Periodic Reporting for period 1 - HyTecHeat (HYbrid TEChnologies for sustainable steel reHEATing)
Reporting period: 2022-12-01 to 2024-05-31
Since the Paris agreement signed on the March 2015 (COM82015) 81, the EU has been deeply engaged to minimize the EU industry sector impact on the GHG emission by following several complementary technological pathways. One of the promising pathways is the abatement of GHG via direct avoidance of CO2 emissions by using green energy carriers such as green hydrogen.
Currently, NG is normally substituted by hydrogen in upstream processes (both blast furnace and DRI), or limited application in finishing lines. Current downstream processes totally rely on NG burning as thermal source. Current average cost of MG is about 0.6 €/Nm3 (average value in EU, source Eurostat), Assuming H2 cost of 0.36€/m3 (4€/kg) and due to the fact the heating value of hydrogen is about one third of the one of NG, equivalent of hydrogen burning would be of 1.08 € per Nm3 of NG replaced. Assuming the forecast of H2 cost of 0.16 €/m3 (from 1.8€/kg), cost of substitution would be of 5.4€/Nm3 of NG replaced, lower than current value.
HyTecHeat aims at adopting hybrid heating technology (based on NG with progressive and increasing H2 utilization) in downstream processes so to path the way for the abatement of CO2 for the whole downstream processes at EU level of 7.5 Mt (if conservatively 30% of H2 is considered) up to about 25 Mt (if 100% of H2 is used). Taking into account that the overall emission of CO2 in EU from all industrial sectors in 2018 (before the COVID pandemic) is estimated to be 2.9 Gt , the implementation of HyTecHeat technology in all EU downstream process (100% of H2) will lead to an abatement of 0.9% (25 Mt) of the EU CO2 emission.
Currently, NG is normally substituted by hydrogen in upstream processes (both blast furnace and DRI), or limited application in finishing lines. Current downstream processes totally rely on NG burning as thermal source. Current average cost of MG is about 0.6 €/Nm3 (average value in EU, source Eurostat), Assuming H2 cost of 0.36€/m3 (4€/kg) and due to the fact the heating value of hydrogen is about one third of the one of NG, equivalent of hydrogen burning would be of 1.08 € per Nm3 of NG replaced. Assuming the forecast of H2 cost of 0.16 €/m3 (from 1.8€/kg), cost of substitution would be of 5.4€/Nm3 of NG replaced, lower than current value.
HyTecHeat aims at adopting hybrid heating technology (based on NG with progressive and increasing H2 utilization) in downstream processes so to path the way for the abatement of CO2 for the whole downstream processes at EU level of 7.5 Mt (if conservatively 30% of H2 is considered) up to about 25 Mt (if 100% of H2 is used). Taking into account that the overall emission of CO2 in EU from all industrial sectors in 2018 (before the COVID pandemic) is estimated to be 2.9 Gt , the implementation of HyTecHeat technology in all EU downstream process (100% of H2) will lead to an abatement of 0.9% (25 Mt) of the EU CO2 emission.
Work Package 1 Investigation of reference industrial scenario
Technical data and the operating conditions of the different pilot and demo furnaces were summarized and compared with industrial furnaces used by the industrial partners (Tata Steel, Tenaris, Arcelor Mittal, Nunki & SSAB) (Task 1.1).
The technical specifications of the burner (provided by Tenova) are defined accordingly to the utilization in the experimental rig of Swerim, (Task 1.2).
Innovative water electrolyzer specifications defined by IDN (Task 1.3).
Different installation scenarios and related hazards have been identified. On such basis, preliminary balance of plant and preliminary safety analysis have been defined. (Task 1.4).
Industrial samples have been collected by partners according to sampling plan defined in the grant agreement. The samples are representative of the steel qualities, industrial cycles and process conditions chosen by the partners. (Task 1.5).
