EnWaRec - Recovery of energy and water from cooling circuits for a sustainable transition to hydrogen-based direct reduction

Initial situation:

The transformation of iron and steel industry from carbon to H2-based production is embedded in new directives as National Energy and Climate Plans focusing on waste heat recovery rates up to 50% to decrease CO2 emissions. Key element of the transformation is the direct reduction process, leading to high energy intakes into gas washing water with temperatures up to 80°C and increasing the cooling water demand. In parallel, climate change causes water stress, limiting the water availability, increases salt contents and freshwater temperatures. Because of challenging water compositions (temperatures, corrosion/scaling potential), no recovery of energy or water recovery is practiced due to lack of suitable technologies. In the EnWaRec proposal, a holistic approach for recovery of waste heat and water from cooling and gas washing circuits including internal energy and water reuse is addressed. It consists of combining sensors and tools for process water monitoring and utilization of energy for decreasing CO2 emissions including water recovery. Suitable corrosion and scaling measurements for a tailored chemical dosing including thermal stable treatment chemicals up to 80°C and coatings for corrosion and wear protection in micro turbines, heat exchangers and nozzles are developed. Microturbines are applied for electricity production from waterpower. EnWaRec shows, how recovered waste heat will be used for steam production with high temperature heat pumps or recovery of water by membrane distillation. A further waste heat utilization is an enhance sludge treatment. Software tools are developed to simulate different scenarios, determine optimum points for chemical dosing, heat outtake and energy production by micro turbines and predict corrosion.

Project targets:

Development of an holistic approach for recovery of waste heat and water from cooling and gas washing circuits including internal energy and water reuse is addressed

Innovative approachs:

  • Combination of sensors and tools for process water monitoring and utilization of waste heat.
  • Development of suitable corrosion and scaling measurements for a tailored chemical dosing including thermal stable treatment chemicals up to 80°C
  • Development of coatings for corrosion and wear protection in micro turbines, heat exchangers and nozzles are developed
  • Application of microturbines for electricity production from waterpower
  • Reuse of recovered waste heat for steam production with high temperature heat pumps or recovery of water by membrane distillation
  • Waste heat utilization for an enhance sludge treatment
  • Development of software tools for simulation of different scenarios, to determine optimum points for chemical dosing, heat outtake and energy production by micro turbines and predict corrosion

Benefits for the industry:

EnWaRec will provide technologies and tools opening a recovery potential waste heat and water, saving CO2 in the case of the European steel industry.

News/Events:

02.12.2026: Consortium Meeting at VDEh-Betriebsforschungsinstitut GmbH

03.12.2026: Open Workshop “Stepwise and efficient modifications of relevant cooling circuits during the transition towards to H2-based production”, Steel Academy Düsseldorf, Germany

About  the project:

This project has received funding from the Research Fund for Coal and Steel (RFCS). Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union. Neither the European Union nor the granting authority can be held responsible for them.

Further information: https://enwarec.eu/

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