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Industrial Fuel Switching Programme, Phase 1: summaries of successful projects

Updated 28 June 2023

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Project Name: Hydrogen for the ceramics sector

The Hydrogen for the Ceramics Sector project will assess and evaluate the switching of the ceramics sector from natural gas to hydrogen. The project will undertake preliminary hydrogen combustion trials under representative environments and prepare for demonstration trials at industrial manufacturing sites.

Project Name: Intelligent pipeline integrity system for industrial hydrogen backbone

This project will undertake feasibility studies of new real time data gathering to develop new, intelligent integrity management systems for gas/hydrogen pipelines. It will do this by exploring the embedding of fibre optic cables in layered composite gas pipes whilst developing the feasibility of providing continuous real time monitoring to identify sections of pipeline which need maintenance/replacement.

Project Name: Connections technology for hydrogen pipelines

The Connections technology for Hydrogen pipelines project will develop large scale cold working processes for welds in gas/hydrogen pipelines. The most promising approaches will be taken to concept design before testing the most promising design at Sustainable Pipeline System’s site.

Project Name: H2Malt

  • Led by: Protium Green Solutions Limited
  • Project Location: London
  • Funding: £226,213
  • Feasibility report: Protium: H2Malt

Protium Green Solutions will investigate the feasibility of decarbonising the malting process by switching a natural gas fired air heater systems to hydrogen. This will enable us to understand the technical parameters and challenges of hydrogen-fired heaters, and the modifications required to incorporate these into existing processes. The project will assess the impact of blending different quantities of hydrogen into heater operation; including efficiency, intake air volume, heat production and impact on the grain. The outcomes will inform the appropriate equipment sizing and design and highlight any challenges in moving toward 100% hydrogen-heaters.

Project Name: HyNet IFS2 (Bid 1) - Kellogg’s & PepsiCo

In partnership with Kellogg’s and PepsiCo, Progressive Energy will determine the feasibility of switching baking ovens, oil heaters and steam boilers used in food and drink production, from natural gas to hydrogen. This will include technical assessments of the associated emissions, efficiency, process constraints and economic considerations of such a fuel switch. Subject to further funding from BEIS under Phase 2 of the Competition, the partners hope to physically demonstrate hydrogen use in these applications in 2023-24.

Project Name: Zero emission industrial steam

Steamology Motion Ltd will look to develop scalable, modular hydrogen-based technology solutions that have commercially viable potential to replace oil and gas fired boilers, for industrial sector steam and medium grade heat users. By engaging and disseminating with industry and investors, the project should increase awareness of novel zero emission steam and heat technology with a range of steam quality, quantity, rapid response, point of use solutions. Assessments of industrial hydrogen and electricity use could also inform policy.

Project Name: HyNet IFS2 (Bid 2) - Kraft-Heinz & Novelis

Progressive Energy will work with Novelis and Kraft-Heinz to determine the feasibility of switching their manufacturing processes from natural gas to hydrogen. The work focuses on switching Novelis’ melting furnaces for recycled aluminium to hydrogen, and working with Kraft-Heinz to determine the potential for a new Combined Heat and Power (hydrogen) gas engine and switching of existing steam boilers to hydrogen. The work will include technical assessment of emissions, efficiency, and process constraints, as well as economic assessments. Subject to further funding from BEIS under Phase 2 of the Competition, the partners hope to physically demonstrate hydrogen use in these applications in 2023-24.

Project Name: HyNet IFS2 (Bid 3) - Essity

In partnership with Essity, Progressive Energy will determine the feasibility of switching paper-making machines and steam boilers from natural gas to hydrogen. This will include technical assessments of the associated emissions, efficiency, process constraints and economic considerations of such a fuel switch. Subject to further funding from BEIS under Phase 2 of the Competition, Progressive and Essity hope to physically demonstrate hydrogen use in these applications in 2023-24.

Project Name: Hydrogen direct reduction of iron - pilot furnace and steelmaking (‘H2DRI pilot’)

The project will examine the feasibility of direct reduction of iron ores using hydrogen, integrating with an existing electric arc furnace at a pilot melting and steelmaking plant, hydrogen network and characterisation facilities. The study will confirm the design for future trials and demonstrate the net energy benefit of using microwaves as well as radiant heating to enhance reaction kinetics.

Project Name: Next-generation composite pipeline technologies enabling industrial fuel switching to hydrogen (H2-IFS)

This project will develop the materials and the manufacturing process for spoolable thermoplastic composite pipes and will demonstrate that Hive Composite’s patented materials and processes can produce pipes that require significantly reduced cost and energy to manufacture, whilst providing a solution that is resistant to hydrogen embrittlement and permeation. They can also be produced up to 5 times faster than some current designs. The Hive methodology could increase the production rate of hydrogen delivery pipes from 200 km to over 1000 km per year.

Project Name: Real Time Natural Gas and Hydrogen Sensor

Bohr is examining the feasibility of using sensor technology to monitor gas properties and impurities in green gases, including Hydrogen. The sensor technology can be used to monitor contaminants in Hydrogen to optimise production, gas blends including Hydrogen or trace hydrogen in flue gas to ensure efficient and environmentally friendly burner control. The technology is zero emissions, low cost and simple to operate, which will allow real-time monitoring of quality during production, storage, transport/distribution and end use, helping enable the incremental transition to Green Gas (hydrogen and biomethane), supporting the UK’s Net Zero mission.

