Periodic Reporting for period 1 - HEATERNAL (innovative High tEmperAture ThErmal stoRage for iNdustrial AppLications)
Período documentado: 2023-05-01 hasta 2024-10-31
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.
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.
The work carried out in WP2 "Requirements analysis specifications from use cases" led to a precise characterization of three use-cases requirements for an implementation of HEATERNAL technology.
During WP3 "Storage materials development", six Phase-Change Material (PCM) formulations for three studied range of temperature (from 600 to 900°C) were characterized. The team of experts selected the 3 most efficient PCM formulations, one for each range of temperature defined in the Grant Agreement of the project. Eventually one of this PCM was selected to be used in the prototype, to be compliant with prototype functioning constraints and was further studied. Particularly some new routes for PCM synthesis were investigated. Additionally, the project has started to produce first knowledge on ceramic refractories and metal alloys PCM compatibility, acquired through experiment between the selected materials.
Characterization of new filaments formulations for ceramic polymer matrix for additive manufacturing was also operated during the first period of the project. New constraints were identified for the extrusion step during the testing phase, leading to upgrading the extruder machine.
WP4 which is "Thermo-mechanical design of LTES Unit" work led the incorporation of materials constraints and thermal transfer in a TES unit design. The thermo-mechanical model developed during WP4 enable to evaluate the impact of the embedded PCM in different unit designs, a compromise has to be found between the unit mechanical robustness and its performances. Endeed,the developed design of HEATERNAL TES unit enable to reach a storage density of 359 kWh/m3 over temperature change of 300K and for 50% PCM inserted, nearly reaching the objective of 400 kWh/m3 storage density.
This allowed to achieve an in depth understanding of the thermal transfers in HEATERNAL TES through the prototype design and identify impacting limitations related to operational functioning of the technology adapted to the use-case. Following this newly acquired knowledge, several prototype design simulations provided an upgraded design ensuring an improved reliability of a safe functioning of the 50kWh prototype.
Knowledge and competence sharing withing WP4 team also improved the understanding of thermo-mechanical models.
WP7 devoted to Techno-Economic Assessment & Life Cycle Analysis particularly evaluated the environmental impact of potential material formulations for PCM studied in WP3, and thus allowed to guide the PCM selection for the different temperature range for TES operation. During the first period of the project, an assesment of techno-economic indicators for TESS technology, such as capital expenditure (CAPEX), operating expenditure (OPEX), and levelised costs of storage (LCOS) has been performed. This study will be refined during the next period with additional data from WP5 (prototype building) and WP6 to confirm the techno-economic feasibility of the HEATERNAL technology.
During WP3 "Storage materials development", six Phase-Change Material (PCM) formulations for three studied range of temperature (from 600 to 900°C) were characterized. The team of experts selected the 3 most efficient PCM formulations, one for each range of temperature defined in the Grant Agreement of the project. Eventually one of this PCM was selected to be used in the prototype, to be compliant with prototype functioning constraints and was further studied. Particularly some new routes for PCM synthesis were investigated. Additionally, the project has started to produce first knowledge on ceramic refractories and metal alloys PCM compatibility, acquired through experiment between the selected materials.
Characterization of new filaments formulations for ceramic polymer matrix for additive manufacturing was also operated during the first period of the project. New constraints were identified for the extrusion step during the testing phase, leading to upgrading the extruder machine.
WP4 which is "Thermo-mechanical design of LTES Unit" work led the incorporation of materials constraints and thermal transfer in a TES unit design. The thermo-mechanical model developed during WP4 enable to evaluate the impact of the embedded PCM in different unit designs, a compromise has to be found between the unit mechanical robustness and its performances. Endeed,the developed design of HEATERNAL TES unit enable to reach a storage density of 359 kWh/m3 over temperature change of 300K and for 50% PCM inserted, nearly reaching the objective of 400 kWh/m3 storage density.
This allowed to achieve an in depth understanding of the thermal transfers in HEATERNAL TES through the prototype design and identify impacting limitations related to operational functioning of the technology adapted to the use-case. Following this newly acquired knowledge, several prototype design simulations provided an upgraded design ensuring an improved reliability of a safe functioning of the 50kWh prototype.
Knowledge and competence sharing withing WP4 team also improved the understanding of thermo-mechanical models.
WP7 devoted to Techno-Economic Assessment & Life Cycle Analysis particularly evaluated the environmental impact of potential material formulations for PCM studied in WP3, and thus allowed to guide the PCM selection for the different temperature range for TES operation. During the first period of the project, an assesment of techno-economic indicators for TESS technology, such as capital expenditure (CAPEX), operating expenditure (OPEX), and levelised costs of storage (LCOS) has been performed. This study will be refined during the next period with additional data from WP5 (prototype building) and WP6 to confirm the techno-economic feasibility of the HEATERNAL technology.
Work from WP3 led to identify some new Phase-Change Material (PCM) formulations for high temperature heat storage. Some new routes have been investigated for these PCM synthesis. Consequently, numerous physico-chemical and thermal analysis have been performed for a full characterization of these innovative materials. Publications are in preparation and will be published after the end of the reporting period.