Periodic Reporting for period 2 - HyTecHeat (HYbrid TEChnologies for sustainable steel reHEATing)
Reporting period: 2024-06-01 to 2025-05-31
Since the Paris agreement signed on the March 2015 (COM82015) 81, the EU has been deeply engaged to minimize the EU industry sector impact on the GHG emission by following several complementary technological pathways. One of the promising pathways is the abatement of GHG via direct avoidance of CO2 emissions by using green energy carriers such as green hydrogen.
Currently, NG is normally substituted by hydrogen in upstream processes (both blast furnace and DRI), or limited application in finishing lines. Current downstream processes totally rely on NG burning as thermal source. Current average cost of MG is about 0.6 €/Nm3 (average value in EU, source Eurostat), Assuming H2 cost of 0.36€/m3 (4€/kg) and due to the fact the heating value of hydrogen is about one third of the one of NG, equivalent of hydrogen burning would be of 1.08 € per Nm3 of NG replaced. Assuming the forecast of H2 cost of 0.16 €/m3 (from 1.8€/kg), cost of substitution would be of 5.4€/Nm3 of NG replaced, lower than current value.
HyTecHeat aims at adopting hybrid heating technology (based on NG with progressive and increasing H2 utilization) in downstream processes so to path the way for the abatement of CO2 for the whole downstream processes at EU level of 7.5 Mt (if conservatively 30% of H2 is considered) up to about 25 Mt (if 100% of H2 is used). Taking into account that the overall emission of CO2 in EU from all industrial sectors in 2018 (before the COVID pandemic) is estimated to be 2.9 Gt , the implementation of HyTecHeat technology in all EU downstream process (100% of H2)
Currently, NG is normally substituted by hydrogen in upstream processes (both blast furnace and DRI), or limited application in finishing lines. Current downstream processes totally rely on NG burning as thermal source. Current average cost of MG is about 0.6 €/Nm3 (average value in EU, source Eurostat), Assuming H2 cost of 0.36€/m3 (4€/kg) and due to the fact the heating value of hydrogen is about one third of the one of NG, equivalent of hydrogen burning would be of 1.08 € per Nm3 of NG replaced. Assuming the forecast of H2 cost of 0.16 €/m3 (from 1.8€/kg), cost of substitution would be of 5.4€/Nm3 of NG replaced, lower than current value.
HyTecHeat aims at adopting hybrid heating technology (based on NG with progressive and increasing H2 utilization) in downstream processes so to path the way for the abatement of CO2 for the whole downstream processes at EU level of 7.5 Mt (if conservatively 30% of H2 is considered) up to about 25 Mt (if 100% of H2 is used). Taking into account that the overall emission of CO2 in EU from all industrial sectors in 2018 (before the COVID pandemic) is estimated to be 2.9 Gt , the implementation of HyTecHeat technology in all EU downstream process (100% of H2)
Work Package 1 Investigation of reference industrial scenario. Technical data and the operating conditions of the different pilot and demo furnaces were summarized and compared with industrial furnaces used by the industrial partners (Tata Steel, Tenaris, Arcelor Mittal, Nunki & SSAB) (Task 1.1).
The technical specifications of the burner (provided by Tenova) are defined accordingly to the utilization in the experimental rig of Swerim, (Task 1.2). Innovative water electrolyzer specifications defined by IDN (Task 1.3).
Balance of plant and preliminary safety analysis have been defined. (Task 1.4).
Industrial samples have been collected by partners according to sampling plan defined in the grant agreement. (Task 1.5).
Work Package 2 Burner and combustion system design for hybrid heating
Snam has identified the relevant normative and standards applicable in the European Union about safety design and operation of H2 system. (Task 2.1)
To properly reproduce the complex series of experiments by means of a Computational Fluid Dynamic (CFD) “digital twin”, the selection of the rights models has been carried out: turbulence-chemistry interaction (a.k.a. the combustion model), the kinetic mechanism, and the radiation model defined. (Task 2.2).
Computation Fluid Dynamic model for the simulation of a flameless has been applied to assess the performances of the preliminary design of the 320 kW multi-fuel TLX burner. (Task 2.3).
