Decarbonization in the rolling mill 

ABP innovation: saving gas with induction heating technology

The need for decarbonization in the steel industry is undisputed, as it is one of the world‘s largest industrial emitters of greenhouse gases. With a 25% share of industrial CO2 emissions and around 9% of total global emissions, this sector is at the center of efforts to replace fossil fuels with climate-friendly alternatives. In this context, induction heating technology, such as the technical innovations from ABP Induction, is becoming increasingly important, especially for rolling mills that previously relied on gas-heated systems.

The decarbonization targets that Germany and other leading industrial nations have set themselves are calling for innovative solutions to reduce CO2 emissions. While green hydrogen is much discussed as a long-term alternative, its current availability and the associated conversion costs are an obstacle. The path to green hydrogen inevitably involves the use of renewable electric energy. Induction heating offers a practical solution that can be implemented quickly, which is characterized by its high degree of efficiency, particularly in the area of long products. This means that green electrical energy can also be used directly, saving the high costs associated with converting it to hydrogen.

The advantages of induction heating systems

Induction heating systems have proven to be particularly advantageous in the melting process. They offer a high degree of flexibility and enable a significant reduction in CO2 emissions thanks to their efficient use of energy. Impressive successes have already been achieved in the melting capacity of more than one million tons per year, as shown by examples of systems with components from ABP Induction in China. This technology, which is traditionally used in foundries and forges, has now also found its way into rolling mills, where it can be used to supplement gas-powered reheating furnaces.

The use of induction in rolling mills offers clear advantages over purely gas-powered systems. In particular, the ability to react dynamically to temperature fluctuations and enable rapid heating makes the technology attractive. A hybrid approach, in which induction furnaces are used to supplement existing gas furnaces, could significantly improve the carbon footprint. Induction furnaces achieve electrical efficiencies of up to 90%, which enables the efficient use of electrical energy and at the same time keeps investment costs low, as they can be integrated into existing process chains.

Further potential of hybrid heating, where induction can be used either before or after the gas furnace, lies in increasing throughput and improving quality. Flexible power regulation and precise temperature control enable an optimum heating pattern to be achieved. This makes it possible to compensate for temperature fluctuations within the material and increase production quality. The ability to achieve high temperature increases with comparatively short system lengths also reduces the space required and offers dynamic process control that meets the requirements of modern production processes.

UHT Thermo-Jet as a pioneering technology

The decarbonization of the steel industry is being accelerated by increasing political and economic pressure, but also by the expectations of employees and the public. Induction heating systems offer a low-emission alternative to fossil fuels by efficiently converting electrical energy into heat. These systems, especially in hybrid combination with gas-fired furnaces, allow a significant reduction in CO2 emissions without major changes to the existing infrastructure. The integration of induction into existing process chains minimizes investment costs and at the same time improves efficiency and flexibility.

The use of alternative fuels will also play a central role in the future of decarbonization. While hydrogen is not available in sufficient quantities, inductive heating offers a technological approach that can already be used today to reduce emissions. In the long term, alternative burners that rely on emission-neutral technologies will replace conventional gas burners. The use of the innovative UHT Thermo-Jet can be of decisive importance here.

The UHT Thermo-Jet is a pioneering technology that heats process gases by induction. This process not only offers high energy efficiency, but also the option of operating in a closed cycle by recirculating furnace gases. This cycle avoids exhaust gas losses and significantly increases efficiency. The aim of this technology is to enable emission-free production in the rolling mill and thus make a significant contribution to achieving global climate targets.

By combining induction heating and innovative technologies such as the UHT Thermo-Jet, the steel industry can take an important and necessary step towards climate neutrality. These technologies not only offer ecological benefits, but also economic efficiency by optimizing energy consumption and improving the carbon footprint. They are therefore an essential part of the transition towards a climate-friendly industry.