The H2Rollout research project, with participation from Westfälische Hochschule, is investigating the combustion behavior of so-called flat flame burners and their conversion to hydrogen.
The galvanizing industry faces the task of significantly reducing CO2 emissions in its high-temperature processes in the future. Green hydrogen offers itself as an alternative fuel for retrofitting existing systems. Due to the differing flame characteristics compared to natural gas, the effects of hydrogen burners on galvanizing kettles, exhaust gas, and overall efficiency must be carefully examined. This is to enable the integration of hydrogen-powered burners into existing processes and plants. The H2Rollout research project, with participation from Westfälische Hochschule, is now investigating the combustion behavior of so-called flat flame burners and their conversion to hydrogen. This type of burner is frequently used in batch hot-dip galvanizing. The project's goal is to achieve a hydrogen content of 100 percent in the galvanizing process.
ZINQ Provides Pilot Plant
The company ZINQ is participating in the project with its location in Castrop-Rauxel and is providing one of its kettles as a pilot plant for demonstrating hydrogen use. Specifically, one of the flat flame burners in use will initially be replaced by a hydrogen-powered variant and integrated into the existing control system. In parallel, ZINQ is examining possible approaches for a stable, long-term, and economical hydrogen supply.
Robert Mill, Head of Plant Engineering at ZINQ, explains: "We have high hopes for the project. It lays the foundation for us to be technically prepared as soon as the framework conditions for the use of hydrogen are created. However, it will be crucial that in the end not only the technical, but also the regulatory, infrastructural, and economic prerequisites are met."
Adaptation of Hydrogen Flame Through Simulation
Prof. Martin Habermehl from Westfälische Hochschule is responsible, among other things, for the flow simulations. These form the basis for adapting the hydrogen flame to the previous operation of the natural gas burners. He and his team also accompany and analyze the trial operation. They record, for example, the combustion behavior, temperatures, as well as the water content and nitrogen oxides in the exhaust gas stream of the hydrogen flame.
Martin Habermehl explains: "The difficulty lies in ensuring that the combustion remains consistently stable and that it can be integrated into the existing process." This is because the liquid zinc in the kettles has only a narrow tolerance range in which the temperature must remain. Additionally, the kettle, the heart of every galvanizing plant, must not sustain any damage.
Optimization of Process Control
The company ProPuls GmbH, a spin-off from Westfälische Hochschule, is responsible for control and regulation technology in the research project. Philipp Neuhaus, Team Leader for Control Systems Engineering at ProPuls, explains: "The data from the simulations and the measured values from the pilot operation are our basis for optimizing the process control."
Model for the Entire Industry
The funding program "T!Raum – TransferRäume für die Zukunft von Regionen" from the Federal Ministry of Education and Research finances the research project. The project is part of the transfer initiative "H2Raum," initiated by Westfälische Hochschule and Fraunhofer IEG, and will investigate the conversion of flat flame burners to hydrogen using the ZINQ galvanizing plant in Castrop-Rauxel as an example until 2028. The consortium partners Westfälische Hochschule, ProPuls GmbH, and the industrial partner ZINQ aim to develop a blueprint for the galvanizing industry as well as other process heat-dependent industrial sectors with the project results.
The H2Raum Initiative
The H2Raum initiative is funded by the funding program "T!Raum – TransferRäume für die Zukunft von Regionen" of the Federal Ministry of Research, Technology and Space. The goal of the funding program is to promote both forward-looking innovations and structural change in structurally weak regions over the long term. Specifically, H2Raum aims to ensure that hydrogen actors in the Ruhr region learn from each other, discuss together, and develop and implement hydrogen projects together. H2Raum addresses all interested parties, from start-ups to small and medium-sized enterprises, universities, educational and research institutions, students, schoolchildren, and extending into civil society.
Westfälische Hochschule has been conducting research in the field of hydrogen technology for over 20 years and is a partner in numerous regional and supraregional initiatives. Since the winter semester 2024/25, the university has been offering the degree program "Hydrogen Systems and Renewable Energies." And with the "H2 Solution Lab," funded as part of the 5-Location Program by the federal government and the state of North Rhine-Westphalia, a pioneering hydrogen laboratory is being established at Westfälische Hochschule as an important pillar of the hydrogen location Gelsenkirchen.
Fraunhofer IEG, as an institution of the Fraunhofer-Gesellschaft, focuses primarily on geothermal energy, energy infrastructures, and industry-related hydrogen research. With TransHyDE, it leads one of the three flagship projects of the Federal Ministry for Economic Affairs and Climate Action on hydrogen technologies, develops innovative storage solutions, and supports the integration of hydrogen technologies into energy systems.
