EAF steelmaking is the key technology for decarbonised steelmaking, either in scrap-based plant by modification of existing processes for further decarbonisation, or as new EAF installations in decarbonised integrated steel works to (partly) replace the classical BF-BOF production. At same time the EAF is the most important example for modular and hybrid heating, already now combining electric arc heating with burner technologies. Consequently, it was selected as main focus of GreenHeatEAF for the Call „Modular and hybrid heating technologies in steel production“. GreenHeatEAF develops and demonstrates the most important decarbonisation approaches at EAFs including the use of hydrogen to replace natural gas combustion in existing or re-vamped burners or innovative technologies like CoJet. Furthermore, decarbonisation of EAF steelmaking by solid materials like DRI/HBI and renewable carbon sources like biochar is tackled. Technologies to re-optimise the heating management with maximum heat recovery of off-gas and slag employing new sensor and soft-sensor concepts as well as extended digital twins are developed: as result the extended CFD and flowsheeting models, and monitoring and control tools will prognose the influences of the different decarbonisation measures on EAF and process chain to support upcoming decarbonisation investments and to enable the control of decarbonised hybrid heating with maximum energy efficiency. GreenHeatEAF combines trials in demonstration scale, e.g. in combustion- and EAF-demo plants, with validations in industrial scale and digital optimisations with high synergy. Thus, it completely follows the Horizon Twin Transition and Clean Steel Partnership objectives and the target to progress decarbonisation technologies from TRL 5 to 7. This synergic concept of GreenHeatEAF supports implementation and digitisation to speed up the transition of the European steel industry to highly competitive energy-efficient decarbonised steel productio

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. Therefore, the massive usage of hydrogen in steel industry, as envisioned in the Carbon Direct Avoidance pathway of the ESTEP/EUROFER masterplan, requires a transformation of entire steelmaking process from liquid production process (UPSTREAM) to the rolling and finishing line (DOWNSTREAM). This research project is aimed at adopting hybrid heating technology (based on NG with progressive and increasing H2 utilization) in downstream processes. Thermal treatment and reheating processes, which are common to both BF and EAF route have a significant NG demand (about 50 Nm3/t of produced steel). also utilization for ladle preheating has a relevant NG demand (in the range 5-15 Nm3/t). In order to allow the shift from NG to H2 and consequently to reduce the environmental impact by using innovative combustion technologies (like flameless and oxyfuel combustion), impacts on steel quality, refractory and furnace must be assessed at high TRL (7). The general objective of this project is to exploit the hybrid heating technologies by evaluating the effects of the steel products, on the refractories and also on the combustion systems. Three Demo cases testing innovative multifuel burner and testing the limit of current systems at TRL 7 will facilitate the hydrogen transition of the steel sector. Achieved results will bring to a CO2 saving in the range 7.5-25Mt/year. Regarding the steel quality, the project activities will individuate the optimum processing parameters to ensure that primary scale and associated scale defects do not persist through to the final product.

The main objective of HyInHeat is the integration of hydrogen as fuel for high temperature heating processes in the energy intensive industries. While some of the equipment is already presented as hydrogen-ready, the integration of hydrogen combustion in heating processes still needs adoption and redesign of infrastructure, equipment and the process itself. HyInHeat realizes the implementation of efficient hydrogen combustion systems to decarbonize heating and melting processes of the aluminium and steel sectors, covering almost their complete process chains. To reach this overarching objective within the project, furnace and equipment like burners or measurement and control technology but also infrastructure is redesigned, modified and implemented in eight demonstrators at technical centres and industrial plants. Besides hydrogen-air heating, oxygen-enriched combustion and hydrogen-oxyfuel heating is implemented to boost energy efficiency and to decrease the future hydrogen fuel demand of the processes. This might result in a total redesign of the heating process itself which will be supported by simulation methods enhancing digitalisation along the value chain. Since critical production processes are converted, it is a fundamental requirement to maintain product quality and yield. Priority is also given to the refractory lining to prove sustainability. From an environmental perspective, new concepts for NOx emission measurement in hydrogen combustion off-gas are developed. Material flow analysis and life cycle analysis methods will support the comprehensive cross-sectorial evaluation, which allows the determination of the potential for the implementation of hydrogen heating processes in energy intensive industry. With these activities, HyInHeat contributes to the objectives of decreasing CO2 emission of the processes while increasing energy efficiency in a cost competitive way keeping NOx emission levels and resource efficiency at least at the same level.

