- AIT develops an innovative energy concept for the Wienerberger brick factoryin Uttendorf/Upper Austria in the NEFI project GreenBricks
- Strongcollaboration betweenindustry and researche enables the realisation of pioneering demonstration projects such as GreenBricks
On 28th November 2024, the greenest brick factory in Europe was officially opened at the Wienerberger site in Uttendorf. As part of the NEFI project "GreenBricks", the AIT developed an innovative overall concept for energy-efficient brick production. The centrepiece of the project is the world's largest industrial electric kiln, which is going into operation at the Uttendorf site. By taking a holistic view of the production chain, from adapted clay mixtures and improved drying processes with integrated heat pumps to efficient firing in the new high-temperature tunnel kiln, CO2 emissions in brick production will be reduced by 90 per cent and energy requirements cut by 30 per cent. The energy required comes entirely from renewable sources, including the plant's own photovoltaic system.
Andreas Kugi, Scientific Director of the AIT: "The successful realisation of the NEFI GreenBricks project shows how crucial close cooperation between industry and research and the use of new technologies are for the future of production. Thanks to innovative digital planning and simulation tools, we were able to make brick production at the Uttendorf site not only more sustainable, but also more efficient. Projects like this show that digitalisation and virtual planning are key to decarbonisation and the competitiveness of the industry."
Strong collaboration between industry and research
The long-standing cooperation between the AIT Austrian Institute of Technology and Wienerberger Austria began in Uttendorf. There, for example, an industrial high-temperature heat pump for drying processes was successfully used for the first time as part of the EU DryFiciency project - a pioneering example of technological innovation.
This partnership was intensified and raised to a new level with the NEFI project "GreenBricks". The Uttendorf site was completely redesigned, modernised and consistently geared towards decarbonisation. A key milestone is the world's largest industrial electric kiln for brick production, which will change industrial energy requirements in the long term.
The close integration of research and practice is made possible by the innovation network NEFI - New Energy for Industry. This network creates ideal conditions for testing new technologies directly in companies and quickly implementing them.
The "GreenBricks" project is funded by the Climate and Energy Fund as part of the RTI initiative "Vorzeigeregion Energie" - a prime example of the synergy between research, business and climate protection.
Innovative energy concept for the Wienerberger brick factory in Uttendorf/Upper Austria
The plant conversion was consistently planned using digital tools developed by experts from the Centre for Energy at the AIT Austrian Institute of Technology. They were used to simulate calculations for the new electric furnace and digitally optimise processes in terms of climate protection. The tools are also used as digital twins in ongoing production. In this way, changes in the framework conditions in the brick manufacturing process and their effects on operation can be predicted and taken into account in the interaction between the dryer, heat pumps and electric kiln.
Heat pumps increase the energy efficiency of the drying process by converting industrial waste heat from the tunnel dryer into usable energy and feeding it back into the process.
"Heat pumps are a real alternative to conventional gas burners for many drying processes and can be used in many industrial sectors, from paper, food and beverages to textiles and various chemical industries, and can be integrated into existing systems," explains Tilman Barz, scientific coordinator of the GreenBricks project and Senior Scientist at the Centre for Energy at the AIT Austrian Institute of Technology.
Electrification of industrial furnaces as a technological leap forward for decarbonisation
The electrification of previously gas-fired industrial furnaces represents a significant technological leap and is associated with many technical challenges and adjustments at process level. "By using new digital tools, innovative virtual planning methods and detailed analyses of high-temperature heating processes up to 950°C, we have created the conditions for replacing conventional firing technology with a green electric furnace while maintaining the same capacity and quality," explains Barz. Europe's greenest brickworks will go into regular operation from 2025.
NEFI - New Energy for Industry
NEFI - New Energy for Industry was established as an innovation network for the transformation of industry in the "Vorzeigeregion Energie" and pursues the approach of decarbonising the industrial energy system with the help of key technologies "made in Austria". The NEFI innovation network has been formed around a consortium of AIT Austrian Institute of Technology, Montanuniversität Leoben, OÖ Energiesparverband and the Upper Austrian location agency Business Upper Austria and pools the diverse experience in the field of energy research and project implementation. Significant support comes from the two industrially strong federal states of Upper Austria and Styria. The constantly growing consortium, which currently has over 120 partners from companies, research organisations and public institutions, is developing technological and systemic solutions in 24 projects to enable the energy transition in industry. The Climate and Energy Fund is supporting the NEFI projects with a total of 30.2 million euros, funded by the Federal Ministry for Climate Action, Environment, Energy, Mobility, Innovation and Technology (BMK). www.nefi.at
About the AIT Austrian Institute of Technology
With 1,527 employees, the AIT Austrian Institute of Technology is Austria's largest research and technology organisation. The focus here is on key future topics in the research areas of "Sustainable and resilient infrastructures", particularly in the fields of energy, transport and health, as well as "Digital transformation of industry and society".
Research & development is the central driver of innovation for industry, the economy and society, secures jobs and prosperity and thus strengthens Austria as a business location. Applied research also provides solutions for the major challenges of our time. The Centre for Energy focuses its research on three central systems: Public energy supply systems, industrial energy supply systems Processes and Cities & Built Environment. Further information about the centre: https://www.ait.ac.at/energy
Mag. Margit Özelt
Marketing & Communications- +43 (0)50550 - 6302
- +43 (0)50550 - 6590
- margit.oezelt(at)ait.ac.at
