GTM-X Simulation Software
Process simulation, design optimization and quality improvement
What is GTM-X?
GTM-X is a Computational Fluid Dynamics (CFD) software simulation package that enables precise simulations of melting and deposition processes. Originally developed to simulate glass furnaces and forehearths, today it is recognized as the most advanced and extensive CFD software for the glass industry. With GTM-X, you can simulate real furnace and forehearth behavior to uncover opportunities for energy savings, lower emissions, and enhanced performance, without interrupting production.
In recent years, we have also successfully applied GTM-X in other industrial processes, such as CVD (Chemical Vapor Deposition) and PVD (Physical Vapor Deposition), and industrial segments like biomass, fertilizer and cement.
How GTM-X helps
Model and compare combustion settings, furnace designs, electric boost setups, alternative fuels and alternative raw materials to achieve measurable energy savings and lower emissions.
Test and optimize process settings and furnace designs to enhance product quality. Product quality is evaluated using key defect indicators based on our unique chemical distribution models.
Identify hotspots, balance heat distribution, and prevent early wear or refractory damage.
Evaluate hybrid or electric melting options and plan CO₂-reduction scenarios safely and efficiently.
Validate new designs, burner layouts and electric boosting strategies to minimize downtime and costs.
Where GTM-X is applied
SUPPORTING FURNACE DESIGN
- Furnace capacity.
- Oxy fuel conversions.
- Improved heat transfer and melt kinetics (e.g., electric boosting and bubbling).
- Optimizing the combustion profile.
- Alternative fuels.
- Batch charging.
- Glass quality improvement.
- Electric melting.
- Design of the forehearth and glass homogeneity.
- Emission reduction.
- Lifetime improvement.
Where GTM-X is applied
SUPPORTING FURNACE DESIGN
- Furnace capacity.
- Oxy fuel conversions.
- Improved heat transfer and melt kinetics (e.g., electric boosting and bubbling).
- Optimizing the combustion profile.
- Alternative fuels.
- Batch charging.
- Glass quality improvement.
- Electric melting.
- Design of the forehearth and glass homogeneity.
- Emission reduction.
- Lifetime improvement.
TROUBLESHOOTING & Optimizing operations
- Glass quality improvement.
- Furnace lifetime extension.
- Electric boosting setup.
- Color change optimization.
- Oxy fuel firing.
- Alternative fuel usage.
- Burner design and set-up.
- Optimization of furnace settings to reduce energy consumption while maintaining glass quality.
GTM-X in action: Validation of furnace design
A luxury fragrance bottle manufacturer partnered with us to support a critical furnace supplier selection. Three competing furnace designs, each with distinct geometries and operating characteristics, were proposed by different suppliers. Using GTM-X, a comprehensive simulation campaign was conducted to evaluate and compare all three concepts under identical process conditions and a defined target product temperature.
The designs were assessed against key performance criteria, including expected furnace lifetime, product quality, energy consumption, and melting behavior. The results were analyzed in detail and reviewed jointly with the customer, highlighting the strengths, limitations, and long-term operational flexibility of each option.
This data-driven approach enabled the customer to make an informed, evidence-based decision when selecting both the furnace design and supplier, significantly reducing technical risk and uncertainty prior to investment.
GTM-X in action: Energy reduction
In combination with on-site furnace audits and insights from CelSian’s extensive benchmark database, GTM-X was used to identify and evaluate potential energy-saving opportunities for a large float glass manufacturer in Southeast Asia. An initial screening identified nearly 18 parameters with the potential to reduce overall energy consumption, ranging from burner ratio adjustments and batch recipe optimization to the introduction of batch preheating.
Each parameter was first evaluated using CelSian’s Energy Balance Model to assess feasibility, required investment, and expected return on investment. Since energy improvements must not compromise product quality or furnace lifetime, the ten most promising measures were subsequently analyzed in detail using GTM-X simulations.
This combined approach allowed the customer to identify specific, actionable measures that could be implemented without negatively impacting glass quality or increasing furnace wear, while remaining economically viable. The study indicated a potential energy reduction of approximately 13.8%, corresponding to an estimated annual cost saving of nearly USD 2 million.
GTM-X in action: Validation of furnace design
A leading furnace designer and supplier partnered with our modeling team to evaluate the impact of an innovative heat-exchange region on furnace performance using GTM-X. The study compared a conventional combustion space design with an alternative configuration incorporating the heat-exchange region. Both concepts were evaluated across a wide range of performance indicators, including energy efficiency, batch reaction gas behavior, NaOH evaporation from the melt, SO₂ flow patterns, and the trajectories of fine inert particles in the combustion space. The simulations demonstrated that including the heat-exchange region resulted in approximately a 4.0% reduction in natural gas consumption.
The new design showed slightly improved quality indicators, including longer residence and fining times and improved sand grain dissolution. Based on the insights from this study, the supplier successfully translated the concept into a commercially viable, next-generation furnace design, now marketed as an alternative to conventional cross-fired oxy-fuel furnaces.
Better understand your process with GTM-X
Great software and knowledgeable people, a strong match to solve all your engineering challenges.