Can synthetic natural gas (SNG) replace natural gas in glass manufacturing plants?

In 2022, the European Council formally approved a target to reduce gas demand by 15%. The regulation established a voluntary goal for member states to decrease natural gas consumption by 15% annually until March 31, 2024, compared to the average consumption from April 1, 2017, to March 31, 2022.

What can replace natural gas? By the end of 2022, there was significant demand for reserve gas delivery systems for glass factories, mainly relying on diesel and liquefied petroleum gas (LPG). In 2024, with the decrease in natural gas prices, the demand for projects replacing it significantly diminished. Nevertheless, the gas crisis clearly demonstrated the necessity of reserve fuel in the industry. Companies that have understood what is biomethane, LPG, and SNG and installed LPG (SNG) gas delivery systems by autumn 2021 could recoup their investments within a few months of the glass factory’s operation.

Below is a chart depicting the prices of various available energy sources for industrial consumers, taking transportation costs into account. Source: http://i-maximum.com

As of today, heating oil remains a backup fuel for many glassworks. However, such an approach is inconsistent with the commitments arising from the "Fit for 55" legislative package - a set of European Union regulations aimed at reducing greenhouse gas emissions by 55% by 2030. Additionally, it is economically impractical due to the high costs of heating oil over prolonged use.

Liquefied Natural Gas (LNG) could offer a solution to the issue of backup energy sources, but the investment costs and logistical challenges of gas delivery undermine the attractiveness of this type of fuel.

"For instance, for the uninterrupted operation of a glass furnace for 24 hours with a capacity of 20,000 kW, 54 tons of LNG are required - equivalent to two LNG tanks of 50,000 liters each. The cost of a comprehensive LNG supply project with regasification installation will exceed 2 million euros. Similar equipment and implementation of the entire project on LPG will range from 500 to 600 thousand euros. A project on SNG may cost up to 1 million, depending on the type of SNG blender, air compressor, and the presence of a Peak Shaving system”

LPG vs natural gas represents an optimal solution from an ecological perspective and requires smaller installation investments, 2–4 times cheaper than those needed for LNG. However, using propane (without air admixture) requires the replacement or adjustment of gas burners and compressor gas systems in internal combustion engines. SNG systems address issues related to reducing and replacing natural gas consumption. By blending propane with air (PROPAN+AIR), we resolve energy companies' challenges associated with the need to halt technological processes and replace gas burners in steam boilers, as well as adapting piston engines in gas power plants.

SNG, or Synthetic Natural Gas, is a gas obtained by blending air with LPG, which has the same calorific value as methane (natural gas). The SNG gas mixture can be used in burners as a direct substitute for natural gas without the need to change or replace the burners. SNG systems are widely used in Asia, South America, and North America. In some countries, the use of SNG systems is mandatory in natural gas pipeline projects to avoid potential emergency situations such as gas cutoffs, pressure drops, and gas calorific value reduction. In Europe, attention was first drawn to SNG during the sudden rise in natural gas prices in 2021-2022.

The components of the installation are as follows:

1. Above-ground or underground LPG tanks.

2. Liquid gas pump ensuring stable pressure, with the recommendation of using two pumps - one as a backup.

3. LPG vaporizer, where the transformation from liquid LPG to gas occurs. It is recommended to choose an autonomous vaporizer that does not require electrical power, such as the KBV model.

4. SNG mixer (SNG-blender) with automatic mixing option - the main element of the system, where LPG is mixed with air.

5. Air compressor with tank.

6. Buffer SNG tank if needed. Ultimately, synthetic gas is delivered to the existing gas network.

In Poland, the first manufacturer of gas mixers has emerged - the company I-Maximum sp. z o.o. , which invites you to the presentation of its new SNG-blender production near Warsaw on April 26, 2024.

Details about the study visit: http//i-maximum.com/presentation2024

I-Maximum's mission is to accelerate the transformation of businesses to Synthetic Natural Gas (SNG) based on LPG and air, with plans to replace LPG with bioLPG in the future. Our company offers comprehensive services including design, sale of equipment, and installation of gas systems based on LPG and SNG for industrial and agricultural enterprises. Additionally, we custom-produce gas blenders (mixers) with operating pressures up to 40 bars, designed for various types of gases, including hydrogen, biogas, natural gas, LPG, and others.

Global natural gas prices have stabilized since the gas crisis of 2021-2022. However, the ongoing war in Ukraine and the threat of conflict in Europe make the energy market extremely delicate and unpredictable. The conclusion of the transit agreement between Ukraine and Russia at the end of 2024 is likely to cause significant changes in gas prices, although media speculate about possible alternative transit options with agreements made by European countries. Nevertheless, entrepreneurs and policymakers should remember that Russia does not always act in accordance with established rules, often causing energy crises.

Below is a chart based on TTF and Argus (daf Brest) quotations for the years 2021-2023.