Through systematic research and collaboration with industry and government, this project will deliver valuable resources, including policy maps, comparative analyses and practical recommendations. These will provide heavy industry with tools to align with and benefit from Australia’s low-carbon policies, and help industry leaders engage effectively with policymakers.

TES is a promising solution for decarbonising heavy industry by providing a cost-effective way to store and use renewable energy in the form of heat. Industries such as alumina refining, iron and steel production, and lime calcination require high-temperature heat (up to 1200°C) for various processes, making TES integration essential. However, while TES is widely recognised as more affordable than alternatives like batteries or hydrogen, integrating it into industrial processes – either retrofitted or in new builds – remains a significant challenge.

This work builds on phase 1 of the project, which identified a range of TES technologies suitable for industrial applications but highlighted the need to refine integration strategies. This new phase extends the scope to medium- and high-temperature use cases, addressing issues such as temperature compatibility, scale, cost-effectiveness, and infrastructure needs.

By conducting case studies, the project will explore TES integration scenarios for processes such as alumina calcination, bauxite digestion and hydrogen-based direct reduced iron. It will also assess practical challenges, such as material durability under extreme conditions and the feasibility of alternative methods for storing heat.

Through three parallel work plans focusing on alumina refining, iron and steelmaking, and cross-industry applications, the project aims to identify a viable use case for future pilot-scale demonstration. By addressing knowledge gaps and practical barriers, this research will pave the way for low-cost, renewable heat solutions, enabling industries to transition away from fossil fuels while maintaining operational efficiency.

• 1.3 Low-carbon high-temperature alumina calcination
• 1.4 Low-carbon heat for the hydrometallurgical process component of alumina refining
• 2.2 Technology to accommodate use of multiple energy sources

• New technology to accommodate multiple energy sources and offer flexibility in switching between them
• New technologies for high temperature heat

• Process models showing feasible integration options for each case study.
• Integrated system models showing how a TES system can be operated over a year, including information relating to reliability of heat supply, sizing of components, and other practical challenges or risk factors.
• Value proposition analysis for each integration option, with comparison to alternative or hybrid options for renewable heat supply.
• Results and analysis from supporting experimental work in target areas.
• Assessment and planning towards a selected use case for future pilot-scale demonstration, including recommended objectives for design.

Alumina refining

• Provides HILT CRC Partners with detailed information on how to integrate TES into alumina calcination processes.
• Identification of the best heat integration methods (in collaboration with the AlumiNEXT™ project).
• An understanding of which combination of TES, direct electrification and hydrogen combustion provides the most viable pathway to calcination decarbonisation.
• Insights into TES options for steam production in digestion and potential applications in bauxite beneficiation.
• Reliability and operational analysis based on long-term data
• Information on energy supply options (grid or dedicated solar/wind) and how these work in conjunction with TES (in collaboration with 007 Unlocking investment in energy infrastructure for net-zero industrial hubs).
• Evaluation of modular TES technologies, focusing on scalability and associated risks.

Iron and steel

• Identification of the most beneficial TES integration opportunities and evaluation of their feasibility and cost-effectiveness.
• Strategies for HILT CRC Partners for integrating TES into H₂DRI processes.
• New knowledge on TES integration for process gas heating, a major energy requirement in DRI.
• New knowledge on TES applications for ore beneficiation processes such as magnetisation roasting, drying and pre-treatment.

Pilot-scale demonstration

• Support for Partners in moving towards a pilot-scale TES demonstration system.
• A preferred use case for detailed assessment to guide the design and implementation of the pilot system.

RP2.017 Advancing the viability of high-temperature thermal energy storage for industrial applications – Phase 2