the basic scientific mechanism behind the coating technology that could allow glass packaging manufacturers to reduce material while maintaining 100% strength and shape.

“The coating reacts with the surface cracks on the glass, creating covalent bonds with the glass matrix, which is predicted to heal a substantial part of the naturally occurring micro-cracks,” he explains. 

Filling in the cracks
Glass loses more than 90% of its theoretical mechanical strength during cooling and forming, Sauer continues. 

Micro-cracks on glass surfaces, invisible to the naked eye, make the material brittle and require increased material use to boost strength and avoid breakages. However, the added weight and matter make glass production energy-intensive relative to competing materials like plastics. Glass loses more than 90% of its theoretical mechanical strength during cooling and forming.

Sauer says the upcoming research may help reduce glass production’s environmental footprint.

“Creating covalent bonds provides increased mechanical strength and, as a result, offers the potential to reduce the glass weight while maintaining the load limit,” he asserts.

Digital trials
Sauer emphasizes the importance of the partners’ digital trials, which will take place prior to material experiments, if successful. The industry adoption of digital trialing is also anticipated to further reduce R&D’s environmental impact. 

Computer simulations of the chemical reactions taking place when the coating is applied will run first, before a lab test series. 

“The main benefits of applying the computer simulations is to secure information at nanoscale that is difficult – if not impossible – to obtain from material experiments,” he explains. 

This software is being leveraged to obtain key insights into the technology’s interface properties, such as adhesion strength, porosity and morphology. 

“In addition, it is expected information on [glass manufacturing] process optimization and possible chemical reactions can be obtained, which can reduce the number of experiments needed,” Sauer details.

Strength through covalent bonds
The companies believe glass containers’ wall thickness can be significantly reduced through the covalent bonding technique at the same nominal strength of traditional glass. 

However, Sauer concedes the potential impact on carbon emissions reductions and other environmental benefits cannot yet be estimated. Covalent bonding technology could be a game changer in decarbonizing glass production, says Sauer.

“At this early stage, we are not in a position to provide further details related to actual numbers as the real potential largely depends on multiple factors – not only on the effectiveness of the coating itself – that can only be assessed through the trials,” he comments. 

“We are just at the beginning of our cooperation. However, Ardagh Group will contribute its glass manufacturing and technical know-how and test production at scale while Exxergy is providing its expertise in relation to the coating technology.” 

COP26: Breaking the glass 
Exxergy, Dassault Systèmes and Ardagh Group are not alone in their efforts to revolutionize glass production decarbonization. 

UK-based non-profit research group Glass Futures recently presented ideas to world leaders at the COP26 summit, demonstrating the potential power of alternative fuel methods for producing glass. 

Among the group’s research projects, which have been awarded £54 million (US$72.6 million) in funding, are experiments on using hydrogen, bio-fuels, hybrid-fuels and electric power for glass furnaces. 

Glass Futures is also looking into robotic operations and automation, Industry 4.0 applications, and raw material and cullet processing technology. 

By Louis Gore-Langton