The SYRIUS project aims to transform the steel industry by enabling hydrogen production and circular energy use within the steelmaking process. Backed by a €10-million grant and a timeline of less than five years, the project seeks to make a significant impact. At its core, SYRIUS will demonstrate the integration of a 4.2 MW Solid Oxide Electrolyzer (SOEC) into a real Electric Arc Furnace (EAF) plant, paving the way for more sustainable steel production.
The steel industry is a significant contributor to global CO2 emissions, accounting for around 9% of total anthropogenic emissions, and it uses an average of 5.2 MWh of primary energy per tonne of steel produced. Reducing its environmental footprint remains a monumental challenge, demanding the adoption of new technologies, enhanced energy efficiency, and more circular energy systems.
This SOEC is the world’s largest and be will demonstrated at a steel plant in Terni, Italy, operated by Acciai Speciali Terni, a leading player in Europe’s stainless-steel sector. With over 1,000 tonnes of stainless and specialty steel produced annually, the site offers the perfect environment for testing hydrogen integration under real steelmaking conditions.
The SOEC will produce 100 kg/h of green hydrogen, which will help power a fuel-flexible 280-ton steel/h, 84 MWth slab reheating furnace. The electrolyser will work in tandem with the furnace, hydrogen storage, the steel plant’s flexible energy loads, and two virtually integrated solar PV plants, all coordinated by a cutting-edge Energy Management System (EMS). SYRIUS will place industrial circularity at its heart by harnessing furnace off-gas heat recovery to generate steam for the SOEC, recovering by-product oxygen in the furnace, and exploring water recycling options. The project is expected to cut CO2 emissions from the steel reheating process by 5,600 tonnes per year.
“This is the largest SOEC project in Europe, backed by a formidable consortium of experts. By demonstrating the SYRIUS concept in a working steel plant, we are not only advancing industrial adoption but also providing a tangible, scalable solution that will unlock new market opportunities. We’re talking about decarbonizing one of the most challenging sectors and endeavoring to make it commercially viable to do so. The potential impact of this initiative is truly exciting, and we’re very proud to be a part of it,” said Martin Skov Skjøth-Rasmussen, CTO at Elcogen.
Elcogen will bring its expertise in solid oxide cell and electrolysis technologies, supplying stacks designed for large-scale production on a specialized platform. Baker Hughes, also a key strategic investor in Elcogen, will lead the design and production of the multi-stack electrolyser prototype, managing its installation and testing to demonstrate the SYRIUS plant at an advanced stage of development, ready for real-world use. Politecnico di Milano will focus on modelling and EMS development. Rheinisch-Westfaelische Technische Hochschule Aachen will the assess environmental and social benefits. Fondazione Bruno Kessler will handle dynamic modelling and digital twins. Tenova Spa will manage SOEC and heat recovery integration, Kiwa Nederland and Vincotte will ensure safety, standardisation, and certification.