Periodic Reporting for period 1 - ModHEATech (Modular HEATing Technology through renewable resources for steel production)
Okres sprawozdawczy: 2023-03-01 do 2024-08-31
ModHEATech aims to decarbonize rolling mills by exploring induction and resistance heating for long steel products to reduce fossil fuel use, replacing gas burners.
Induction heating is effective in various industries but faces challenges with long steel products due to uneven heat distribution, limiting it to a TRL of 6-7. A validated model suggests spacing heating elements apart to avoid thermal stress. Multi-stage heating via inductors has been proposed. However, integration with existing plants, like ORI-Martin and SIDENOR, shows that induction heating’s temperature increase is constrained to 100°C, which limits environmental benefits. Integrating induction into gas furnaces has reduced furnace efficiency, and studies are ongoing to optimize this hybrid setup.
Resistance heating remains experimental at TRL 4 and is not yet scaled for long steel products, but preliminary studies show it may achieve up to 80% energy efficiency over fuel burners, providing uniform temperatures with only a 10°C core-skin difference, compared to 30°C in traditional methods. A model created for Feralpi’s steel grades demonstrates uniform heat distribution and reduced processing times, though challenges like oxide scale formation and clamp durability require further validation.
A virtual study on SIDENOR’s rolling mills explores combining induction heating with hydrogen burners, assessing material, maintenance, and lifecycle impacts (LCA, LCC, SLCA) to evaluate sustainability and cost-effectiveness. The study identifies an optimal thermal induction case-study but highlights significant limitations in induction’s integration with existing furnaces, as seen with ORIMartin, where layout restrictions reduce induction’s environmental impact.
Induction heating is effective in various industries but faces challenges with long steel products due to uneven heat distribution, limiting it to a TRL of 6-7. A validated model suggests spacing heating elements apart to avoid thermal stress. Multi-stage heating via inductors has been proposed. However, integration with existing plants, like ORI-Martin and SIDENOR, shows that induction heating’s temperature increase is constrained to 100°C, which limits environmental benefits. Integrating induction into gas furnaces has reduced furnace efficiency, and studies are ongoing to optimize this hybrid setup.
Resistance heating remains experimental at TRL 4 and is not yet scaled for long steel products, but preliminary studies show it may achieve up to 80% energy efficiency over fuel burners, providing uniform temperatures with only a 10°C core-skin difference, compared to 30°C in traditional methods. A model created for Feralpi’s steel grades demonstrates uniform heat distribution and reduced processing times, though challenges like oxide scale formation and clamp durability require further validation.
A virtual study on SIDENOR’s rolling mills explores combining induction heating with hydrogen burners, assessing material, maintenance, and lifecycle impacts (LCA, LCC, SLCA) to evaluate sustainability and cost-effectiveness. The study identifies an optimal thermal induction case-study but highlights significant limitations in induction’s integration with existing furnaces, as seen with ORIMartin, where layout restrictions reduce induction’s environmental impact.
WP1: Project Coordination & Management
WP1 ensures effective project execution, emphasizing robust administrative, technical, and financial management. A Data Management Plan (DMP) following the FAIR principles guarantees secure data handling, aligning with GDPR compliance. Data is stored on a centralized SharePoint, ensuring only authorized access, with cybersecurity measures in place. A clear governance framework with committees for decision-making and intellectual property management maintains smooth operations. Regular project meetings and adherence to Horizon Europe guidelines promote transparency and effective risk management.
WP2: Demosite 1 (ORI Martin)
WP2 focuses on designing, implementing, and evaluating an induction heating system to raise billet temperatures from 800–900°C to 1100°C, reducing fossil fuel reliance. Two configurations were considered: one near the furnace exit and another along the roller path. While each configuration has pros and cons related to layout modifications and environmental impact, cost analyses indicate minimal differences in expenses. Alternative solutions, such as an offline induction heating system, are under review to optimize environmental benefits. A photovoltaic installation at ORI Martin will generate 10,300 MWh/year to meet the furnace’s energy needs, aligning with the project’s green energy goals.
WP3: Demosite 2 (FERALPI, Italy)
WP3 explores heating billets with direct current (DC) to ensure uniform heating, as alternating current (AC) leads to uneven distribution. A simulation model using COMSOL software verified the effectiveness of DC heating, though it requires significant power. Tests revealed minor temperature discrepancies, confirming the viability of DC heating for industrial application. However, careful design adjustments are essential to prevent excessive power demand.
WP4: Virtual Demosite 1 (SIDENOR)
This WP examines the feasibility of hybrid heating (natural gas and induction) to reduce energy consumption and emissions. The SIDENOR plant case study indicates potential gas consumption reductions of 4.4-9.4% depending on setup. Lifecycle assessments (LCA) show the environmental burden of natural gas, mainly contributing to climate change and resource depletion. Future LCAs will update these impacts post-implementation. Economic evaluations through lifecycle cost analysis (LCC) confirm the financial viability of these eco-friendly solutions. The Social Hotspots Database (SHDB) assesses social impacts on workers and stakeholders. Critical component analyses focus on hydrogen embrittlement and oxidation resistance, with predictive maintenance strategies planned for system reliability.
WP5: Virtual Demosite 2 (FERALPI, Germany)
WP5 builds on WP3, analyzing the Joule heating system for billets connected via DC grips, which ensures homogeneous heating. Challenges include power supply limitations and maintaining temperature homogeneity across billet cross-sections. Movement constraints due to large cables mean billets remain stationary during trials. Billet samples with unique wave mold surfaces are being prepared to match ESF billets' conditions for upcoming trials.
