METAWAVE: High-temperature heating processes with breakthrough microwave and digital technologies for increased energy efficiency

Industrial Use Case #1: GRES ARAGÓN (Ceramics – Spain)

GRES ARAGÓN is a major Spanish ceramics manufacturer. The ceramics industry is energy-intensive and responsible for about 1% of EU industrial CO₂ emissions—mainly due to high-temperature processes like firing.

With METAWAVE’s microwave-based heating and smart technologies, GRES ARAGÓN expects:

• Up to 33% energy savings (from 5.76 GWh to 3.8 GWh/year)

• 40% fewer emissions, cutting 427 tons of CO₂ per year

• 6% increase in productivity, adding 576 tonnes of output annually

• 37% reduction in energy intensity

• 32% less heat loss

• 70% heating efficiency using microwave technology

Improvements come from a combination of Microwave heating, Smart digital controls, Eco-friendly refractories and Innovative ceramic additives.

Industrial Use Case #2: COPHA (Asphalt – Spain)

COPHA operates in asphalt refining—an industry that emits over 3 million tons of CO₂ per year in the EU, mainly due to fossil-fuel-powered drying and mixing processes.

With METAWAVE’s microwave technology and smart upgrades, COPHA expects:

• 47% energy savings (from 7.3 GWh to 3.8 GWh/year)

• 64% emissions reduction, avoiding 1,152 tons of CO₂ annually

• 10% boost in productivity, adding 10,000 tonnes of output per year

• 52% lower energy intensity

• 47% reduction in thermal losses

• 90% heating efficiency with microwave systems

Performance improvements will come from High-efficiency microwave heating, Advanced digital controls and modeling, Smart refractories and Innovative 2D material additives.

Industrial Use Case #3: METLEN (Aluminium – Greece)

METLEN operates in aluminium production, where heat-related emissions are a major challenge—accounting for 10 million tons of CO₂ per year in the EU, with anode production alone responsible for 7.23 MtCO₂ annually.

With METAWAVE’s innovative technologies, MYTILINEOS expects:

• 33% energy savings (reducing use from 104 GWh to 70 GWh/year)

• 7.7 kt CO₂ reduction per year—a 40% emissions cut

• 20% increase in productivity, adding 18,800 tonnes per year

• 44% drop in energy intensity

• 39% less thermal loss

• 65% heating efficiency with microwave systems

These results will come from High-performance microwave heating, Smart refractories and ceramic additives and Digital process control and energy optimisation.