Project Name: Green hydrogen in steel manufacture

British Steel will lead a feasibility study, with partners EDF Energy, the Materials Processing Institute and University College London, into switching its manufacturing processes from natural gas to green hydrogen. The study could lead to new technology being adopted by British Steel and other UK steel manufacturers to deliver large CO2 emission reductions. A techno-economic assessment of green hydrogen delivery will be undertaken by EDF Energy, while British Steel, the Materials Processing Institute and University College London will assess the technical implications on product and process. Together, they will assess the economic viability and environmental impact of switching.

Project Name: Amburn

  • Led by: Flogas Britain Ltd
  • Project Location: Syston
  • Funding: £242,050
  • Feasibility report: Project Amburn Phase 1

The UK based “Amburn” Consortium aims to produce computer aided designs for an innovative megawatt scale ammonia-fed steam boiler system. The study will explore the feasibility of ammonia-fed steam boiler systems to replace existing fossil-fuels on off-grid industrial sites. The resultant product would be a world-first, with plans to demonstrate at a real Flogas customer site in Phase 2.

Project Name: Deep decarbonisation of brick manufacturing

Michelmersh Brick Holdings PLC will trial the feasibility of replacing natural gas with hydrogen for firing in brick production, with the ultimate aim of demonstrating a potential decarbonisation route for clay brick manufacturing. The project will investigate the feasibility of retrofitting gas burners used for brick firing, trialling 100% green hydrogen in a test kiln at Michelmersh’s site in Sussex. In parallel, project partner Limpsfield Combustion will develop and conduct laboratory testing of burners and investigate their energy efficiency. Other partners/contractors in the project include the University of Brighton, Greater South East Net Zero Hub, Net Zero Associates and Geopura.

Project Name: H2M

Hillside Combined Renewable Systems Ltd will conduct a feasibility study to switch from gas/oil boilers to an enhanced biomethane fuel. The biomethane will be enhanced through the introduction of green hydrogen produced via wind energy to an anaerobic digestion cycle. The project will assess the use of green hydrogen to enhance methane output using secondary anaerobic digestion infrastructure and use co-produced oxygen to displace nitrogen within the anaerobic digester and increase boiler efficiency.

Project Name: Application of novel high-temperature heat pump technology for the efficient electrification of industrial process heat

Futuraheat will carry out a techno-commercial feasibility study for its ground-breaking high-temperature heat pumps, with leading food and pharma businesses. The project will develop a modular heat pump design concept that is suitable for scaling across manufacturing sites. Commercial feasibility evaluation will deliver a refined business plan and route-to-market strategy. Central to Futraheat’s product offering is TurboClaw®, a new type of turbo-compressor which operates at greatly reduced speeds without oil, yielding lower manufacturing, operating and maintenance costs. This unique technology enables the cost-effective electrification of process heat by efficiently recovering and reusing industry’s waste heat, drastically reducing energy consumption and carbon emissions.

Project Name: Heat Batteries for Industrial Fuel Switching

Caldera Heat Batteries will assess the feasibility of a heat battery charged with renewables that can discharge steam on demand for industrial uses, such as pharmaceuticals, food processing and brewing. The project will examine the potential of the technology to electrify steam production in industrial processes.

Project Name: Zap

Burton’s Foods Limited will examine the feasibility of the electrification of gas-fired industrial baking ovens. The project will characterise the thermal and humidity profile of an industrial baking line to explore the feasibility of electrical switching and the technology development necessary from the current nearest best available offerings required to enable the switch. The potential greenhouse gas emissions reductions from Burton’s Foods sites is over 10,000tCO2e per year.

Project Name: CO2 and NOx reduction at temperature controlled Fast Moving Consumer Goods [FMCG] distribution hubs, replacing red diesel with electricity to power auxiliary trailer refrigeration units [TRU]

Sherwood Limited, in partnership with a leading retailer, will examine the feasibility of electrifying auxiliary power on trailer refrigeration units (typically used to transport fresh produce). Currently, when at a distribution centre, refrigeration units run on diesel during loading and unloading. Sherwood Limited will provide electric docking stations, which will mean trailers can be plugged into the building’s electricity to cool the produce instead. The additional electricity capacity which is required can be met by installing on site renewable energy generation and electrical energy storage. These changes will lead to reduced carbon emissions, improved air quality, and lower costs for the retailer.

Project Name: Renewable, waste-derived biofuels for glass and ceramics manufacturing

The Renewable, Waste-Derived Fuels for Glass and Ceramics Manufacturing project will examine switching glass container furnaces from natural gas to waste-derived fuels. The project will build upon findings from Glass Futures’ previous projects, which successfully demonstrated the use of biofuels on a commercial glass container furnace. The team will produce detailed plans for industrial-scale trials of the most attractive waste-derived fuels identified at commercial glass and ceramics plants.

Project Name: Modular Approach to Decarbonisation of Energy (MADE) for Glass

The MADE for Glass project explores switching flat glass and glass fibre production facilities from natural gas to gasified waste and biomass. The consortium will look to show that KEW’s modular advanced gasification technology can successfully convert waste and biomass to a hydrogen rich syngas, substituting the combustion of carbon-intensive natural gas at two glass production facilities. The feasibility study will assess the potential for integration of the technology into these sites and the potential greenhouse gas savings through industrial integration.

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