R&D Projects

One Step Ahead.

Our scientific commitment goes far beyond the mere further development of our products. It is the big issues that move us: energy transition, green gases and consistent minimization of pollutants. 

Thanks to decades of close cooperation with renowned scientific institutions as well as outstanding results from completed research projects, WS enjoys an excellent reputation with all project sponsors and research funders and is a sought-after advisor in the preparation of policy direction decisions. 

Current R&D projects

The scope of this project is the investigation of the flexible use of hydrogen as fuel in continuously operated annealing lines and similar steel strip furnaces, aiming at the reduction of CO2 emissions. The use of hydrogen is being tested in existing radiant tube systems in the research lab. In parallel, modern radiant tube systems using fuel-flexible and energy-efficient FLOX® burners in Double-P-tubes with minimal NOx emissions are being developed and demonstrated. Hydrogen use is supposed to be possible within a 0-100% range without manual adjustment of the overall furnace or changes to the radiant tube system. Despite changes in the fuel supply, the goal is to maintain high stability of the process as well as energy-effiency and low-emission combustion.
 
The project will support decarbonisation efforts in steel processing as well as the acceptance of hydrogen as future fuel in the industry. The solutions developed within the project will not only apply to new installations but aim at retrofit solutions as well in order to allow for quick market diffusion. Demonstration will take place in a continuous annealing line for steel strip. The results will show the effects of switching from natural gas to hydrogen and will give a well founded estimate for a realistic potential of carbon reduction due to the switch in fuel.
 
 
Topic page: FlexHeat2Anneal

In the BMWi funded project "ReOrgAl", WS investigates the potential of the FLOX® technology in relation to its use of low-calorific value fuels with fluctuating composition from the thermal pre-treatment of recycled and organically contaminated aluminum scrap. The overall goal of the project is to increase energy and resource efficiency and optimize the recycling processes in the aluminum industry. A comprehensive project description with project goals and methodology can be found on the following website of the project coordinator:


Link to the project homepage

The aim of the "FLOX-2" research project is the development of an innovative combustion system that will allow for the FLOX® technology to be used at process temperatures below 850°C. In process firing, multi-stage flameless combustion will enable the flexible substitution of fossil fuels with LCV fuels, waste gases or synthetic ("green") fuels, such as hydrogen, methane or ammonia, and thus a significant reduction in anthropogenic CO2 emissions. Due to the configuration of the combustion system not only the thermal NOx formation but also the formation of fuel NO can be significantly abated. Further information on the project can be found on the project-specific website of our project partner, the Departement for Industrial Furnaces and Heat Engineering at RWTH Aachen University:


Link to the project homepage

The objective of the "Hybrid Radiant Tube" project is to test a hybrid heating system for thermoprocessing plants. Hybrid here means the use of fuel gas and electrical energy. The electricity comes preferably from renewable energy sources. If there is surplus electricity from renewable sources in the power grid, it is possible to switch from gas heating to electric heating. In this way, the plant can be heated in a CO₂-neutral manner and an overload of the power grid can be prevented.

 

Modified flame tubes were installed in a classic radiant tube. The electric heating coil was arranged helically on the flame tube. A ceramic recuperative burner is used for gas heating. During the project, the hybrid jet tube was able to demonstrate its technical feasibility. Preparations for industrial testing of the hybrid radiant tube have been largely completed. In conclusion, the hybrid radiant tube can already be used today to respond to the volatile supply on the energy market. In terms of price and CO₂ balance, the more favorable heating variant can be selected in each case.

 

Report (in German language)

 

Project Homepage

Past R&D Projects

Extension of the application limits of FLOX® technology for small and large burner inputs.

Project Homepage: www.eu-projects.de

Flameless combustion conditions and efficiency improvement of single- and multi-burner-FLOX furnaces in relation to changes in fuel and oxidizer composition

Project Information

Ceramic Heat Exchangers with Enhanced Material Properties, CEREXPRO

www.cerexpro.org

Development of a combustion process for coal power generation, free of CO2 emissions.

Project website

Extension of the expected life of parts used in corrosive, thermal and mechanical challenging environments up to 1200 °C.

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Dynamic Behavior of a Multi-Burner Excess Enthalpy Combustion System (MEEC) for Industrial Process Furnacess

Engineered ceramic components for the reduction of energy use in thermal processing applications with highly intensive gas recirculation at higher temperatures.

Reduction of energy use and emissions in glass melting using recuperative air preheat.

New Burner Technology for Low Grade Biofuels to Supply Clean Energy for Processes in Biorefineries.

Partners: GWI, University Bochum, RWTH Aachen, IST, DLR, Ansaldo, WS, Uni Delft, DGT, Snecma, Alstom (Siemens)
Timespan: 2001 - 2004
Funding Institution: EU

 

Development of FLOX® burners for the use in gas turbines.