Work Package 2 Burner and combustion system design for hybrid heating
Snam with the collaboration of project partners has identified the relevant normative and standards applicable in the European Union about safety design and operation of H2 system. (Task 2.1)
To properly reproduce the complex series of experiments by means of a Computational Fluid Dynamic (CFD) “digital twin”, the selection of the rights models has been carried out: turbulence-chemistry interaction (a.k.a. the combustion model), the kinetic mechanism, and the radiation model defined. (Task 2.2).
Computation Fluid Dynamic model for the simulation of a flameless has been applied to assess the performances of the preliminary design of the 320 kW multi-fuel TLX burner. (Task 2.3).
Sensoring of the burner defined. (Task 2.4).
The burner was built on the basis of the engineering carried out considering the technical data defined in deliverable 1.2 (Technical specifications of the multi-fuel burner prototype), on the basis of the results of the CFD simulations described in deliverable 2.3 (Preliminary designs of multi-fuel H2 /CH4 burner prototype and possible variants) and depending on the sensors that will be installed on the burner as described in deliverable 2.4 (Selection of embedded sensors for burner digitalization) (Task 2.5).
The differences in the oxidation kinetics of a variety of steel grades, covering both carbon and stainless steels, with increasing water vapour content in the furnace atmosphere resulting from H2 combustion in air instead of natural gas, were defined by RINA CSM and AMMR by Isothermal thermo-gravimetric oxidation tests. The RINA-CSM TGA tests were performed at 900°C, 1050°C and 1200°C for two hours, AMMR tests were performed at 700, 800, 900, 1000, 1100 and 1200°C for 15 min. (Task 3.1).
CSM start to perform preliminary descaling tests in NG and H2 combustion atmosphere (18% vs 33% H2O) simulating reference industrial condition. (Task 3.2).
Preparations are ongoing for the gas infrastructure and adaption of furnace for new fuels and burners. The burner models and specifications has been decided with the burner suppliers Tenova and Linde. The operating conditions during the experimental runs has been preliminary set, awaiting the final test runs after the burners have been installed. The steel grades have been decided together with SSAB and Tata Steel, where different types of micro-alloyed, high strength and electrical steels will be tested. (Task 3.3).
Work Package 4
In accordance with the change of activities ownership between Snam and Tenova reported in minute of meeting November 2023, Snam has released a Purchase Order to buy a bigger H2 supply system (H2 buffer storage), while Tenova is managing the permitting step, BOP design and purchase (that is strictly linked to permitting) and related safety study (see Project proposal: tasks 1.3 and D1.3 in WP 1). Waiting for the H2 storage delivery, Snam has shared with Tenova the layout and the design. In the buffer storage supply is included a Pressure Safety Valve (PSV) with 32 bar as safety pressure, which has been tailored to the operating pressures of the Tenova plant. The integration of the electrolyser, the hydrogen tank and the existing plant (TenovaLAB) is designed and ready to be installed by Tenova (Task 4.1)
Technical data and the operating conditions of the different pilot and demo furnaces were summarized and compared with industrial furnaces used by the industrial partners (Tata Steel, Tenaris, Arcelor Mittal, Nunki & SSAB) (Task 1.1).
The technical specifications of the burner (provided by Tenova) are defined accordingly to the utilization in the experimental rig of Swerim, (Task 1.2).
Innovative water electrolyzer specifications defined by IDN (Task 1.3).
Different installation scenarios and related hazards have been identified. On such basis, preliminary balance of plant and preliminary safety analysis have been defined. (Task 1.4).
Industrial samples have been collected by partners according to sampling plan defined in the grant agreement. The samples are representative of the steel qualities, industrial cycles and process conditions chosen by the partners. (Task 1.5).
Work Package 2 Burner and combustion system design for hybrid heating
Snam with the collaboration of project partners has identified the relevant normative and standards applicable in the European Union about safety design and operation of H2 system. (Task 2.1)
To properly reproduce the complex series of experiments by means of a Computational Fluid Dynamic (CFD) “digital twin”, the selection of the rights models has been carried out: turbulence-chemistry interaction (a.k.a. the combustion model), the kinetic mechanism, and the radiation model defined. (Task 2.2).
