The RFCS (EU)-funded research and development project InduGasHeat proposes the development and demonstration of Ultra-High-Temperature Thermo Jet (UHT-Thermo Jet®) induction-based gas-heating systems to replace fossil-fuel burners in two critical applications: heating furnaces for forging processes and ladle preheating stations. By leveraging renewable electricity, this project aims to deliver a "plug-and-play" solution that achieves gas temperatures comparable to those of conventional systems and greater efficiency than hydrogen burners.
Advancing Green Steelmaking with High-Temperature Induction-Based Gas Heating
The InduGasHeat research and development project is a forward-thinking initiative that addresses the urgent need to decarbonize in the steel industry. With steel production responsible for approximately 8% of global carbon emissions, achieving the European Union’s climate neutrality target by 2050 requires innovative solutions for energy-intensive processes. While green technologies are emerging for core steel production, auxiliary processes such as forging and ladle preheating still rely heavily on fossil fuels.
The InduGasHeat project focuses on developing and testing the Ultra-High-Temperature Thermo Jet (UHT-Thermo Jet®), an innovative induction-based gas heating system designed to decarbonize auxiliary steelmaking processes. The UHT-Thermo Jet® uses a high-melting metallic radiator heated by an external induction coil to produce ultra-high-temperature gas streams. This technology enables precise control of gas temperatures, reaching above 1200°C, while operating on renewable electricity to achieve CO2-free heating (patent pending).
The European Union funds the InduGasHeat research and development project via the Research Funds for Coal and Steel (RFCS).
Two Use Cases for Induction-Based Gas Heating to Target Key Auxiliary Processes in Steel Production
Heating Furnaces for Forging Processes
InduGasHeat aims to replace fossil fuel burners in forging furnaces with UHT-Thermo Jet® systems, increasing furnace heating efficiency by 10–15%. This improvement is expected to reduce CO2 emissions by 35% while achieving the required furnace temperatures for the process and improving energy utilization compared to conventional systems.
Ladle Preheating Stations
The project also focuses on replacing gas-fired ladle preheating systems with electric heating solutions. This application will result in a 100% reduction in direct CO2 emissions and a significant increase in energy efficiency. The technology ensures optimal preheating of refractory materials, reducing heat losses and improving the overall sustainability of the process.
The InduGasHeat project is committed to achieving Technology Readiness Level (TRL) 8 for both applications, ensuring that the UHT-Thermo Jet® is ready for industrial deployment. Additionally, the project explores cross-sectoral applications in industries such as non-ferrous metals, glass, ceramics, and chemicals, demonstrating its potential to drive decarbonization across multiple sectors.
InduGasHeat: induction-based gas heating technology in testing phase
InduGasHeat: close-up of induction-based gas heating technology
Benefits of the InduGasHeat Induction-Based Gas Heating Solution
- Scientific advancement: The project drives innovation in electric, inductive heating technology and gas recirculation, improving efficiency in high-temperature industrial processes.
- Economic and technological impact: InduGasHeat aims to reduce operational costs through the use of renewable energy and savings in carbon tax. The benefit will lead to growth in steel production and other energy-intensive industries through a reduction in CO2 footprint (up to 40% for heating furnaces used in forging processes and up to 100% for ladle preheating stations).
- Environmental benefits: The project targets major reductions in CO2 emissions and other pollutants, contributing to improved environmental sustainability and occupational safety by eliminating direct carbon monoxide emissions and reducing nitrogen oxides (NOX).
- Energy efficiency improvements: The UHT-Thermo Jet® technology can increase furnace heating efficiency by 10–15% in heating furnaces for forging processes and in ladle preheating stations; an absolute energy efficiency of 70% or higher is targeted.
- Material quality enhancements: The technology aims to reduce scale formation by reducing oxygen-rich atmospheric conditions, leading to significant savings in primary steel production.
- Alignment with EU policies: The project supports the European Green Deal, Clean Steel Partnership, Fit for 55, and REPowerEU by reducing fossil fuel dependency and advancing carbon-neutral steel production.
- Cross-sector applications: The UHT-Thermo Jet® technology has potential uses in non-ferrous metals, glass, ceramics, and chemical industries, driving electrification across multiple sectors.
*Primetals Technologies is a licensee of the UHT-Thermo Jet® by K23 Entwicklungs mbH.
