In 2020, industrial activities within the EU emitted a total of 351 million metric tons of CO2 equivalent, marking an 8% reduction from the levels recorded in 2019. Numerous instances require continuous high-temperature heat for these processes, and currently, no feasible solution for decarbonization exists. The implementation of viable short-term thermal energy storage, lasting up to 48 hours, would facilitate the substitution of fossil fuels with industrial waste heat and renewable electricity.

HEATERNAL brings together four specialized public research teams focused on prototyping and modeling thermal systems, phase-change materials, and 3D printing. Additionally, it involves two manufacturers each from the metals and ceramics sectors, a process engineering SME, an equipment manufacturer, an SME specialized in life cycle assessment (LCA) and techno-economic analysis, as well as an SME experienced in dissemination and communication. The collaborative objective is to create a prototype and model for an innovative thermal energy storage concept that draws from substantial scientific and industrial expertise. This involves two key components: (i) inventive phase-change materials and unit designs that amplify unit energy density by 350% compared to ceramic bricks, and (ii) manufacturing proficiency that guarantees swift integration of materials and units into factories by 2030. Consequently, the project aims to produce a 50-kWh prototype (at Technology Readiness Level 5) along with scaled-up storage system models tailored for factory integration.

A preliminary techno-economic study anticipates a return on investment within three years and a levelized cost of stored energy below 6€/MWh. This is notably 60% lower than molten salt storage, which lacks effectiveness at sufficiently high temperatures for major industries dealing with metals and minerals such as steel, glass, cement, and ceramics. The solution proposed by HEATERNAL effectively addresses industrial requisites, including a minimal footprint, a lifespan exceeding 10 years, and swift return on investment. The strategic exploitation plan aims to introduce the solution in the first factory by 2030. Sales projections indicate potential earnings of 286 million euros through the sales of phase-change materials, ceramic refractories, and engineering services by 2040, consequently preventing the emission of 147.5 million metric tons of CO2 equivalent by 2040, courtesy of the HEATERNAL thermal energy storage systems.