Periodic Reporting for period 1 - ELITHE (Electrification of ceramic industries high temperature heating equipment)
Periodo di rendicontazione: 2024-01-01 al 2025-06-30
The ceramic industry is one of Europe’s most energy-intensive sectors, relying heavily on high-temperature processes such as melting, calcination and firing. These operations are traditionally powered by fossil fuels, mainly natural gas, which makes the sector responsible for a significant share of greenhouse gas emissions and highly exposed to energy price volatility and supply risks. Decarbonising these processes is therefore a priority for the European Union to achieve climate neutrality by 2050 and to strengthen the resilience of energy-intensive industries.
The eLITHE project addresses this challenge by demonstrating sustainable and cost-effective electrification pathways for high-temperature heating in ceramics. It combines three pilot technologies covering the most representative processes of the sector:
a frit smelter powered by induction and electrodes,
a microwave-based alumina calciner, and
a hybrid tunnel kiln for brick firing that integrates electricity and hydrogen combustion.
These pilots will validate innovative furnace concepts and prove that electricity, increasingly generated from renewable sources, can replace fossil fuels in industrial high-temperature operations. In parallel, the project develops novel material compositions compatible with electric heating, investigates circular waste materials for high-temperature thermal energy storage, and delivers digitalisation tools such as digital twins and decision support systems to ensure efficient, flexible and safe operation.
By combining advanced technologies, new materials, and digital intelligence, eLITHE creates a comprehensive pathway to decarbonise the ceramic sector. The project contributes to several EU policy goals, including the European Green Deal, the REPowerEU plan and the Strategic Energy Technology Plan. The expected impact is significant: each full-scale unit could reduce over 97,000 tonnes of CO2 emissions annually and avoid more than 505 GWh of natural gas consumption per year, directly reducing Europe’s dependence on fossil fuel imports.
Beyond environmental gains, eLITHE also supports the transition to a circular and resilient economy, fosters industrial competitiveness, and contributes to the creation of green jobs. Social and economic dimensions are addressed through engagement with industry stakeholders, consideration of workforce skills and safety, and dissemination of best practices. The project also assesses the flexibility and integration of electrified processes within future energy systems, enabling industry to act as an active player in renewable-based electricity markets.
Overall, eLITHE demonstrates that the electrification of high-temperature processes in ceramics is technically feasible, economically attractive and environmentally necessary. Its results will serve as a blueprint for wider replication in other energy-intensive industries, supporting Europe’s leadership in clean industrial technologies.
The eLITHE project addresses this challenge by demonstrating sustainable and cost-effective electrification pathways for high-temperature heating in ceramics. It combines three pilot technologies covering the most representative processes of the sector:
a frit smelter powered by induction and electrodes,
a microwave-based alumina calciner, and
a hybrid tunnel kiln for brick firing that integrates electricity and hydrogen combustion.
These pilots will validate innovative furnace concepts and prove that electricity, increasingly generated from renewable sources, can replace fossil fuels in industrial high-temperature operations. In parallel, the project develops novel material compositions compatible with electric heating, investigates circular waste materials for high-temperature thermal energy storage, and delivers digitalisation tools such as digital twins and decision support systems to ensure efficient, flexible and safe operation.
By combining advanced technologies, new materials, and digital intelligence, eLITHE creates a comprehensive pathway to decarbonise the ceramic sector. The project contributes to several EU policy goals, including the European Green Deal, the REPowerEU plan and the Strategic Energy Technology Plan. The expected impact is significant: each full-scale unit could reduce over 97,000 tonnes of CO2 emissions annually and avoid more than 505 GWh of natural gas consumption per year, directly reducing Europe’s dependence on fossil fuel imports.
Beyond environmental gains, eLITHE also supports the transition to a circular and resilient economy, fosters industrial competitiveness, and contributes to the creation of green jobs. Social and economic dimensions are addressed through engagement with industry stakeholders, consideration of workforce skills and safety, and dissemination of best practices. The project also assesses the flexibility and integration of electrified processes within future energy systems, enabling industry to act as an active player in renewable-based electricity markets.
Overall, eLITHE demonstrates that the electrification of high-temperature processes in ceramics is technically feasible, economically attractive and environmentally necessary. Its results will serve as a blueprint for wider replication in other energy-intensive industries, supporting Europe’s leadership in clean industrial technologies.
During the first reporting period, the project focused on preparing the pilot demonstrations and ensuring alignment with safety, environmental and operational requirements.
Baseline assessments: Fossil-based processes for frit smelting, alumina calcination and brick firing were characterised in terms of energy demand, flexibility and emissions, establishing reference scenarios for comparison with electrified technologies.
