EU-funded HyInHeat project explores hydrogen fuel sources to decarbonise aluminium industry

The EU-funded HyInHeat project explores the possibility of utilizing hydrogen as a fuel source in the aluminium and steel sectors. With a budget of €24 million, the project intends to incorporate hydrogen into the high-temperature heating processes of energy-intensive sectors, with €17.7 million coming from the EU.

The project's primary goal will be accomplished by redesigning, modifying, and implementing infrastructure in eight demonstrations at technical centres and manufacturing facilities, together with equipment including burners, measurement and control technologies, and infrastructure. To decarbonize the heating and melting processes used in the aluminium and steel industries, HyInHeat implements effective hydrogen combustion systems that nearly span their whole process chains.

"While some components such as burners have already been classified as suitable for hydrogen combustion, the holistic integration of hydrogen as a fuel in industrial thermal processes requires an adaptation of the plant technology, the process technology as well as the infrastructure," said Professor Herbert Pfeifer, head of the IOB.

A variety of heating techniques are being investigated by researchers, including hydrogen-air heating, oxygen-enhanced combustion, and hydrogen-oxyfuel heating. The objective is to lower the demand for hydrogen fuel and increase energy efficiency.

The project prioritizes refractory lining sustainability since maintaining product quality and output is vital while changing key production processes. The study is also looking into reducing NOx emissions from burning hydrogen. In energy-intensive sectors, material flow and life cycle analysis will be used to estimate the full potential of hydrogen heating processes.

The thorough cross-sectoral evaluation that enables the estimation of the potential for the deployment of hydrogen heating processes in energy-intensive industries will be supported by material flow and life cycle analysis methodologies.By engaging in these activities, HyInHeat helps to reduce CO2 emissions from the processes while boosting energy efficiency in a cost-competitive way and maintaining resource efficiency and NOx emission levels at least at the same level.

The Department for Industrial Furnaces and Heat Engineering (IOB) at RWTH Aachen University oversees the project, which will be carried out through the end of 2026 with 30 partners from 12 other nations. Additionally engaged are the University's Institute for Combustion Technology (ITV) and the Institute for Mineral Engineering (GHI).