Periodic Reporting for period 1 - METAWAVE (High-temperature heating processes with breakthrough microwave and digital technologies for increased energy efficiency)
Reporting period: 2024-01-01 to 2025-06-30
Process industries are central to the European economy, transforming raw materials into essential products. However, they are highly energy-intensive and heavily reliant on fossil fuels, particularly for process heating, which accounts for about 50% of industrial energy use in the EU. This makes industrial heating responsible for over 20% of GHG emissions in the sector. To meet the European Green Deal’s climate neutrality goals, improving energy efficiency and integrating renewable energy sources (RES) into industrial heating is crucial. Electrification offers a promising solution, especially through replacing fossil-fuel-based furnaces with electric alternatives.
The METAWAVE project supports this transition by introducing advanced microwave-based heating systems for high-temperature processes (above 400°C). These systems align with circular economy principles and aim to enhance efficiency, reduce emissions, and boost productivity. Key objectives include:
• Developing new design methods for microwave heating.
• Optimising processes with digital technologies.
• Powering systems via a virtual power plant to maximise RES use.
• Deploying modular, energy-efficient microwave systems.
• Ensuring economic viability and promoting adoption.
• Demonstrating the technology in ceramics, asphalt, and aluminium sectors at TRL6.
By 2032, METAWAVE targets a 420 GWh energy reduction, 95,000 tonnes of CO2 savings, a 19% productivity boost, €230M in revenue, and 900+ new jobs. The project unites 20 partners from 9 countries, including SMEs, research centres, universities, and large enterprises.
The METAWAVE project supports this transition by introducing advanced microwave-based heating systems for high-temperature processes (above 400°C). These systems align with circular economy principles and aim to enhance efficiency, reduce emissions, and boost productivity. Key objectives include:
• Developing new design methods for microwave heating.
• Optimising processes with digital technologies.
• Powering systems via a virtual power plant to maximise RES use.
• Deploying modular, energy-efficient microwave systems.
• Ensuring economic viability and promoting adoption.
• Demonstrating the technology in ceramics, asphalt, and aluminium sectors at TRL6.
By 2032, METAWAVE targets a 420 GWh energy reduction, 95,000 tonnes of CO2 savings, a 19% productivity boost, €230M in revenue, and 900+ new jobs. The project unites 20 partners from 9 countries, including SMEs, research centres, universities, and large enterprises.
In the first 18 months, METAWAVE focused on consolidating technological and industrial process specifications, identifying critical monitoring and control parameters, and defining safety requirements. Based on this groundwork, three prototypes were designed for the ceramics, asphalt, and aluminium industries. Circular refractory materials were identified and parametrised, and 2D nanostructured additives were developed. These were used to create and test refractory components for integration into the heating prototypes. Initial designs were completed for a roller kiln using microwave plasma torches (ceramic sector), a tunnel kiln combining microwaves and hot air (asphalt), and a cylindrical furnace using both microwaves and induction heating (aluminium). To support these designs, multi-physics CFD and FEM models were developed for each prototype, enabling simulations that informed and refined the prototype designs. The reference architecture for the data platform and distributed control system was delivered, along with a monitoring network and a simulation framework to support future metaverse-ready process industries. Work also began on developing high-temperature-resistant fibre optic sensors (FOS) for real-time monitoring and on defining the architecture for the Virtual Power Plant (VPP) and Energy Management System (EMS), which will be implemented in the next project phase.
During the first 18 months of the project, significant advancements were made across multiple domains, including materials, processes, measurement systems, and modelling techniques, all aimed at enhancing the efficiency of microwave-assisted processes in energy-intensive industries.
A new class of circular refractories was developed and tested for use as insulating linings, susceptors, or to enhance microwave attenuation. These materials, tailored with active compounds like copper slag and graphene-based additives, were characterised for their thermal and electrical properties. Predictive models of permittivity were created, enabling the production of castable and formed products via geopolymerization. This marks a major leap forward, addressing the previous lack of materials and data specific to microwave heating applications.
Advanced multi-physics modelling and new post-processing algorithms were implemented to assess temperature and heat distribution uniformity. These tools go beyond standard commercial software by providing quantitative indicators of heating effectiveness. Simplified modelling approaches, such as one-way coupling and 2D approximations, were introduced to accelerate the optimisation of microwave applicator designs, supporting a “design for processing” strategy focused on performance and efficiency.
Modular microwave-plasma furnace sections were proposed, enabling smaller prototypes that replicate larger systems for reliable scale-up data. A new plasma torch design minimised microwave emission, simplifying the ceramic firing prototype and improving material handling and shielding. For asphalt processing, a redesigned system reduced operating temperatures by over 1000°C and enabled recycled asphalt processing on a conveyor belt instead of a trommel. In anode baking, the integration of microwave and induction heating, with frequency-controlled solid-state sources, allowed for precise heat pattern control.
Advanced sensor systems are under development, including distributed FOS and multispectral SWIR cameras, to monitor high temperatures in real-time and to function without metal components, ensuring accurate readings in strong electromagnetic fields.
Sensor data will feed into a five-step methodology for real-time process monitoring and control via an IEC61499-compliant automation platform, which supports flexible sensor integration and cloud connectivity, enabling digital twin comparisons. Finally, a layered data architecture has been developed, enabling seamless data flow from the shop floor to the cloud, supporting secure data hosting and sharing.
A new class of circular refractories was developed and tested for use as insulating linings, susceptors, or to enhance microwave attenuation. These materials, tailored with active compounds like copper slag and graphene-based additives, were characterised for their thermal and electrical properties. Predictive models of permittivity were created, enabling the production of castable and formed products via geopolymerization. This marks a major leap forward, addressing the previous lack of materials and data specific to microwave heating applications.
Advanced multi-physics modelling and new post-processing algorithms were implemented to assess temperature and heat distribution uniformity. These tools go beyond standard commercial software by providing quantitative indicators of heating effectiveness. Simplified modelling approaches, such as one-way coupling and 2D approximations, were introduced to accelerate the optimisation of microwave applicator designs, supporting a “design for processing” strategy focused on performance and efficiency.
Modular microwave-plasma furnace sections were proposed, enabling smaller prototypes that replicate larger systems for reliable scale-up data. A new plasma torch design minimised microwave emission, simplifying the ceramic firing prototype and improving material handling and shielding. For asphalt processing, a redesigned system reduced operating temperatures by over 1000°C and enabled recycled asphalt processing on a conveyor belt instead of a trommel. In anode baking, the integration of microwave and induction heating, with frequency-controlled solid-state sources, allowed for precise heat pattern control.
Advanced sensor systems are under development, including distributed FOS and multispectral SWIR cameras, to monitor high temperatures in real-time and to function without metal components, ensuring accurate readings in strong electromagnetic fields.
Sensor data will feed into a five-step methodology for real-time process monitoring and control via an IEC61499-compliant automation platform, which supports flexible sensor integration and cloud connectivity, enabling digital twin comparisons. Finally, a layered data architecture has been developed, enabling seamless data flow from the shop floor to the cloud, supporting secure data hosting and sharing.