Material characterisation: Detailed analyses of frits, refractory bricks and other materials identified their properties under high-temperature electric conditions, guiding the selection of suitable compositions and new formulations.
Circular materials: An open database of ceramic wastes and by-products was compiled, showing the potential of clinker and other residues for thermal energy storage, supporting circularity.
Health and safety: Preventive measures and procedures (design safety, human factor engineering, permit-to-work and lock-out/tag-out protocols) were developed to be applied during pilot implementation.
Digitalisation and data management: ICT requirements and data architecture were defined, including digital twins, a decision support system for flexibility and predictive maintenance, supported by interoperable data strategies.
Pilot engineering: Significant progress was made in the design of the three demonstrators:
Frit smelter (TCID): design of induction/electrode heating and refractory integration.
Microwave calciner (MYT): furnace architecture, power coupling and insulation for continuous 1200 °C operation.
Hybrid kiln (IZF): layout integrating radiant walls and hydrogen/gas burners with safety systems.
These activities provide the baseline for pilot construction and installation, with demonstrations planned in the next period.
Baseline assessments: Fossil-based processes for frit smelting, alumina calcination and brick firing were characterised in terms of energy demand, flexibility and emissions, establishing reference scenarios for comparison with electrified technologies.
Material characterisation: Detailed analyses of frits, refractory bricks and other materials identified their properties under high-temperature electric conditions, guiding the selection of suitable compositions and new formulations.
Circular materials: An open database of ceramic wastes and by-products was compiled, showing the potential of clinker and other residues for thermal energy storage, supporting circularity.
Health and safety: Preventive measures and procedures (design safety, human factor engineering, permit-to-work and lock-out/tag-out protocols) were developed to be applied during pilot implementation.
Digitalisation and data management: ICT requirements and data architecture were defined, including digital twins, a decision support system for flexibility and predictive maintenance, supported by interoperable data strategies.
Pilot engineering: Significant progress was made in the design of the three demonstrators:
Frit smelter (TCID): design of induction/electrode heating and refractory integration.
Microwave calciner (MYT): furnace architecture, power coupling and insulation for continuous 1200 °C operation.
Hybrid kiln (IZF): layout integrating radiant walls and hydrogen/gas burners with safety systems.
These activities provide the baseline for pilot construction and installation, with demonstrations planned in the next period.
The eLITHE project goes well beyond the current state of the art, where electrification of high-temperature processes remains rare and niche. Today, ceramic frits, alumina and bricks are produced almost entirely with natural gas furnaces, which are carbon-intensive and inflexible.
eLITHE introduces a new generation of electrified furnaces—induction, microwave and hybrid electric–hydrogen—combined with advanced materials and digitalisation. These innovations enable efficient operation at >1,000–1,500 °C with renewable electricity, for the first time at industrial scale. The project also pioneers the reuse of ceramic wastes for thermal energy storage, linking decarbonisation with circular economy goals.
A major advance is the integration of digital twins, predictive maintenance and decision-support tools, allowing real-time optimisation, energy market participation and safe, reliable operation under fluctuating renewable supply.
By project end, eLITHE will deliver: three industrially validated pilot demonstrators; new material and refractory formulations; an open database of ceramic wastes; a digital platform for monitoring and flexibility; comprehensive H&S protocols; and full life-cycle and techno-economic assessments.
The expected impact is considerable: each full-scale eLITHE unit could cut >97,000 tCO2 and save 505 GWh of natural gas annually, while boosting competitiveness, resilience and circularity in Europe’s ceramic and other energy-intensive industries.
eLITHE introduces a new generation of electrified furnaces—induction, microwave and hybrid electric–hydrogen—combined with advanced materials and digitalisation. These innovations enable efficient operation at >1,000–1,500 °C with renewable electricity, for the first time at industrial scale. The project also pioneers the reuse of ceramic wastes for thermal energy storage, linking decarbonisation with circular economy goals.
A major advance is the integration of digital twins, predictive maintenance and decision-support tools, allowing real-time optimisation, energy market participation and safe, reliable operation under fluctuating renewable supply.
By project end, eLITHE will deliver: three industrially validated pilot demonstrators; new material and refractory formulations; an open database of ceramic wastes; a digital platform for monitoring and flexibility; comprehensive H&S protocols; and full life-cycle and techno-economic assessments.
The expected impact is considerable: each full-scale eLITHE unit could cut >97,000 tCO2 and save 505 GWh of natural gas annually, while boosting competitiveness, resilience and circularity in Europe’s ceramic and other energy-intensive industries.