Sensoring of the burner defined. (Task 2.4).
The burner was built on the basis of the engineering carried out considering the technical data defined in deliverable 1.2 , on the basis of the results of the CFD simulations described in deliverable 2.3 (Preliminary designs of multi-fuel H2 /CH4 burner prototype and possible variants) and depending on the sensors that will be installed on the burner as described in deliverable 2.4 (Selection of embedded sensors for burner digitalization) (Task 2.5).
WP3 is about oxidation tests comparing the effect of NG and H2 atmosphere. The differences in the oxidation kinetics of a variety of steel grades, covering both carbon and stainless steels, with increasing water vapour content in the furnace atmosphere resulting from H2 combustion in air instead of natural gas, were defined by RINA CSM and AMMR by Isothermal thermo-gravimetric oxidation tests. The RINA-CSM TGA tests were performed at 900°C, 1050°C and 1200°C for two hours, AMMR tests were performed at 700, 800, 900, 1000, 1100 and 1200°C for 15 min. (Task 3.1). Rina CSM performed tests at 48% H2O simulating air enrichment. CSM performed also descaling tests in NG and H2 combustion atmosphere (18% vs 33% H2O) simulating reference industrial condition, while AMMR performed industrial desclaing tests (Task 3.2).
Swerim is revamping its combustion facility to test poxidation and descaling simulating industrial conditions, using burners provided by Tenova and Linde.Those tests will be performed in November 2025.
The steel grades to be tested have been decided together with SSAB and Tata Steel, where different types of micro-alloyed, high strength and electrical steels will be tested. (Task 3.3).
Work Package 4
In accordance with the change of activities ownership between Snam and Tenova reported in minute of meeting November 2023, Snam has released a Purchase Order to buy a bigger H2 supply system (H2 buffer storage), while Tenova is managing the permitting step, BOP design and purchase (that is strictly linked to permitting) and related safety study (see Project proposal: tasks 1.3 and D1.3 in WP 1). Waiting for the H2 storage delivery, Snam has shared with Tenova the layout and the design. In the buffer storage supply is included a Pressure Safety Valve (PSV) with 32 bar as safety pressure, which has been tailored to the operating pressures of the Tenova plant. The integration of the electrolyser, the hydrogen tank and the existing plant (TenovaLAB) ihas been completed. due to delays in permitting, the commissioning of the system will be carried out in September 2025. The adaptation of pilot facility of Tata Steel is almost completed and tests will start in October 2025.
WP5
Nunki steel started the design of the industrial tests of refractort preheating with a blend of NG and Hydrogen. Thsi analysis is requiring more time than expected due to the modificed regulation framework, with new restrictions for hydrogen storage ands utilization
will lead to an abatement of 0.9% (25 Mt) of the EU CO2 emission.
The technical specifications of the burner (provided by Tenova) are defined accordingly to the utilization in the experimental rig of Swerim, (Task 1.2). Innovative water electrolyzer specifications defined by IDN (Task 1.3).
Balance of plant and preliminary safety analysis have been defined. (Task 1.4).
Industrial samples have been collected by partners according to sampling plan defined in the grant agreement. (Task 1.5).
Work Package 2 Burner and combustion system design for hybrid heating
Snam has identified the relevant normative and standards applicable in the European Union about safety design and operation of H2 system. (Task 2.1)
To properly reproduce the complex series of experiments by means of a Computational Fluid Dynamic (CFD) “digital twin”, the selection of the rights models has been carried out: turbulence-chemistry interaction (a.k.a. the combustion model), the kinetic mechanism, and the radiation model defined. (Task 2.2).
Computation Fluid Dynamic model for the simulation of a flameless has been applied to assess the performances of the preliminary design of the 320 kW multi-fuel TLX burner. (Task 2.3).
Sensoring of the burner defined. (Task 2.4).
The burner was built on the basis of the engineering carried out considering the technical data defined in deliverable 1.2 , on the basis of the results of the CFD simulations described in deliverable 2.3 (Preliminary designs of multi-fuel H2 /CH4 burner prototype and possible variants) and depending on the sensors that will be installed on the burner as described in deliverable 2.4 (Selection of embedded sensors for burner digitalization) (Task 2.5).