WP6: Exploitation, Communication, and Dissemination
WP6 outlines strategies for sharing project results across websites, social media, and scientific publications. The project has been presented at key industry events and will host a technical session in October 2024 to showcase induction heating models. Key results include proving induction heating as a viable partial electrification method and testing resistance heating as an alternative low-emission solution. Networking with industry stakeholders and related EU projects enhances collaboration, ensuring the project’s industrial and environmental impacts.
WP1 ensures effective project execution, emphasizing robust administrative, technical, and financial management. A Data Management Plan (DMP) following the FAIR principles guarantees secure data handling, aligning with GDPR compliance. Data is stored on a centralized SharePoint, ensuring only authorized access, with cybersecurity measures in place. A clear governance framework with committees for decision-making and intellectual property management maintains smooth operations. Regular project meetings and adherence to Horizon Europe guidelines promote transparency and effective risk management.
WP2: Demosite 1 (ORI Martin)
WP2 focuses on designing, implementing, and evaluating an induction heating system to raise billet temperatures from 800–900°C to 1100°C, reducing fossil fuel reliance. Two configurations were considered: one near the furnace exit and another along the roller path. While each configuration has pros and cons related to layout modifications and environmental impact, cost analyses indicate minimal differences in expenses. Alternative solutions, such as an offline induction heating system, are under review to optimize environmental benefits. A photovoltaic installation at ORI Martin will generate 10,300 MWh/year to meet the furnace’s energy needs, aligning with the project’s green energy goals.
WP3: Demosite 2 (FERALPI, Italy)
WP3 explores heating billets with direct current (DC) to ensure uniform heating, as alternating current (AC) leads to uneven distribution. A simulation model using COMSOL software verified the effectiveness of DC heating, though it requires significant power. Tests revealed minor temperature discrepancies, confirming the viability of DC heating for industrial application. However, careful design adjustments are essential to prevent excessive power demand.
WP4: Virtual Demosite 1 (SIDENOR)
This WP examines the feasibility of hybrid heating (natural gas and induction) to reduce energy consumption and emissions. The SIDENOR plant case study indicates potential gas consumption reductions of 4.4-9.4% depending on setup. Lifecycle assessments (LCA) show the environmental burden of natural gas, mainly contributing to climate change and resource depletion. Future LCAs will update these impacts post-implementation. Economic evaluations through lifecycle cost analysis (LCC) confirm the financial viability of these eco-friendly solutions. The Social Hotspots Database (SHDB) assesses social impacts on workers and stakeholders. Critical component analyses focus on hydrogen embrittlement and oxidation resistance, with predictive maintenance strategies planned for system reliability.
WP5: Virtual Demosite 2 (FERALPI, Germany)
WP5 builds on WP3, analyzing the Joule heating system for billets connected via DC grips, which ensures homogeneous heating. Challenges include power supply limitations and maintaining temperature homogeneity across billet cross-sections. Movement constraints due to large cables mean billets remain stationary during trials. Billet samples with unique wave mold surfaces are being prepared to match ESF billets' conditions for upcoming trials.
WP6: Exploitation, Communication, and Dissemination
WP6 outlines strategies for sharing project results across websites, social media, and scientific publications. The project has been presented at key industry events and will host a technical session in October 2024 to showcase induction heating models. Key results include proving induction heating as a viable partial electrification method and testing resistance heating as an alternative low-emission solution. Networking with industry stakeholders and related EU projects enhances collaboration, ensuring the project’s industrial and environmental impacts.
At M18, the following results have been achieved:
1. Induction model has been set and validated, and allow to study the optimal parameters to avoid thermal stress on billet
2. Induction Heating: the model and preliminary validation tests, together with studies on layout, show that the potential of induction heating is limited due to space constraints: on current configuration, it is possible to provide by induction only 100 °C, less than the initial aim. Moreover, the modification on the layout implies a certain reduction of furnace efficiency. Other configurations are ongoing with the aim to maximize the environmental benefits from electrical heating.
3. Resistance heating: a thermal model is used to define the thermal profile inside the billet, and set the design-of-experiment. Additional constraints derived from the power input necessary to the pilot plant, which installation requires specific studies.
4. Identification of best case for installation of induction heating in SIDENOR plant on the basis of the findings of induction heating model has been completed; the analysis is supported by impact studies on emissions and energy consumption.
5. LCA-LCC-SLCA: the first part of the activity has been completed on the basis of SIDENOR current production
1. Induction model has been set and validated, and allow to study the optimal parameters to avoid thermal stress on billet
2. Induction Heating: the model and preliminary validation tests, together with studies on layout, show that the potential of induction heating is limited due to space constraints: on current configuration, it is possible to provide by induction only 100 °C, less than the initial aim. Moreover, the modification on the layout implies a certain reduction of furnace efficiency. Other configurations are ongoing with the aim to maximize the environmental benefits from electrical heating.
3. Resistance heating: a thermal model is used to define the thermal profile inside the billet, and set the design-of-experiment. Additional constraints derived from the power input necessary to the pilot plant, which installation requires specific studies.
4. Identification of best case for installation of induction heating in SIDENOR plant on the basis of the findings of induction heating model has been completed; the analysis is supported by impact studies on emissions and energy consumption.
5. LCA-LCC-SLCA: the first part of the activity has been completed on the basis of SIDENOR current production