Launched in 2016 as a joint venture owned by SSAB, LKAB, and Vattenfall, with support from the Swedish Energy Agency, HYBRIT aims to create the world’s first fossil-free, ore-based steel, with renewable electricity and green hydrogen.
This involves shifting from coal-powered blast furnaces that use coal as a reduction medium to a direct reduction process using hydrogen produced via renewable energy. The first HYBRIT pilot plant in Luleå, Sweden began operations in 2020, with commercial-scale production targeted by 2027.
Kanthal is proud to have contributed to HYBRIT’s groundbreaking journey by developing an electricity-based process gas heater for the hydrogen-based direct reduction process under the name Prothal®. This project showcased the feasibility of fossil-free industrial heating solutions and laid the groundwork for scaling up these technologies to meet the steel industry’s future needs.
A vision for fossil-free steel
Traditional steelmaking methods rely heavily on coal, significantly contributing to global CO₂ emissions. HYBRIT seeks to phase out coal by using hydrogen in the reduction process, producing water as a byproduct instead of CO₂.
A key aspect of this vision is an emissions-free heating technology. Kanthal’s renowned expertise in industrial heating has led to the development of a gas-heating solution entirely powered by electricity.
The role of electric process gas heaters
Kanthal’s team worked closely with HYBRIT to design, install, and test electric gas heaters concept capable of heating hydrogen gas to the high temperatures required for the direct reduction process.
The Kanthal solution uses metallic resistance materials as heating elements and structural components. This innovative approach minimizes heat loss, reduces design complexity, and ensures high efficiency.
The developed heater concept can handle several gas mixtures, including 100% hydrogen, hydrogen-nitrogen (H₂-N₂) blends, and air. It is designed to operate at extreme temperatures, reaching up to 1,000°C (1,832°F), making it highly adaptable for direct reduction.
