BFI VDEh-Betriebsforschungsinstitut GmbH

Initial situation:

To avoid energy-related CO₂ emissions, the natural gas used in thermal processing plants with temperatures of around 1,300 °C can be replaced by hydrogen. The use of H₂ requires a suitable hydrogen supply infrastructure. In addition, adjustments to the fittings, Measurement and control (M&C) and process control must be planned and implemented. Combustion behaviour and the influence on product quality must also be systematically investigated.

Project targets:

The use of hydrogen as a fuel is systematically investigated using the example of a continuous reheating furnace. First of all, the combustion and the impact on the furnace atmosphere as well as the heat input into the product will be investigated. Furthermore, the impact of the changed furnace atmosphere on scale formation and scale properties as well as innovative descaling techniques will be examined. As part of the project, a pilot furnace is to be retrofitted for the use of hydrogen and tested on an industrial scale. Operational safety, productivity and product quality will be ensured.

Innovative approaches:

• First systematic investigation of the use of hydrogen to heat a reheating furnace
• Demand scenarios and supply concept for the combined use of continuous and discontinuous processes in the plant network (generation, storage, transportation)
• Safety-related consideration of gas storage, hydrogen supply and operation with hydrogen
• Modeling of the continuous reheating process with natural gas, hydrogen and natural gas-hydrogen mixtures using OPEN FOAM to ensure transferability
• Furnace automation
• Industrial long-term testing

Benefits for the industry:

• Compilation of potentials and obstacles to the efficient and cost-effective use of hydrogen technology
• Cost analysis
• Catalog of measures and roadmap for converting from natural gas to hydrogen
• CO₂ savings of around 1.1 million tCO₂ at reheating furnaces in Germany