Periodic Reporting for period 1 - HyInHeat (Hydrogen technologies for decarbonization of industrial heating processes)
Reporting period: 2023-01-01 to 2024-06-30
HyInHeat - Hydrogen technologies for decarbonization of industrial heating processes - is a European project funded by Horizon Europe which aims for the application of hydrogen for high-temperature heat generation for energy intensive production processes of the steel and aluminium sector. For that purpose, a consortium built up on 28 partners from academia, RTO´s and industry is focused on the development of technologies for the implementation of hydrogen in energy intensive processes improving Technology Readiness Level (TRL) from 3 to 7.
HyInHeat aims to introduce effective hydrogen combustion systems to reduce the carbon footprint of heating and melting processes in the aluminium and steel industries. In order to achieve this primary goal, the project aims for the following objectives.
- Redesign of heating processes specifically for H2 as a fuel, which include H2 heating demonstrators, full off-gas system redesign, greenfield reheating furnace design study, and retrofit design studies.
- Integrate the technology for characterizing fuel composition and flow effectively by fuel quality measurement, combustion control, NOx emission measurement and predictive emission monitoring (PEM).
- Develop O2 combustion processes by involving six demonstrators using pure O2 as an oxidizer and one demonstrator with oxygen-enhanced combustion.
- Equipment modification for H2 use. This objective includes burner adjustments, development of measurement instrumentation for fuel supply and combustion control, implementation of H2-compatible fuel supply systems, and optimization of refractory materials.
- Establish economic viability in comparison with other heating alternatives. Demonstrators will be the reference point cases based on Key Performance Indicators (KPIs). Case studies evaluations will be developed to provide a comprehensive assessment of the comparative economic feasibility.
Due to the implementation of hydrogen heating in high-temperature industrial heating processes, adjusted equipment, control, and measurement technologies as well as measures to adjust simulation and emission control of H2 combustion the HyInHeat project generates a great knowledge base on the quality impact of H2 combustion, lower climate impact of approx. 25 to 65% less emissions of heating processes and an overall decrease of NOx emissions.
HyInHeat aims to introduce effective hydrogen combustion systems to reduce the carbon footprint of heating and melting processes in the aluminium and steel industries. In order to achieve this primary goal, the project aims for the following objectives.
- Redesign of heating processes specifically for H2 as a fuel, which include H2 heating demonstrators, full off-gas system redesign, greenfield reheating furnace design study, and retrofit design studies.
- Integrate the technology for characterizing fuel composition and flow effectively by fuel quality measurement, combustion control, NOx emission measurement and predictive emission monitoring (PEM).
- Develop O2 combustion processes by involving six demonstrators using pure O2 as an oxidizer and one demonstrator with oxygen-enhanced combustion.
- Equipment modification for H2 use. This objective includes burner adjustments, development of measurement instrumentation for fuel supply and combustion control, implementation of H2-compatible fuel supply systems, and optimization of refractory materials.
- Establish economic viability in comparison with other heating alternatives. Demonstrators will be the reference point cases based on Key Performance Indicators (KPIs). Case studies evaluations will be developed to provide a comprehensive assessment of the comparative economic feasibility.
Due to the implementation of hydrogen heating in high-temperature industrial heating processes, adjusted equipment, control, and measurement technologies as well as measures to adjust simulation and emission control of H2 combustion the HyInHeat project generates a great knowledge base on the quality impact of H2 combustion, lower climate impact of approx. 25 to 65% less emissions of heating processes and an overall decrease of NOx emissions.
During the initial one and a half years of the HyInHeat project, the focus was on work packages (WP) 1, 2, 3 and 4. In particular, during WP1 on “Process analysis and retrofitting requirements” a detailed baseline definition for the demonstrators was performed. Crucial information was gathered for the subsequential modification and redesign of current infrastructures. Tasks within WP1 focused on data collection. Accomplishments included establishing KPIs, gathering retrofitting requirements for demonstrators, creating a refractory database, summarizing EU energy landscape policies, producing baselines for Life Cycle Assessment (LCA) and Multi-Layer plant-level Material Flow Analysis (ML-MFA) as well as developing concepts for measurement technologies and NOx emission limits. All deliverables within WP1 were successfully completed.
