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Major Energy Transition Breakthrough: First Hydrogen Production from Steel Off-Gases

At Utility, we have achieved a groundbreaking milestone in our pursuit of affordable and practical sustainability for heavy industry: 

  • First-ever hydrogen produced directly from steel Blast Furnace Gas (BFG) emissions in a single reactor step
  • Proven under actual field operating conditions

The Bottom Line: We’re Ready to Scale and Commercialize, Making the Energy Transition a Near-Term Reality

Our H2GenTM technology is now ready to scale, producing substantial quantities of hydrogen for immediate industrial use. This hydrogen can serve as a reductant in blast furnaces or as a low carbon fuel source for co-located Direct Reduced Iron (DRI) plants. H2Gen is a game-changer, leveraging the residual energy from BFG to revolutionize steel manufacturing with cleaner, more sustainable processes.

A Quantum Leap Toward Commercialization

H2Gen's advancement to Technology Readiness Level (TRL) 8 marks a significant milestone on our path to full-scale commercialization. This achievement confirms H2Gen has been rigorously  tested and validated in real-world operating environments. We are poised for final refinement and large-scale deployment. 

Unmatched Flexibility and Purity

H2Gen demonstrates exceptional adaptability, handling a variety of gases from industries including steel, chemicals, refining and petrochemical operations. This flexibility ensures seamless integration into diverse operational environments, adapting effortlessly to changes. H2Gen produces a high-purity hydrogen stream by eliminating impurities from the feedstock gas. Additionally, the process converts the feedstock gas into high-concentration CO2 gas, enabling cost-effective capture for use in green chemicals, food and beverage, cement or sequestration.

H2Gen Demonstration Plant at Steel Mill

Our first field demonstration and testing facility operates 24/7, proving our eXEROTM technology under real-world conditions. Producing reliable, cost-effective hydrogen from difficult-to-process off-gases is now a reality.

Overview of H2Gen for Steel

H2Gen, developed by Utility, is a groundbreaking method to efficiently convert BFG and steam, into on-site hydrogen without relying on external electricity or additional infrastructure. Powered by our eXERO technology platform, H2Gen harnesses the residual energy from the CO in BFG to drive the conversion process, making it a highly efficient and sustainable solution for steel manufacturing.

Electrochemical Conversion Process

The H2Gen reactor operates similarly to a Solid Oxide Electrolysis Cell (SOEC) electrolyzer, with a ceramic membrane separating the anode and cathode sides of the reaction. Unlike traditional electrolyzers, H2Gen does not require external electricity. The reaction is driven by the overpotential between the gases on each side of the membrane. In the cathode, oxygen ions are separated from water molecules (steam) and transferred through the membrane to the anode, where CO in BFG is converted to CO2. The selective and dual-conducting ceramic membrane efficiently transfers electrons and oxygen ions, enabling effective hydrogen production.

FTF webpage graphic-01 trans

Field Test Facility (FTF) Implementation

Following the success of the Houston Pilot Plant in 2023, the next step was constructing a Field Test Facility (FTF) at an operating blast furnace plant to validate H2Gen's capability to convert actual BFG to hydrogen.

In 2023, Utility designed, engineered, constructed, commissioned and started up the FTF. The goal was a fully assembled system that could be shipped to the project partner’s site and easily installed. The project partner provided a location within their facility and supplied BFG and required utilities. Utility Global managed all project permits.

Field Testing Key Objectives

  1. Validate the pre-treatment technology for removing contaminants from BFG that could damage the electrolyte membrane of the reactor cells
  2. Confirm the system’s ability to handle variations in BFG flow, pressure and composition
  3. Produce detailed performance data to support scale-up and design

 

FTF General Process DesignFTF webpage graphic-02

The FTF is designed to process BFG directly from the blast furnace and produce high purity H2. The heating and cooling units shown in the diagram are simplified for the FTF.  In scaled versions, counter-heat exchangers will recover heat from hot exit gases to heat incoming ambient temperature gases.

 

Plant_REVISED with exero

SEE THE FTF RESULTS >

 

EXPLORE THE FTF IMPACT >

Rigorous Safety Protocols

Strict safety protocols were followed throughout the construction and installation process, totaling over 20,000 man-hours and completed without incident. The system was delivered on schedule in September 2023. Despite several design and construction changes, it was ready for commissioning in early October 2023.

 

UG FTF 2

Future Prospects and Conclusion

We aim to achieve a significant cost advantage over technologies such as electrolyzers and Steam Methane Reformers (SMR), making H2Gen a more competitive and sustainable solution for the steel industry.

This breakthrough not only marks progress in reducing carbon emissions but also opens new avenues for sustainable steel production. By harnessing the residual energy from BFG, H2Gen technology has the potential to drive significant sustainability changes within the steel industry. As the demand for environmentally friendly steel grows, the successful implementation of H2Gen promises a cleaner, greener future.