Bird’s eye view of an asphalt mixing plant

Green pioneers

Hydrogen burner in Norwegian asphalt production

The clock is ticking – and the countdown to climate neutrality by 2045 is becoming ever more urgent. To drive sustainability in the asphalt industry and to secure the very foundation of companies, Benninghoven offers a number of pioneering technologies. The stand-out products are the world’s first burners that can be run with 100 % green hydrogen. This innovation sets new standards for maximum ecology in asphalt production.

The Veidekke construction company is a stand-out example – a pioneer using hydrogen as a fuel for asphalt production. In contrast to many other companies, the Norwegian asphalt producer, who holds a top rank in the national climate index, is already perfectly set up for the challenges of tomorrow. How well are you prepared for the future?

An innovative industrial adventure

It is the first time in history that asphalt has been produced completely without greenhouse gas emissions. Veidekke and Benninghoven prove that it is possible.

The latest burner technology

The features of the new MULTI JET burner generation from Benninghoven enable the use of a total of four different fuels simultaneously, in addition to hydrogen. These fuels can be solid, liquid or gaseous.

MULTI JET control

The new MULTI JET Control burner control system is optimised to allow changes between fuels on the fly without any interruption or plant shutdown, while also enabling simultaneous use of mixed fuels from different energy sources.

View of a burner
View of a burner
A view of the new MULTI JET burner control

On the way to climate neutrality in the construction industry

Working more efficiently with sustainable and economical technologies is the order and at the same time the challenge of today and tomorrow. It is no secret that the construction industry is responsible for around 40 % of the worldwide CO₂ emissions. That is why Veidekke is rather straightforward about seeing itself as part of a problem that urgently need resolving. The Norwegian company has set itself the unconditional target of becoming fully climate neutral by 2045 and is actively working towards this objective.

The Scandinavians are facing the challenge of, on the one hand, reducing their own emissions wherever possible, while, on the other hand, using their own expertise and competence to reduce the ecological footprint of their customers and suppliers. The MULTI JET multi-fuel burner also plays a special role in two projects between the Norwegian company and Benninghoven. “Veidekke are choosing this path because we as a construction company firmly believe that we can make the world a little better within the realm of our possibilities,” says Eddie Heggard Engebretsen, Senior Project Manager at Veidekke.

Eddie Heggard Engebretsen, Senior Project Manager at Veidekke Industri AS, smiles for the camera in safety clothing

“Veidekke promotes performance with a purpose. We want to make the world better with climate-friendly solutions. That is why we see social and ecological change as an opportunity to leverage of our innovative corporate culture and engineering expertise. Together with our customers and suppliers, we will take on an active role in climate change in order to overcome key challenges and shape a better future. Hydrogen burners from Benninghoven are an enormous help with this!”

Eddie Heggard Engebretsen, Senior Project Manager at Veidekke Industri AS

Gas line with “Hydrogen” label

Hydrogen as a new hope –

potential, challenges and outlook

“I get the impression that this is the only way forward – not only in Norway, but across the globe,” states Engebretsen as head of the hydrogen project. “Up here in the north, we have a lot of green energy that is generated with hydroelectric power. But overall, unfortunately it has to be said that its availability is still lagging behind, despite the immense potential. From my point of view, it can only be a matter of time until this has been understood and will be appropriately promoted and subsidised.”

Green hydrogen is currently regarded as the most sustainable fuel available and therefore as a key to a successful energy transition. It produces no greenhouse gases and its high energy density makes it ideal for thermal processes. Based on the current state of knowledge, hydrogen will have significant price advantage over fossil fuels in the future, as it generates no CO₂ emissions and is therefore not subject to any taxation.

Plant owners who want to use hydrogen as an energy source, however, are still faced with a limited infrastructure in many areas. The Benninghoven network is already providing customers with support for this challenge.

The hydrogen burner system from Benninghoven marks important progress in asphalt production, offering a pioneering solution for more sustainable road construction. The world’s first burner that can be run with 100 % green hydrogen enables virtually emissions-free asphalt production. This technological innovation is crucial for achieving a substantial reduction of the CO₂ emissions in road construction, which account for up to 45 % of the overall emissions.

