A strategic investment in a sustainable future
The transition to a sustainable industrial future is not just an environmental goal—it is a strategic investment. European industries play a crucial role in achieving climate neutrality by 2050, as they are responsible for 20% of CO₂ emissions and 25% of total energy consumption in Europe (4).
The majority of industrial energy consumption is driven by thermal energy use; accounting for 81% of industrial energy use (2,390 TWh per year) (Figure 1, 1,4). Thermal energy use can be broadly categorised into four main areas: process heating, process cooling, space heating, and space cooling. Among these, process heating dominates, representing 66% of total final energy consumption (2).
The implementation of industrial heat pumps aligns closely with the EU-2050 strategic priority to build a competitive European industry and circular economy as key enablers for achieving climate neutrality (3).
Recognising this challenge, Halcor is taking proactive steps toward industrial decarbonisation by investing in cutting-edge heat pump technologies through StreamStep, a major European initiative set to transform the way thermal energy is managed in the industrial sector.
StreamStep Project: European Funding for a Sustainable Future
StreamStep is a 48-month project under the HORIZON-CL4-2024-TWIN-TRANSITION-01 program, with a EUR 17.54 million budget, of which EUR 14.99 million is EU-funded.
Halcor is participating in the StreamStep project as a demonstrator, investing EUR 730,000 (with EUR 511,000 in EU funding) to implement waste heat recovery solutions at its Viotia foundry to enhance energy efficiency. Halcor’s foundry operations produce 82,000 tons of copper annually and hold a leading position in copper recycling. Key Objectives of the Project:
- Integration of high-temperature heat pumps (HTHPs) to reduce natural gas consumption
- Digitalisation of energy management through advanced digital tools
- Reduction of energy costs and CO₂ emissions
As part of StreamStep, Halcor will integrate innovative waste heat recovery technologies into its foundry operations, which produce 82,000 tons of copper annually and hold a leading position in copper recycling.
Technology Implementation at Halcor’s Foundry:
- Recovery of heat from exhaust gases in the continuous copper casting line
- Installation of a high-temperature heat pump to increase combustion air temperature from 60-80°C to 155°C
- Reduction of energy demand by 6.25 GWh per year
Recent developments
The design phase of the project began on January 17, 2024, with a technical visit to HALCOR’s foundry by experts from Brunel University London and SINTEF, one of Europe’s largest research organizations.
Led by Brunel University’s Heat Pipe and Thermal Management Research Group, the project integrates state-of-the-art thermal energy management solutions, cutting-edge waste heat recovery and digital twinning technologies to enhance industrial energy efficiency.
References
1. Eurostat. Energy Balances. 2019.
2. Fleiter T, Elsland R, Rehfeldt M, Steinbach J, Reiter U, Catenazzi G, et al. Heat Roadmap Europe. Deliverable 3.1: Profile of heating and cooling demand in 2015. 2017.
3. European Commission. A Clean Planet for all. A European long-term strategic vision for a prosperous, modern, competitive and climate neutral economy. 2018.
4. Strengthening Industrial Heat Pump Innovation - Decarbonising Industrial Heat.