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Green Electrified Ultrafast In-Line Heat Treatment for Net-Zero Forging and Casting

Objetivo

The forging and casting sectors are among the most energy-intensive manufacturing industries in Europe, where conventional batch heat treatment represents up to 30% of total operational costs and 40% of energy consumption. Current practices rely heavily on fossil-fuel-based furnaces, leading to high carbon footprints and exposure to EU climate policies such as ETS and CBAM. There is an urgent need for innovative, electrified, and resource-efficient solutions that reduce emissions while safeguarding product quality and competitiveness.

GREENLINE aims to develop and demonstrate a novel in-line heat treatment (HT) process that integrates electric heating with an innovative ultra-fast cooling system to exploit the residual heat from forging and casting operations. By directly transferring hot parts to a compact, electrified modular furnace, GREENLINE eliminates the reheating step required in batch processes, achieving substantial energy and CO2 savings while ensuring compliance with metallurgical standards. The project will deliver six major results: (R1) thermal navigation charts for phase transformations, (R2) a low-footprint ultra-fast cooling system, (R3) multiphysics-based cooling models, (R4) a modular and flexible furnace design, (R5) prototype forged parts validated under industrial conditions, and (R6) prototype ADI cast parts produced with GREENLINE. These will be validated at CIE Legazpi (forging pilot) and Betsaide (casting pilot), supported by Sidenor (steel supply), IOB (furnace design), Tecnodelta (integration), and leading RTOs (Azterlan, RWTH Aachen, AGH University). EE-IP will lead dissemination and exploitation.

GREENLINE directly addresses the topic’s expected outcomes by bridging net-zero technology providers and energy-intensive industries, enabling sustainable and cost-efficient energy use, opening new markets for electrified furnaces, and accelerating adoption of replicable, standardised yet flexible solutions.

Ámbito científico (EuroSciVoc)

Palabras clave

Programa(s)

Tema(s)

Régimen de financiación

HORIZON-IA - HORIZON Innovation Actions

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Convocatoria de propuestas

(se abrirá en una nueva ventana) HORIZON-CL4-2025-01

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Coordinador

FUNDACION AZTERLAN
Aportación neta de la UEn
€ 970 700,00
Dirección
ALIENDALDE 6
48200 Durango
España
Región
Noreste País Vasco Bizkaia
Tipo de actividad
Research Organisations
Enlaces
Coste total
€ 970 700,00

Participantes (10)