Don’t wait – invest now!

Despite the currently limited availability of hydrogen, companies should not hesitate but be proactive. Investing in the new multi-fuel burner generation of Benninghoven is a low-risk step into the future. These burners are already pre-configured for the use of hydrogen and can be flexibly activated when it becomes viable for the respective site and business case – at the press of a button, without losing any time.

Flexible end-to-end solution from Benninghoven

Benninghoven has developed an optimally adapted end-to-end solution for material drying, which for the first time enables customers to use the new burner generation and thereby run their plant with up to 100 % green hydrogen. The perfectly coordinated hydrogen drying system consists of a multi-fuel burner, an intelligent burner control, a feed system with a patented pressure control section which reduces the hydrogen for the burner from 350 bar to the required 1.3 barA as well as other plant components that are specifically adapted to the use of hydrogen. This end-to-end solution connects directly to the hydrogen source – flexibly from different units such as trailers, pipe systems or remote electrolysers.

The hydrogen burner system from Benninghoven marks important progress in asphalt production, offering a pioneering solution for more sustainable road construction. The world’s first burner that can be run with 100 % green hydrogen enables virtually emission-free asphalt production. This technological innovation is crucial for achieving a substantial reduction of the CO₂ emissions in road construction, which account for up to 45 % of the overall emissions. In addition to reducing the CO₂ emissions, the NOx emissions in particular are a critical factor in hydrogen combustion. The Benninghoven system includes exhaust gas recirculation which ensures low NOx emissions.

Within the complete cycle of road construction, 45 % of all CO₂ emissions in road construction come from the asphalt mixing plant. The electrical energy required for this and for the wheel loaders is almost negligible in this context. In the end, 41 % is caused by the combustion process. The burner is therefore the greatest lever for reducing these emissions.

Benefit and advantages for users

Asphalt producers benefit from the positive ecological footprint as well from the high flexibility in choosing fuels. The option of using multiple fuels allows plant owners to react to the availability and price development of the energy sources. The tax on CO₂ will influence the pricing in the future.

This system ensures a reliable supply with different fuels, offering plant owners a high level of flexibility when selecting the most cost effective and most readily available energy source. This significantly contributes to lowering the operating costs.

Conversion possible at any time

New plants as well as existing asphalt mixing plants can be equipped with the Benninghoven burner technologies. This also applies to plants supplied by other manufacturers – Veidekke also uses the burner with a third-party plant. This gives any plant owner the opportunity to change to the latest technologies at any time – a key aspect for achieving economical and sustainable asphalt production and securing the future of the site in the long-term.

“In the past, we have evaluated where we can reduce CO₂ emissions in our processes as quickly as possible. For the asphalt installation itself, we came to the conclusion that we can currently only achieve a reduction of 3 % – but asphalt production is a different story! Here, we can already now reduce the emissions by a whole 40 %. Which is why we then started working on the prototype in Kristiansund with Benninghoven in 2023.”

Veidekke’s plant with a MULTI JET burner in Ålesund has been running since 2023. Thanks to the Benninghoven burner, Veidekke has already been able to lower the generated CO₂ emissions by 40 %. A step in the right direction, as legislation will require a reduction of at least 65 % from 2030 and then even 100 % from 2045.

From study and prototype to pilot project and beyond

The hydrogen project between Benninghoven and Veidekke was initiated in autumn 2021. During the first phase of the project study, the two parties examined the general technical conditions as well as the costs and potentials, in order to then determine the measures required for using hydrogen in the plant during the concept phase. They developed a new solution for a hydrogen system and the associated burner, which was subsequently detailed further with the help of simulations. But because simulation results are only as good as the underlying assumptions, not only the burner, but also the associated operating materials were planned in detail during the design engineering phase.

MULTI JET burner: Benninghoven burner test rig – where it all begins.

