Saint-Gobain Weber achieves up to 27 per cent efficiency improvement through hydrogen enrichment

Hydrogenera delivered and integrated a hydrogen enrichment system at the Saint-Gobain Weber production facility in Kostinbrod, Bulgaria. The project demonstrates how green hydrogen can be reliably integrated into an existing high-temperature industrial combustion process to improve energy efficiency and reduce fuel consumption, without replacing the primary fuel or disrupting operations.

The system has been in continuous industrial operation for over 18 months, with stable performance and independently validated results.

Saint-Gobain Weber operates energy-intensive production processes that rely on natural gas-fired combustion systems. Improving combustion efficiency is critical for reducing operating costs and emissions while maintaining strict process stability and product quality.

The challenge was to enhance the performance of an existing 1.5 MW CNG-powered sand-drying burner, without major equipment replacement, process redesign, or production downtime.

Hydrogenera supplied and commissioned a 60 kW alkaline electrolyser, integrated directly into the existing combustion system as a hydrogen enrichment solution.

Key elements of the system included:

• On-site hydrogen production using a Hydrogenera E-series alkaline electrolyser

• Controlled hydrogen and oxygen injection into the combustion process

• Integration with the existing burner and process control environment

• Engineering supervision, commissioning, and operational support

The electrolyser was commissioned in June 2024 and designed to operate as a combustion enhancer. Hydrogen was used to improve flame characteristics and heat transfer, not to replace natural gas as the primary energy source.

Following commissioning, the system demonstrated consistent and measurable improvements under real production conditions.

Key results include:

• Up to 27 per cent improvement in energy efficiency and fuel cost reduction

• Stable combustion and improved flame characteristics

• More uniform heat distribution within the drying process

• Reduced natural gas consumption through enhanced combustion dynamics

• Continuous operation for over 18 months without disruption to production

The efficiency improvement was achieved through better combustion behaviour and heat utilisation, rather than direct fuel substitution.

The system's long-term operational performance is confirmed in a formal recommendation letter issued by Saint-Gobain.

“The successful performance of Hydrogenera’s electrolyser over a period of 18 plus months confirms the system’s reliability and suitability for industrial operation.”

This statement reflects continuous operation under real production conditions, rather than short-term pilot testing.

System performance was initially validated through testing conducted in an independent, accredited laboratory. The results confirmed the expected efficiency and operational benefits of hydrogen enrichment.

Over the full operating period, performance data has remained consistent with the initial validation, demonstrating:

• High system reliability in an industrial environment

• Stable long-term operation under continuous load

• Predictable and repeatable performance

Hydrogenera provided professional supervision and timely maintenance throughout the operational period to ensure system stability and uptime.

This project confirms that hydrogen enrichment is a mature and practical solution for improving efficiency in existing industrial combustion systems.

For Saint-Gobain Weber, the system delivered measurable efficiency gains without production interruptions or major infrastructure changes.

For Hydrogenera, the project demonstrates the readiness of its alkaline electrolyser technology for industrial combustion applications, supported by long-term operational data and third-party validation.

• Hydrogen enrichment can improve industrial combustion efficiency without replacing existing fuels

• Long-term operational proof matters more than pilot results

• Industrial hydrogen integration succeeds through engineering discipline and system control