Increased energy efficiency, flexibility and reduction of green-house gases using thermal battery

Project Information

HEAT2VALUE

Grant agreement ID: 859232

DOI

10.3030/859232

Project closed

EC signature date 5 November 2019

Start date 1 December 2019

End date 30 November 2023

Funded under

• INDUSTRIAL LEADERSHIP - Innovation In SMEs

Total cost

€ 2 050 500,00

EU contribution

€ 1 435 350,00

Coordinated by

ENERGYNEST AS
Norway

Periodic Reporting for period 2 - HEAT2VALUE (Increased energy efficiency, flexibility and reduction of green-house gases using thermal battery)

Reporting period: 2022-02-01 to 2023-11-30

Summary of the context and overall objectives of the project

ENERGYNEST has developed a breakthrough ThermalBattery solution that enables a step-change in improved efficiency, flexibility, and environmental performance for the power and industrial manufacturing sectors. By storing energy in the form of heat rather than electricity, our technology unlocks a vast new market that has so far been largely overlooked. Energy-intensive industries and several types of thermal power plants emit large quantities of high-temperature heat. Recovered, stored and discharged upon demand; high-grade heat can be used to produce high-value energy in the form of electricity, process steam/heat, district heating and even cooling which would otherwise have to be produced from fuel combustion, hence reducing fuel consumption and CO2 emissions. The potential cumulative CO2 savings for these sectors is greater than 500 million tons between 2020-2040. Our solution offers strong business cases with IRRs in the range of 20–40% in a market estimated to be greater than 7 billion € per year in Europe.

The objective of this project is to demonstrate the ENERGYNEST ThermalBattery system at the Avery Dennison production plant in Turnhout, Belgium where excess solar thermal energy from a new CST plant of Azteq BV will be stored and used to supply thermal energy, which is used in the production, thus reducing fuel consumption (natural gas) and subsequent CO2 emissions within the plant. The total installation will provide heat equivalent to 2.3 GWh of gas consumption, reducing the plant’s greenhouse gas emissions by an average of 9 percent annually – compared to current rates. During summer months and high-sunshine periods, it will provide up to 100 percent of the factory’s heat demand.

The project also represents an important milestone in the commercial proliferation of the ThermalBattery technology and proves that CO2 reduction for industrial production can be achieved with current technologies. The demonstration system will familiarize our future customers with the ThermalBattery, establishing trust in its performance, benefits and our capabilities. The ThermalBattery innovation relies on a patented system design using a unique concrete-like storage medium. The project will activate a European supply chain, with steel fabrication in The Czech Republic/Romania, concrete fabrication in Germany, prefabrication of Thermal Battery Modules in the Netherlands, and local engineering services in Norway and Spain.

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 work and tasks carried out during the project periods were aligned to obtain the planned and expected outcomes of the project. Initial and detailed engineering of the ThermalBattery system was completed, including the design of the modules and preparation for production, along with general project management.

The CST plant – built by Azteq – concentrates energy from direct sunlight into a collector tube filled with absorption liquid (heat transfer fluid). Additionally, thermal energy from this process will be stored in the ThermalBattery system, and dispatched on demand as secure, green heat. When coupled with the six battery modules providing a capacity of 5.5 MWh thermal power, the installation is able to cover approximately 10% of the total heat demand on site as it is configured today, with 70% provided by the solar field, and
30%provided by the thermal battery. The integration of the TB system enables the CST platform to produce and dispatch high-temperature thermal energy both day and night on demand.

Major milestones passed in the first period were the signed agreement established with Azteq as host for the demonstration project, and initiation of construction at project site (by the host). In the second period, the CST field and TB system construction were completed, and the plant was successfully commissioned late August. Exploitable results will continue to be generated following the second project period as the system is operated.

Dissemination and Exploitation activities as part of the commercial roll-out and marketing & communication (M&C) activities has been an on-going part of the project. ENERGYNEST has continuously intensified in disseminating and exploiting the SME-I project in 2023, with a special highlight on the inauguration late in September, 2023. The focus shifted from project and construction progress to highlighting customer value and societal impact, emphasizing its role in the decarbonization of industry. Marketing and communication activities centers around the company's projects, international expansion, and commercialization, emphasizing leadership in discussions on industrial heat within the context of energy transition and decarbonization. The primary goal is to raise awareness of ENERGYNEST solutions, showcasing their value in target industries and segments.

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 ThermalBattery system to be installed at the CST plant of Azteq will be the first thermal energy storage system operating with the new silicone-based, non-toxic and more environmentally friendly heat transfer fluid (HTF) developed by Wacker Chemie AG. The system will be designed to ensure safe operation with this new HTF. The system has further been designed to allow fast transition between operational modes with outlet temperature control, enabling simpler control logics and easier integration with the CST plant. Industry is responsible for about 40% of global greenhouse gas emissions, of which industrial heat is the single largest source – that is 12 billion tonnes of CO2 every year. To reach our net zero goals, one of our focus areas is decarbonizing industrial processes that require heat at high temperatures. This installation allows us to demonstrate how one can generate, store and dispatch heat on demand to an industrial facility.

The main impact of the project is reduced fossil fuel consumption and subsequently reduced carbon emissions in the Avery Dennison facility in Turnhout. The nominal ThermalBattery capacity of the demonstration system is 5.5 MWh which can displace a corresponding 2100 MWh of natural gas and save around 450 tons of CO2 emissions per year. With ENERGYNESTs ThermalBattery™ running on thermal oil, like the CST platform, (excess) thermal energy will be stored in the storage system and dispatched on demand and at night, keeping production running and helping to further reduce emissions and enabling the plant to meet their reduction target of 70% as part of the company’s 2030 sustainability targets, plus meet net zero emissions by 2050.

TB modules assembly process at project site

TB modules assembly process at project site