Hydrogen Mobility Europe (H2ME) brings together Europe’s 4 most ambitious national initiatives on hydrogen mobility (Germany, Scandinavia, France and the UK). The project will expand their developing networks of HRS and the fleets of fuel cell vehicles (FCEVs) operating on Europe’s roads, to significantly expand the activities in each country and start the creation of a pan-European hydrogen fuelling station network. In creating a project of this scale, the FCH JU will create not only a physical but also a strategic link between the regions that are leading in the deployment of hydrogen. The project will also include ‘observer countries’ (Austria, Belgium and the Netherlands), who will use the learnings from this project to develop their own hydrogen mobility strategies. The project is the most ambitious coordinated hydrogen deployment project attempted in Europe. The scale of this deployment will allow the consortium to: • Trial a large fleet of FCEVs in diverse applications across Europe - 214 OEM FCEVs (Mercedes and Toyota) and 125 fuel cell range-extended vans (Symbio collaborating with Renault) will be deployed • Deploy 29 state of the art refuelling stations, using technology from the full breadth of Europe’s hydrogen refuelling station providers. The scale will ensure that stations will be lower cost than in previous projects and the breadth will ensure that Europe’s hydrogen station developers advance together • Conduct a real world test of 4 national hydrogen mobility strategies and share learnings to support other countries’ strategy development • Analyse the customer attitude to the FCEV proposition, with a focus on attitudes to the fuelling station networks as they evolve in each country • Assess the performance of the refuelling stations and vehicles in order to provide data of a sufficient resolution to allow policy-makers, early adopters and the hydrogen mobility industry to validate the readiness of the technology for full commercial roll-out.

Hydrogen Mobility Europe 2 (H2ME 2) brings together action in 8 European countries to address the innovations required to make the hydrogen mobility sector truly ready for market. The project will perform a large-scale market test of hydrogen refuelling infrastructure, passenger and commercial fuel cell electric vehicles operated in real-world customer applications and demonstrate the system benefits generated by using electrolytic hydrogen solutions in grid operations. H2ME 2 will increase the participation of European manufacturers into the hydrogen sector, and demonstrate new vehicles across a range of platforms, with increased choice: new cars (Honda and Mercedes), new vans (range extended vehicles from Renault/Symbio and Renault/Nissan/Intelligent Energy) and a new medium sized urban delivery truck (Renault Trucks/Symbio). H2ME 2 develops an attractive proposition around range extended vehicles and supports a major roll-out of 1,000 of these vehicles to customers in France, Germany, Scandinavia and the UK. 1,316 new hydrogen fuelled vehicles will be deployed in total, trebling the existing fuel cell fleet in Europe. H2ME 2 will establish the conditions under which electrolytic refuelling stations can play a beneficial role in the energy system, and demonstrate the acquisition of real revenues from provision of energy services for aggregated electrolyser-HRS systems at a MW scale in both the UK and France. This has the further implication of demonstrating viable opportunities for reducing the cost of hydrogen at the nozzle by providing valuable energy services without disrupting refuelling operations. H2ME 2 will test 20 new HRS rigorously at high level of utilisation using the large vehicle deployment. The loading of stations by the end of the project is expected to average 20% of their daily fuelling capacity, with some stations exceeding 50% or more. This will test the HRS to a much greater extent than has been the case in previous projects.