WP3 is about oxidation tests comparing the effect of NG and H2 atmosphere. The differences in the oxidation kinetics of a variety of steel grades, covering both carbon and stainless steels, with increasing water vapour content in the furnace atmosphere resulting from H2 combustion in air instead of natural gas, were defined by RINA CSM and AMMR by Isothermal thermo-gravimetric oxidation tests. The RINA-CSM TGA tests were performed at 900°C, 1050°C and 1200°C for two hours, AMMR tests were performed at 700, 800, 900, 1000, 1100 and 1200°C for 15 min. (Task 3.1). Rina CSM performed tests at 48% H2O simulating air enrichment. CSM performed also descaling tests in NG and H2 combustion atmosphere (18% vs 33% H2O) simulating reference industrial condition, while AMMR performed industrial desclaing tests (Task 3.2).
Swerim is revamping its combustion facility to test poxidation and descaling simulating industrial conditions, using burners provided by Tenova and Linde.Those tests will be performed in November 2025.
The steel grades to be tested have been decided together with SSAB and Tata Steel, where different types of micro-alloyed, high strength and electrical steels will be tested. (Task 3.3).
Work Package 4
In accordance with the change of activities ownership between Snam and Tenova reported in minute of meeting November 2023, Snam has released a Purchase Order to buy a bigger H2 supply system (H2 buffer storage), while Tenova is managing the permitting step, BOP design and purchase (that is strictly linked to permitting) and related safety study (see Project proposal: tasks 1.3 and D1.3 in WP 1). Waiting for the H2 storage delivery, Snam has shared with Tenova the layout and the design. In the buffer storage supply is included a Pressure Safety Valve (PSV) with 32 bar as safety pressure, which has been tailored to the operating pressures of the Tenova plant. The integration of the electrolyser, the hydrogen tank and the existing plant (TenovaLAB) ihas been completed. due to delays in permitting, the commissioning of the system will be carried out in September 2025. The adaptation of pilot facility of Tata Steel is almost completed and tests will start in October 2025.
WP5
Nunki steel started the design of the industrial tests of refractort preheating with a blend of NG and Hydrogen. Thsi analysis is requiring more time than expected due to the modificed regulation framework, with new restrictions for hydrogen storage ands utilization
will lead to an abatement of 0.9% (25 Mt) of the EU CO2 emission.
Innovative burner: CFD analysis confirmed the high performances of the H2 ready burner and its capability to wprk in hybrid mode (hydrogen blended with natural gas and LPG)
Oxidation tests: this activity revealed the effect due to H2 conbustion on a large variety of steel grades. The effect of steel compostion and correlation with atmpsphere , time and temperatiure has been assessed. tests with 48% of water (simulating O2 enrichment) carried out
Descaling tests: this activity has been done. The result beyond the state of the art is the correlation with hydrogen combustion atmosphere and scale removal for a large variety of steel grades. Some more tets (not foreseen) will be carried out in autumn for deeper understanding of phenomena
The development of the first democase (1 MW electrolyser installation at Tenova premises and connection with innovative hydrogen ready burner) is ready. this democase will show the complete value chain, from renewable energy installation, green hydrogen production and utilization in industrial burner. (Commissioning of the system September 2025)
Oxidation tests: this activity revealed the effect due to H2 conbustion on a large variety of steel grades. The effect of steel compostion and correlation with atmpsphere , time and temperatiure has been assessed. tests with 48% of water (simulating O2 enrichment) carried out
Descaling tests: this activity has been done. The result beyond the state of the art is the correlation with hydrogen combustion atmosphere and scale removal for a large variety of steel grades. Some more tets (not foreseen) will be carried out in autumn for deeper understanding of phenomena
The development of the first democase (1 MW electrolyser installation at Tenova premises and connection with innovative hydrogen ready burner) is ready. this democase will show the complete value chain, from renewable energy installation, green hydrogen production and utilization in industrial burner. (Commissioning of the system September 2025)