Then, regarding WP2, named “Modification and Redesign of equipment and processes“, results show the effects of H2 on product quality, efficiency, and refractories. More into detail, HyInHeat partners investigated promising refractories through laboratory tests and thermodynamic calculations, focused on the effect of H2 on scale formation and the impact of H2 in steel, refractories, and aluminium, among others. Further work regarding the theoretical background for simulation and MFA was initiated. Also, the tests and engineering designs for the adaptation of hydrogen in the direct and indirect heating applications were done. The final results are scheduled for the end of 2024.
WP3 on the “Design of safe and efficient H2 and O2 infrastructure” is also currently still ongoing. This work package already provided the engineering documentation and recommendations to supply the demonstrators with H2 and O2. For that purpose, the definition of operating conditions in standard and non-standard conditions was described. Additionally, steady-state simulations of the H2 and O2 infrastructure from supply to utilization under specified operating conditions were done. These results play a crucial role on the first step for the detailed design process for the demonstrators in WP5 and WP6. Finally, within this WP training concepts for H2 safety are addressed and worked out. This task will run parallel to the demonstrations and will integrate operator feedback into the H2 safety training concepts.
Finally, WP4 provides the improvement of sensors, analysers, and algorithms for optimizing H2 combustion processes through online process control, as well as for online monitoring of NOx emissions to reduce emissions and facilitate reporting. Measurements with optical emission spectroscopy for industrial flame analysis were performed. Regarding combustion control, a solid-state electrolytic sensor for detecting O2, H2, and NOx for high temperatures has been developed. The final outcomes are expected by the end of 2024.
Then, regarding WP2, named “Modification and Redesign of equipment and processes“, results show the effects of H2 on product quality, efficiency, and refractories. More into detail, HyInHeat partners investigated promising refractories through laboratory tests and thermodynamic calculations, focused on the effect of H2 on scale formation and the impact of H2 in steel, refractories, and aluminium, among others. Further work regarding the theoretical background for simulation and MFA was initiated. Also, the tests and engineering designs for the adaptation of hydrogen in the direct and indirect heating applications were done. The final results are scheduled for the end of 2024.
WP3 on the “Design of safe and efficient H2 and O2 infrastructure” is also currently still ongoing. This work package already provided the engineering documentation and recommendations to supply the demonstrators with H2 and O2. For that purpose, the definition of operating conditions in standard and non-standard conditions was described. Additionally, steady-state simulations of the H2 and O2 infrastructure from supply to utilization under specified operating conditions were done. These results play a crucial role on the first step for the detailed design process for the demonstrators in WP5 and WP6. Finally, within this WP training concepts for H2 safety are addressed and worked out. This task will run parallel to the demonstrations and will integrate operator feedback into the H2 safety training concepts.
Finally, WP4 provides the improvement of sensors, analysers, and algorithms for optimizing H2 combustion processes through online process control, as well as for online monitoring of NOx emissions to reduce emissions and facilitate reporting. Measurements with optical emission spectroscopy for industrial flame analysis were performed. Regarding combustion control, a solid-state electrolytic sensor for detecting O2, H2, and NOx for high temperatures has been developed. The final outcomes are expected by the end of 2024.
Results going beyond the state of the art include data generated regarding kinetic mechanism for H2/O2 combustion as well as new radiation models for numerical simulation as well as burner, combustion, and process design that are innovative outcomes.
Furthermore, the project provides for the first time the implementation of a newly developed tabulated chemistry combustion model in the commercial software ANSYS-Fluent. For that purpose, a model assessment for thermo-diffusive instabilities and its application into Reynolds-Averaged Navier-Stokes (RANS) simulations of turbulent flames with tabulated chemistry was done. Also, the fully premixed H2/air round jet flame using detailed chemistry direct numerical simulations (DNS), serves as a reference to evaluate how well these new models predict the flame behaviour of hydrogen combustion in RANS simulations, particularly its unique diffusion characteristics.
Next steps will include the technical demonstration phase of the new technologies systems to validate the full potential for uptake and future commercialisation.
Furthermore, the project provides for the first time the implementation of a newly developed tabulated chemistry combustion model in the commercial software ANSYS-Fluent. For that purpose, a model assessment for thermo-diffusive instabilities and its application into Reynolds-Averaged Navier-Stokes (RANS) simulations of turbulent flames with tabulated chemistry was done. Also, the fully premixed H2/air round jet flame using detailed chemistry direct numerical simulations (DNS), serves as a reference to evaluate how well these new models predict the flame behaviour of hydrogen combustion in RANS simulations, particularly its unique diffusion characteristics.
Next steps will include the technical demonstration phase of the new technologies systems to validate the full potential for uptake and future commercialisation.