F. Bassetti, U. d'Agostino
Magaldi Technologies LLC, Magaldi Green Energy,
United States
Keywords: industrial decarbonization, thermal energy storage, steam generation
Summary:
Addressing climate change necessitates pragmatic solutions to transition toward renewable energy systems while ensuring energy reliability and flexibility. Renewable energy generation, coupled with Long Duration Energy Storage (LDES) technologies, is vital to overcoming challenges associated with intermittent power sources. Among the most promising technologies is the integration of renewables energy sources with Thermal Energy Storage (TES) to enable dispatchable heat, while reducing reliance on fossil fuels. Magaldi has developed the Magaldi Green Thermal Energy Storage (MGTES), a Power-to-Heat system charged by renewable electricity and/or the grid. This modular, sustainable solution leverages fluidized bed technology to decarbonize industrial processes, by producing zero-carbon medium-to-high temperature steam. The MGTES system utilizes silica sand as a TES medium, leveraging its stability at temperatures above 1000°C, long lifespan, and cost-effectiveness. The sand bed’s fluidization - achieved by air blown through the bottom of the fluid bed module - enhances thermal diffusivity, heat exchange, and system responsiveness, during system charging and discharging phases. When charge and discharge phases are complete, the fluidization ceases, allowing thermal energy to be stored efficiently for days or weeks. MGTES integrates energy charge, storage, and transfer to steam into a single unit, providing modular and flexible configurations (5 MWh to GWh scale) to meet diverse energy needs. The operational Alpha-4 pilot system, installed in Magaldi’s facility in Buccino, Italy, has validated the technology, demonstrating efficient electrical charging, energy storage (with fluid bed temperature up to 620°C) and superheated steam generation at medium-to-high temperatures. This P2H technology supports industrial decarbonization across sectors such as food and beverages, textiles, pulp and paper, chemicals, and mining, improving system capacity factors, reducing land requirements, and providing grid services. A significant milestone in the deployment of MGTES technology is its first industrial application, currently under construction. Enel X and Magaldi Group have partnered to implement a ~7.5 MWh MGTES system by Q2 2025. This system will support the continuous production of green steam at I.GI, a vegetable oil refinery in Buccino, Italy, which supplies the Ferrero Group. This project exemplifies the potential of MGTES technology to enable sustainable industrial processes while reducing carbon emissions, contributing to a resilient and decarbonized energy future.