Computation Fluid Dynamic model for the simulation of a flameless has been applied to assess the performances of the preliminary design of the 320 kW multi-fuel TLX burner. (Task 2.3).
Sensoring of the burner defined. (Task 2.4).
The burner was built on the basis of the engineering carried out considering the technical data defined in deliverable 1.2 (Technical specifications of the multi-fuel burner prototype), on the basis of the results of the CFD simulations described in deliverable 2.3 (Preliminary designs of multi-fuel H2 /CH4 burner prototype and possible variants) and depending on the sensors that will be installed on the burner as described in deliverable 2.4 (Selection of embedded sensors for burner digitalization) (Task 2.5).
The differences in the oxidation kinetics of a variety of steel grades, covering both carbon and stainless steels, with increasing water vapour content in the furnace atmosphere resulting from H2 combustion in air instead of natural gas, were defined by RINA CSM and AMMR by Isothermal thermo-gravimetric oxidation tests. The RINA-CSM TGA tests were performed at 900°C, 1050°C and 1200°C for two hours, AMMR tests were performed at 700, 800, 900, 1000, 1100 and 1200°C for 15 min. (Task 3.1).
CSM start to perform preliminary descaling tests in NG and H2 combustion atmosphere (18% vs 33% H2O) simulating reference industrial condition. (Task 3.2).
Preparations are ongoing for the gas infrastructure and adaption of furnace for new fuels and burners. The burner models and specifications has been decided with the burner suppliers Tenova and Linde. The operating conditions during the experimental runs has been preliminary set, awaiting the final test runs after the burners have been installed. The steel grades have been decided together with SSAB and Tata Steel, where different types of micro-alloyed, high strength and electrical steels will be tested. (Task 3.3).
Work Package 4
In accordance with the change of activities ownership between Snam and Tenova reported in minute of meeting November 2023, Snam has released a Purchase Order to buy a bigger H2 supply system (H2 buffer storage), while Tenova is managing the permitting step, BOP design and purchase (that is strictly linked to permitting) and related safety study (see Project proposal: tasks 1.3 and D1.3 in WP 1). Waiting for the H2 storage delivery, Snam has shared with Tenova the layout and the design. In the buffer storage supply is included a Pressure Safety Valve (PSV) with 32 bar as safety pressure, which has been tailored to the operating pressures of the Tenova plant. The integration of the electrolyser, the hydrogen tank and the existing plant (TenovaLAB) is designed and ready to be installed by Tenova (Task 4.1)
Innovative burner: CFD analysis confirmed the high performances of the H2 ready burner and its capability to wprk in hybrid mode (hydrogen blended with natural gas and LPG)
Oxidation tests: this activity ios still ongoing. the results are showing the effect due to H2 conbustion on alarge variety of steel grades. The effect of steel compostion and correlation with atmpsphere , time and temperatiure is under assesment
Descaling tests: this activity is just started. The result beyond the ste of the art will be the correlatiopn with hydrogen combustion atmosphere and scale removal for a large varmiety of steel grades.
Teh development of the first democase (1 MW electrolyser installation at Tenova premises and connection with innovative hydrogen ready burner) is ongoing. this democa will show the cpomplete valiue chain, from renewable energy installation, green hydrogen production and utilization in industrial burner.
Oxidation tests: this activity ios still ongoing. the results are showing the effect due to H2 conbustion on alarge variety of steel grades. The effect of steel compostion and correlation with atmpsphere , time and temperatiure is under assesment
Descaling tests: this activity is just started. The result beyond the ste of the art will be the correlatiopn with hydrogen combustion atmosphere and scale removal for a large varmiety of steel grades.
Teh development of the first democase (1 MW electrolyser installation at Tenova premises and connection with innovative hydrogen ready burner) is ongoing. this democa will show the cpomplete valiue chain, from renewable energy installation, green hydrogen production and utilization in industrial burner.