In 2020, industrial activities in the EU emitted a 351 million tonnes of CO2 equivalent, marking an 8% reduction from the levels from 2019. Numerous industrial processes require continuous high-temperature heat, and currently, no viable solution for decarbonizing these processes exists. The implementation of a thermal energy storage, lasting up to 48 hours, could facilitate the substitution of fossil fuels with industrial waste heat and renewable electricity.
HEATERNAL project brings together four specialized public research teams focused on prototyping and modeling thermal systems, phase-change materials, and 3D-printing. It also involves two manufacturers from the metal industry and two from the ceramic sector, a process engineering expertand equipment manufacturer, an organism specialised in life cycle assessment (LCA) and techno-economic analysis (TEA), as well as a dissemination and communication expert. HEATERNAL aims to create a prototype and model for an innovative thermal energy storage concept, drawing from substantial scientific and industrial expertise. This involves two key components: (i) innovative phase-change materials and unit designs that amplify unit energy density by 350% compared to ceramic bricks, and (ii) manufacturing proficiency that guarantees swift integration of materials and units into factories by 2030. During the 42 months duration of the project, the team will produce a 50-kWh prototype (Technology Readiness Level 5) along with storage system models tailored for factory integration.
A preliminary TEA anticipates a return on investment within three years and a levelized cost of stored energy below 6€/MWh. This is 60% lower than molten salt storage, which does not operate at temperatures high enough for major metal and mineral industries dealing. The HEATERNAL solution effectively addresses industrial requisites, including a minimal footprint, a lifespan exceeding 10 years, and swift return on investment. The strategic exploitation plan aims to introduce the solution in the first factory by 2030. Sales projections indicate potential earnings of 286 million€ through the sales of phase-change materials, ceramic refractories, and engineering services by 2040, while preventing the emission of 147.5 million tonnes of CO2 equivalent by 2040.
The project objectives and related ambitions are described below:
• HEATERNAL ambition 1: OPTIMIZED COST-EFFECTIVE SYSTEM
o To maximise thermal performances of TES Unit (energy density, heat transfer capacity) ;
o To simulate full TESS integration for 3 use cases ;
o To ensure economic viability and environmental sustainability of the system ;
• HEATERNAL ambition 2: LIFETIME > 10 YEARS
o To ensure the reliability of the thermal storage Unit from 600-900°C ;
o To validate a 50 kWh-scale (TRL5) prototype via accelerated aging tests corresponding to 2 years operation of one use-case and via thermomechanical models considering heat transfer and thermal stress ;
• HEATERNAL ambition 3: MANUFACTURABILITY FOR RAPID MARKET ENTRY
o To minimize system footprint ;
o To ensure that HEATERNAL R&D leads to a system that can be rapidly manufactured and improved after the project: i) Compatible with high MRL7 processes to meet urgent needs to decarbonize processes, ii) Exploration of lower MRL processes for longer term higher thermal performances (next-generation TES) ;
• HEATERNAL ambition 4: TO ENSURE MARKET ENTRY BY 2030 and 10% market share by 2040
o To engage stakeholders to invest in TRL7/8 demonstration and/or factory adoption.
