Thermochemical Heat Recovery and Upgrade for Industrial Processes (TechUPGRADE)

Project Information

TechUPGRADE

Grant agreement ID: 101103966

DOI

10.3030/101103966

EC signature date 25 April 2023

Start date 1 May 2023

End date 30 April 2027

Funded under

• Climate, Energy and Mobility

Total cost

€ 4 999 765,00

EU contribution

€ 4 999 765,00

Coordinated by

DANMARKS TEKNISKE UNIVERSITET
Denmark

Periodic Reporting for period 1 - TechUPGRADE (Thermochemical Heat Recovery and Upgrade for Industrial Processes (TechUPGRADE))

Reporting period: 2023-05-01 to 2024-10-31

Summary of the context and overall objectives of the project

The TechUPGRADE project, officially titled "Thermochemical Heat Recovery and Upgrade for Industrial Processes", aims to target developing and demonstrating novel thermochemical heat upgrade systems to address critical challenges in industrial energy efficiency. The TechUPGRADE system will allow an effective upgrade of both industrial low-grade waste heat and solar energy supplies to the temperature range between 150 and 250°C using salt hydrates as the reactive material. Industries today face challenges associated with the effective utilization of low-grade waste heat and the dependency on fossil fuels for process heating. Very little of this available waste heat can serve directly in appropriate temperature ranges for various technical and economic reasons. Besides this, global commitments to carbon neutrality make it imperative to look toward innovation that reduces energy consumption and emissions of greenhouse gases.
Using novel approaches, the TechUPGRADE project tackles some of the most pressing industrial challenges related to energy efficiency and decarbonization. The main activities will focus on advanced development in the area of reactive materials and optimization of salt hydrate for more than 100-cycle-long cycling stability with an energy density above 300 kWh/m³, with a production cost below €3/kg for industrial scalability. The project focuses on designing modular, closed-system heat upgrade reactors capable of undergoing cyclic dehydration and hydration with temperature increases exceeding 100°C. Additionally, it aims to integrate these systems into industrial processes at an affordable Levelized Cost of Heat (LCOH) of 4-6 c€/kWh or less. The valorization of waste heat streams with very low electricity consumption enables the project to contribute to developing carbon-neutral energy systems. Focusing on the highest-impact sectors for projects such as the petrochemical sector, where process heat demand fits into the objectives of the project, would enable TechUPGRADE to upgrade low-exergy heat at very low costs. Expected outcomes include improved energy efficiency, decreased reliance on fossil fuels, significant reductions in CO2 emissions, and adaptable solutions for various industries and energy systems aimed at achieving the EU and global climate protection goals.
This project is part of the priorities to decarbonize the industry and develop sustainable technologies from a political and strategic context marked by the Green Deal of the European Union and the objective of carbon neutrality set for 2050.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The TechUPGRADE project achieved great success in the development of thermo-chemical heat upgrade systems for industrials. The main milestones involve:
Material Development and Characterization
An extensive screening of salt hydrates concerning materials for the temperature ranges around 90-150°C and 150-250°C was performed. Promising candidates like SrBr2∙H2O and other Tutton salts were suggested and tested for long-term cycling stability in real applications. It evidences long-term stability after 100 cycles with energy densities greater than 300 kWh/m³, marking key achievements concerning the demands of this project. Other works are done to enhance the material properties, incorporating them into carrier structures such as metal foams and zeolites, which have shown promising compatibility and thermal performances in the first tests.

Heat Reactor Design and Testing
Original modular reactor designs were developed for such closed-system configurations to optimize heat and mass transfer of the cyclic dehydration and hydration processes. Its prototype was prepared with SrBr2∙H2O and performed very well during the laboratory tests. Proper heat transfer and periodic stability with high-temperature lifts (>100°C) operation were assured through the developed prototype of the reactor. Experimental data allowed the performance of important numerical simulations that enabled important conclusions to be drawn with a view to designing optimization that increases performance and durability.

System Integration
The system-level design related to industrial applications, mainly from the petrochemical field where waste heat sources fit the operating range of the project, has already started. Preliminary sizing and process mapping indicate strong potential for integration at low-cost operation (LCOH ≤ 4-6 c€/kWh). Overall, the project successfully reached the critical milestones towards creating scalable and sustainable solutions to recover and upgrade industrial heat. Efforts will be performed to integrate the system, optimize multi-criteria, and conduct demonstrations at full scale.

Dynamic Modeling and Optimization
Dynamic models of the thermochemical system have been developed in the Dymola and COMOL environments. These models simulate hydration and dehydration cycles, hence offering insight into the thermal reaction kinetics of the reactor. Preliminary results are in good agreement with experimental data and ensure robust design validation. Work in progress includes refining such models toward dynamic integration with waste heat and solar energy sources.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The state-of-the-art in thermochemical heat upgrading has been advanced by developing innovative systems for efficient waste heat recovery and boosting the use of salt hydrates within the TechUPGRADE project. The major achievements include identifying and optimizing materials like SrBr2∙H2O, which show stability over more than 100 cycles with energy densities above 300 kWh/m³, meeting cost and performance targets. This enables the way for novel modular designs actually allowing temperature lifts > 100°C and direct integration at an affordable LCOH into industrial processes. (LCOH ≤ 4 to 6 c€/kWh)
These systems have gained validation through dynamic modeling and prototype testing, greatly enhancing thermal performance and scalability. Further pilots, demonstrations at scale, integration with different industrial applications, and removing commercialization barriers to market uptake- for example, on regulatory standards, market access, and IPR management- are relevant next steps. The project contributes to carbon-neutral energy solutions, with a very high potential to reach EU climate goals by reducing emissions in high-impact sectors.

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