Innovation from the close cooperation between Veidekke and Benninghoven

The first test of the burner was planned for the spring of 2023, but it turned out that there were no feed systems capable of supplying the burner with the required hydrogen volume. This was resolved during the test at Benninghoven, though, clearing the way for the field test in Norway.

The installation in October 2023 in Kristiansund turned out to be a special challenge, with temperatures below zero and freezing rain. But as soon as the setup had been completed, the burner ran very well from the start. Several thousand tons of asphalt have been produced with hydrogen since then.

The plant in Ålesund has now also been up and running since 2024. The objective there was to validate the process and to check whether a reliable result could be achieved in altered conditions. This step was crucial for achieving product maturity.

But it did not end with Kristiansund and Ålesund: The next hydrogen-powered plant for Veidekke is scheduled to be commissioned in 2025.

Commissioning

First burner in Kristansund.

The world’s first asphalt factory with hydrogen

“Thanks to a small industrial adventure at our asphalt factory in Kristiansund, 3 000 tons of asphalt were produced this autumn with green hydrogen as the only energy source.”

Øivind Larsen, CEO Veidekke Infrastrukture and Martin Traeholt Holmqvist, Direktør Veidekke Asfalt

A group of people in work clothing start up the burner.
Øivind Larsen, CEO Veidekke Infrastrukture, and Martin Traeholt Holmqvist, Direktør Veidekke Asfalt, both in work clothing, smile for the camera.

“We have a total of 25 plants in Norway and several are from Benninghoven. We consider Benninghoven to be a very competent partner for our mission. Since commissioning the MULTI JET burner, we have already produced several thousand tons of asphalt without emissions by using hydrogen as a power source.”

Eddie Heggard Engebretsen, Senior Project Manager at Veidekke Industri AS

Benninghoven revolutionises asphalt production with modern burner technology

To limit man-made climate change and global warming to 1.5 °C, climate neutrality has to be achieved in all areas of life and industry. Construction companies are facing great challenges today, but they also have fantastic opportunities thanks to modern technology. Benninghoven is a world market leader in burners for asphalt mixing plants and a manufacturer of multi-fuel burners for up to four fuels. Ecological foresight and unique know-how from a wealth of experience from over 70 years of burner competence support the development of unique burners with excellent properties, like the MULTI JET.

The hydrogen drying system from Benninghoven is a crucial factor for saving large amounts of CO₂ emissions, making a significant contribution towards more economical, more efficient and more eco-friendly asphalt production. The combination of technical progress, flexible fuel usage and compliance with environmental standards is the key to establishing sustainable road construction.

A burner against a blurred background.
NEW
Is the clock ticking ever more loudly in your company as well?

Learn more about burner technology from Benninghoven! By the way: Our multi-fuel burner, which will use up to 100 % hydrogen among other things, will be available as a standard product for bauma 2025.

A crucial step towards more economic efficiency and sustainability in asphalt production: In addition to an improved ecological footprint and compliance with environmental regulations, plant owners benefit from a significant reduction of operating costs while securing the long-term future of their company.

Veidekke wins 2024 Climate Award

Benninghoven Technology makes it possible: On 24 October 2024, Veidekke received the Climate Award for its work with hydrogen-produced asphalt.

“The winner conducted an impressive analysis of its own emissions and actively strove to lower the emissions in its own industry. When explaining its choice, the jury stressed that the winner was future-oriented and ready to work with new solutions. The winner sets a standard which all other companies from any industry can look up to,” said Ole Erik Almlid, CEO of NHO, during the awards ceremony.

The winner therefore serves as an inspiration for companies across all industries.

*Image source: https://zero.no/veidekke-vant-naeringslivets-klimapris/

The index for the year 2024 was generated by auditing and consulting firm PwC, focusing on Norway’s largest companies and their restructuring in terms of climate targets. To be among the best in the survey, a company has to have had an average reduction in emissions of 7 % in the last three years. Only 18 of 100 of Norway’s largest companies succeeded in reducing their emissions in line with the Paris Agreement. Along with Veidekke, only three other companies reduced their absolute emissions as well as their carbon intensity.

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