Advancing circular energy solutions in European industry: decarbonisation pathways through green hydrogen, carbon capture, and heat recovery
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Date
2025-12-19
Authors
Mostafa, Mohamed
Journal Title
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Publisher
University College Cork
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Abstract
This thesis develops plant-specific, operations-aware methods to advance industrial decarbonisation through circular energy pathways: hydrogen blending in steel melt-shop operations, carbon capture integrated with renewable synthetic-methane production, and a cross-industry framework for direct heat-to-heat recovery. Grounded in European policy and market conditions, the work aims to generate decision-grade evidence that reflects operational constraints, electricity-procurement structures, and consistent emissions accounting.
The first strand examines the feasibility of introducing green hydrogen into existing natural-gas furnace systems in an electric-arc-furnace melt shop. A full-year operational framework evaluates blending limits, plant integration requirements, electricity-sourcing strategies and the interactions between hydrogen supply, storage, and safety constraints. The results outline the operational envelopes within which hydrogen blending can achieve meaningful emissions reductions using existing assets.
The second strand develops an integrated process and techno-economic framework that couples post-combustion CO₂ capture with catalytic methanation to produce synthetic methane on the same steel site. The modelling links CO₂ capture profiles with electrolytic hydrogen supply and incorporates industrial electricity-procurement arrangements. Comparative analyses across technologies and policy scenarios clarify when synthetic methane can act as a circular, drop-in fuel for high-temperature industrial demand.
The third strand advances a transparent multi-criteria decision-analysis framework for direct heat-to-heat recovery. Building on an existing tool developed within the wider project, the thesis contributes the methodological structure, technology catalogue, feasibility-first screening, and ranking procedure. A demonstration of an industrial case study illustrates how the framework enables explainable, preference-weighted shortlisting and reveals how stakeholder priorities shape early-stage technology selection.
Collectively, the thesis provides integrated frameworks for hydrogen blending, capture-to-synthetic-methane pathways, and heat-to-heat recovery. Together, they offer practical and scalable routes for industrial decarbonisation through circular energy pathways, including circular carbon utilisation where appropriate.
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Controlled Access
Keywords
Energy , Hydrogen , Renewable energy , Carbon capture , Heat recovery
Citation
Mostafa, M. 2025. Advancing circular energy solutions in European industry: decarbonisation pathways through green hydrogen, carbon capture, and heat recovery. PhD Thesis, University College Cork.